Miniature circuit breaker online stamping and welding integrated production line

Abstract

This invention relates to the field of electrical component manufacturing equipment technology, and discloses an online stamping and welding integrated production line for miniature circuit breakers. The production line includes a raw material supply unit, a conveyor track, a multi-station continuous welding unit one, and a multi-station continuous welding unit two, arranged sequentially along the conveying direction of the material strip. A finished product platform is located between the multi-station continuous welding unit one and the multi-station continuous welding unit two. The multi-station continuous welding unit one is used for preliminary welding of the material strip stamped by the raw material supply unit, while the multi-station continuous welding unit two is used for subsequent multi-stage welding processes. The finished product platform is used to temporarily store the semi-finished products processed by the multi-station continuous welding unit one for further processing by the multi-station continuous welding unit two. By integrating all processes such as raw material supply, stamping, multi-stage welding, hot-melt connection, and final unloading into a continuous production line, the defects of existing technologies, such as process fragmentation, equipment dispersion, and excessive manual intervention, are overcome.

Description

Technical Field

[0001] This invention relates to the field of electrical component manufacturing equipment technology, specifically to an integrated online stamping and welding production line for miniature circuit breakers. Background Technology

[0002] As a key protection and switching element in electrical control systems, the internal thermal components of miniature circuit breakers directly determine the product's operating accuracy, lifespan, and reliability. A typical thermal component usually consists of multiple precision parts such as a bimetallic strip, moving contact, moving contact support, inlet plate, copper braided wire, and riveting base. It requires more than ten processes, including stamping, riveting, bending, multiple welding, hot melting, and final assembly, to form a complete functional unit.

[0003] In existing technologies, the above-mentioned processes generally adopt segmented and discrete production methods. The entire process involves multiple independent machines, multiple manual loading and unloading, intermediate buffers and logistics turnover. This not only occupies a lot of factory space, but also makes it difficult to match the cycle time of each process, which can easily cause product accumulation or production line bottlenecks. More importantly, due to the lack of unified positioning benchmarks and closed-loop control between processes, the workpiece is prone to cumulative errors during multiple handling processes, resulting in problems such as welding misalignment, unstable contact resistance, and discrete thermal action characteristics, which seriously affect product consistency and yield. Summary of the Invention

[0004] To address the aforementioned technical problems, this invention provides an integrated online stamping and welding production line for miniature circuit breakers.

[0005] To achieve the above objectives, the present invention provides the following technical solution: The miniature circuit breaker online stamping and welding integrated production line is used for continuous processing and forming of hot component raw material strips. It includes a raw material supply unit, a conveying track, a multi-station continuous welding unit one, and a multi-station continuous welding unit two arranged sequentially along the material strip conveying direction. A finished product platform is set between the multi-station continuous welding unit one and the multi-station continuous welding unit two. The multi-station continuous welding unit one is used for preliminary welding of the material strips stamped and formed by the raw material supply unit. The multi-station continuous welding unit two is used for subsequent multiple welding processes. The finished product platform is used to temporarily store the semi-finished products processed by the multi-station continuous welding unit one for subsequent processing by the multi-station continuous welding unit two.

[0006] To achieve highly integrated substrate forming, preferably, the raw material supply unit includes a stamping mechanism and a roll holder A and a roll holder B for carrying raw material rolls, respectively. The stamping mechanism is equipped with a cooperating upper die and a lower die. The lower die integrates a first station for convex forming of material A from the roll holder A, a second station for punching material B from the roll holder B, a third station for riveting material A and material B, and a fourth station for bending, shaping, and pre-cutting the riveted assembly. The first station and the second station are arranged perpendicularly in space so that material A and material B are fed in mutually perpendicular directions after entering the lower die and are synchronously processed to form the substrate assembly.

[0007] To improve stamping stability and facilitate waste management, the first and second workstations are further equipped with cutting sections at their inlets, and the upper and lower dies are respectively provided with punches and blanking channels, with the blanking channels connected to an external waste collection box.

[0008] To achieve efficient integrated welding of bimetallic strips with copper braided wires and feed plates, preferably, the multi-station continuous welding unit includes a first worktable, a turntable positioned above the first worktable, clamps spaced apart on the turntable, and a bimetallic strip feeding tray, a copper braided wire welding unit, a feed plate feeding tray, a welding station, and a welding station two arranged sequentially around the turntable on the first worktable. It also includes a first robotic arm corresponding to the bimetallic strip feeding tray and the turntable, a second robotic arm and a third robotic arm corresponding to the feed plate and the turntable, and a fourth robotic arm corresponding to the welding station two and the turntable. A coil feeder is provided on one side of the copper braided wire welding unit, from which the copper braided wire is continuously fed. Upon passing through the copper braided wire welding unit, it is cut to a fixed length and welded to the bimetallic strip fed from the preceding station.

[0009] To achieve precise docking between the base component and the semi-finished product, the conveying track is further set on the first workbench, located on one side of the turntable, and the welding station is located on the extension path of the conveying track, used to receive the base component conveyed by the conveying track, and to work in coordination with the turntable.

[0010] To improve clamping reliability and assembly tolerance adaptability, the fixture further includes a plate, on which a first clamping area, a second clamping area, and a placement groove are provided. A limit block is installed on the plate on one side of the first clamping area and the second clamping area by means of an elastic element.

[0011] To achieve buffering and scheduling of semi-finished products, preferably, the finished product platform includes a second workbench, a turntable two disposed above the second workbench, with clamps two installed at intervals on the turntable two; and a moving contact component feeding track, a bimetallic bracket component unloading and handling module, a welding station three, and a discharge channel arranged sequentially around the turntable two on the second workbench, and also includes a fifth robotic arm corresponding to the moving contact component feeding track and a sixth robotic arm located between the discharge channel and the turntable two.

[0012] To achieve material feeding for the bimetallic bracket, the bimetallic bracket assembly unloading and handling module further includes a cutting station and a seventh robot arm. The seventh robot arm is arranged colinearly with the cutting station and is located on the extension path of the cutting station. It is used to receive the semi-finished products conveyed by the cutting station and works in cooperation with the turntable. The cutting station includes a cutting frame fixedly installed on the second workbench. The cutting frame is equipped with an upper cutting die and a lower cutting die. The upper cutting die is driven by a servo stamping structure and can reciprocate vertically relative to the lower cutting die to cut the bimetallic bracket strip output from the previous process and separate individual bimetallic bracket assemblies.

[0013] To achieve full functional integration of the moving contact sub-assembly, preferably, the multi-station continuous welding unit two includes a third workbench, a turntable three positioned above the third workbench, clamps three installed at intervals on the turntable three, and a moving contact feeding tray, a moving contact support feeding tray, a copper braided wire welding unit two, a hot melt unit, and an eighth robot arm arranged sequentially around the turntable three on the third workbench. It also includes a ninth robot arm corresponding to the moving contact feeding tray and the turntable three, a tenth robot arm corresponding to the moving contact support feeding tray and the turntable three, and an eleventh robot arm corresponding to the copper braided wire welding unit two and the hot melt unit, respectively. Among them, a coil feeder is provided on one side of the copper braided wire welding unit two, and the copper braided wire is continuously fed by the coil feeder. When passing through the copper braided wire welding unit two, it is cut to a fixed length and welded to the moving contact fed in by the previous station.

[0014] To support the process logic of welding before assembly, the fixture three further includes a plate three, on which a fourth clamping area and a fifth clamping area are formed. A limit block three is installed on the plate three on one side of the fourth clamping area and the fifth clamping area by means of an elastic element. When the moving contact in the fourth clamping area is processed by the copper braid welding unit two, it is transferred by the eleventh robot to the fifth clamping area and assembled with the moving contact bracket.

[0015] The beneficial effects of this invention are: 1. The miniature circuit breaker online stamping and welding integrated production line provided by the present invention integrates all processes such as raw material supply, stamping, multi-stage welding, hot melt connection and final assembly into a continuous production line. It overcomes the defects of existing technologies such as process fragmentation, equipment dispersion and excessive manual intervention. It realizes single-line continuous automatic production from raw material roll to complete hot component finished product, without intermediate transfer, buffering or manual intervention, shortening the production cycle and significantly improving unit capacity.

[0016] 2. By simultaneously feeding material A and material B into an integrated progressive lower die in mutually perpendicular directions, and sequentially completing convex forming, punching, orthogonal overlapping, weldless riveting, and bending shaping within a single stamping cycle, the integrated and efficient manufacturing of bimetallic brackets and auxiliary materials is achieved. This not only eliminates the multiple positioning and transfer required by traditional multi-process step-by-step processing, significantly improving production efficiency and product consistency, but also avoids material performance degradation caused by heat through a mechanically locked weldless riveting structure, ensuring the accuracy and long-term reliability of thermal components.

[0017] 3. By integrating bimetallic strip feeding, copper braided wire length cutting and laser welding, wire feed assembly and secondary welding through a rotary multi-station layout, and combining it with a misalignment mechanism to prevent stacking, elastic clamp self-adaptive positioning, wedge and roller drive precision pressing, and contact and vision closed-loop quality control, the high-speed, high-precision, fully automated integrated manufacturing of the core semi-finished products of the thermal components is realized. This effectively solves the technical problems of dispersed processes, excessive manual intervention, poor welding consistency and easy deviation of copper braided wires in traditional processes, significantly improving production efficiency and product yield, and providing a reliable technical path for the intelligent manufacturing of relay thermal components.

[0018] 4. The rotary table with three robotic arms enables step-by-step feeding, zoned clamping, pre-welding and post-assembly, and hot-melt integration of moving contacts, supports, and copper braided wires. It employs a compact lateral clamping mechanism with elastic limit fixtures, wedge and roller drives, and a visual final inspection system that integrates geometric feature recognition and template matching. This effectively solves problems such as easy component displacement, poor welding consistency, and assembly misalignment during the hot-melt process. While ensuring high-strength and low-resistance connections, it achieves high-precision, high-cycle, and fully automated manufacturing of hot-melt semi-finished products, significantly improving product yield and production line flexibility. This provides reliable technical support for the intelligent production of core electrical contact components of relays. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a schematic diagram of the internal structure of the raw material supply unit of the present invention; Figure 3 This is a schematic diagram of the lower mold structure of the present invention; Figure 4This is a schematic diagram of the convex hull block mounting structure of the present invention; Figure 5 This is a schematic diagram of the pad installation structure of the present invention; Figure 6 This is a schematic diagram of the material roll holder structure of the present invention; Figure 7 This is a schematic diagram of the overall structure of the multi-station continuous welding unit of the present invention; Figure 8 This is a schematic diagram of the fixture structure of the present invention; Figure 9 This is a schematic diagram of the copper braid welding unit of the present invention; Figure 10 This is a schematic diagram of the feeding mechanism in the copper braid welding unit of the present invention; Figure 11 This is a schematic diagram of the fixed-length cutting module structure in the copper braid welding unit of the present invention; Figure 12 This is a schematic diagram of the laser welding module structure in the copper braid welding unit of the present invention; Figure 13 This is a schematic diagram of the feeding mechanism of the present invention; Figure 14 This is a schematic diagram of the detection device of the present invention; Figure 15 This is a schematic diagram of the overall structure of the finished product platform and the multi-station continuous welding unit of the present invention; Figure 16 for Figure 15 Second perspective; Figure 17 This is a schematic diagram of the finished product material platform structure of the present invention; Figure 18 for Figure 17 Second perspective; Figure 19 This is a schematic diagram of the material handling module of the bimetallic support assembly of the present invention; Figure 20 This is a schematic diagram of the second fixture structure of the present invention; Figure 21 This is a schematic diagram of the internal structure of the clamp 2 of the present invention; Figure 22 This is a schematic diagram of the three-structure welding station of the present invention; Figure 23 for Figure 22 Second perspective; Figure 24 This is a schematic diagram of the three-structure clamp of the present invention; Figure 25 This is a schematic diagram of the hot melt unit structure of the present invention; Figure 26 This is a schematic diagram of the finished structure of the thermal component of the present invention; Figure 27 This invention relates to the visual testing requirements of a detection camera. Figure 28 This invention relates to the requirements for testing the dual vision of the detection camera. Figure 29 This invention relates to the testing requirements for the three vision systems of the detection camera.

[0020] The attached diagram lists the components represented by each number as follows: 100. Raw material supply unit; 110. Stamping mechanism; 101. Mounting cavity; 111. Machine body; 112. Crankshaft; 113. Crank; 114. Connecting column; 115. Slide rail one; 116. Transmission wheel; 117. Gear set; 120. Material coil holder A; 121. Frame; 122. Support plate; 123. Threaded rod; 124. Rocker arm; 125. Sliding sleeve; 126. Inner liner plate; 127. Adjusting arm; 130. Material coil holder B; 140. Upper die; 141. Punch; 142. First guide rod; 143. Second guide rod; 144. Riveting block; 14 41. Pressing pin; 150. Lower mold; 151. First station; 1511. First horizontal bar; 1512. Convex block; 1513. First slide groove; 1514. Spring 1; 1515. Inclined groove 1; 1516. Through groove; 152. Second station; 153. Third station; 1531. Second horizontal bar; 1532. Second slide groove; 1533. Spring 2; 1534. Pad block 1; 1535. Spring 3; 1536. Inclined groove 2; 154. Fourth station; 155. Material discharge channel; 156. Channel groove; 157. Guide block; 160. Cutting station; 200. Conveying track; 300. Multi-station continuous welding unit 1; 310. First worktable; 320. Turntable 1; 321. Fixture 1; 3211. Plate 1; 3212. First clamping area; 3213. Second clamping area; 3214. Placement slot; 3215. Limiting block 1; 330. Bimetallic sheet feeding tray; 340. Copper braided wire welding unit 1; 341. Overall support; 342. Laser welding module; 3421. Cylinder 11; 3422. Upper welding head; 3 423. Upper connecting seat; 3424. Cylinder 12; 3425. Lower welding head; 3426. Lower connecting seat; 3427. Roller 1; 3428. Slide rail 2; 3429. Wedge-shaped pad; 343. Feeding mechanism; 3431. Feeding seat 1; 3432. Cylinder 3; 3433. Clamping plate; 3434. Conveyor frame; 3435. Braided trough; 3436. Feeding seat 2; 3437. Cylinder 4; 3438. Pressure plate; 344. Cylinder 2; 345. Fixed-length cutting module; 3451. Upper cutter; 3452. Lower cutter; 3453. Cover; 3454. Swing rod; 3455. First push rod; 3456. Second push rod; 3457. Cylinder 9; 3458. Connecting block; 3459. Distance sensor; 346. Hot melt clamp; 350. Feed tray for infeed sheet; 360. Welding station 1; 370. Welding station 2; 380. Material shifting mechanism; 381. Material shifting upright plate; 382. 383. Double-metal transition seat; 384. Double-metal positioning plate; 385. Limit seat one; 390. Cylinder one; 301. Detection camera one; 302. First robotic arm; 303. Second robotic arm; 304. Third robotic arm; 305. Fourth robotic arm; 305. Detection device one; 3051. Detection frame; 3052. Cylinder five; 3053. Detection plate; 3054. Infrared sensor; 3055. Elastic probe; 306. Limit block four; 307. Cylinder zero; 400. Finished Product Platform; 410. Second Workbench; 420. Turntable II; 421. Fixture II; 4211. Plate II; 4212. Third Clamping Area; 4213. Limiting Block II; 4214. Positioning Pin; 4215. Moving Contact Assembly Placement Area; 4216. Limiting Seat II; 4217. Irregular Shaped Plate; 4218. Clamping Block; 4219. Drive Rod; 430. Moving Contact Assembly Feeding Track; 440. Bimetallic Support Assembly Unloading and Handling Module; 450. Welding Station III; 451. Support Frame; 4511. Base Plate; 4512. Guide Column; 4513. Horizontal Plate; 4514. Slide Rail III; 4515. Slide Table; 4516. Cylinder Mounting Hole; 452. Pneumatic... Cylinder Thirteen; 453. Push Block; 454. Upper Dynamic Plate; 455. Fixing Rod; 456. Lower Dynamic Plate; 457. Welding Rod; 458. Cylinder Fourteen; 459. Top Block; 460. Material Discharge Channel; 470. Cutting Station; 471. Cutting Frame; 472. Upper Cutting Die; 473. Lower Cutting Die; 480. Scrap Material Recycling Station; 481. Scrap Shelf; 482. Support Rail; 483. Drop Groove; 484. Cutting Mechanism; 490. Detection Device Two; 401. Fifth Robotic Arm; 402. Sixth Robotic Arm; 403. Seventh Robotic Arm; 404. Detection Camera Three; 405. Inclined Slot Three; 406. Pin; 407. Spring Four; 408. Shock Absorber; 409. Tension Spring; 500. Multi-station continuous welding unit two; 510. Third workbench; 520. Turntable three; 521. Fixture three; 5211. Plate three; 5212. Fourth clamping area; 5213. Fifth clamping area; 5214. Limiting block three; 530. Moving contact feed tray; 540. Moving contact support feed tray; 550. Copper braided wire welding unit two; 560. Hot melt unit; 561. Hot melt frame; 562. Gas Cylinder 6; 563, Hot melt pressure head assembly; 5631, Mounting plate; 5632, Hot melt welding head; 5633, Guide rail; 564, Clamping rod; 565, Cylinder 7; 566, Cylinder 8; 567, Wedge block; 568, Roller 2; 569, Return spring; 570, Detection camera 2; 501, Eighth robotic arm; 502, Ninth robotic arm; 503, Tenth robotic arm; 504, Eleventh robotic arm. Detailed Implementation

[0021] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] 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," and "counterclockwise," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention 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. Therefore, they should not be construed as limitations on this invention. Example 1

[0023] like Figure 1 - Figure 29 As shown, this invention relates to an integrated online stamping and welding production line for miniature circuit breakers, used for continuous processing and forming of raw material strips for hot components. It includes a raw material supply unit 100, a conveying track 200, a multi-station continuous welding unit 300 and a multi-station continuous welding unit 500 arranged sequentially along the conveying direction of the strip. A finished product platform 400 is provided between the multi-station continuous welding unit 300 and the multi-station continuous welding unit 500. The units are mechanically connected and linked by signals to form a complete intelligent manufacturing production line.

[0024] The multi-station continuous welding unit 1300 is used for the initial welding of the material strip formed by the stamping of the raw material supply unit 100. The semi-finished products processed by the multi-station continuous welding unit 1300 are then supplied to the multi-station continuous welding unit 2500 for further processing.

[0025] After the material strip is stamped and formed by the raw material supply unit 100, it forms an integrally connected bimetallic bracket and bimetallic bracket auxiliary material, and is sent into the conveying track 200. At the same time, two welding processes are completed sequentially in the multi-station continuous welding unit 300. First, the bimetallic sheet is welded to the copper braided wire. Then, the wire feed piece is welded to the already welded copper braided wire assembly to form a complete bimetallic sheet assembly. It is then assembled onto the bimetallic bracket in the conveying track 200 and fixed by welding process to form a preliminary integrated semi-finished product structure.

[0026] On the other hand, two welding processes are also completed sequentially in the multi-station continuous welding unit 2500. First, the moving contact is welded to the copper braid wire to form a moving contact sub-assembly. Then, the sub-assembly is fixed to the moving contact bracket by hot melt welding to obtain a complete moving contact assembly. The moving contact assembly is then transported to the finished product platform 400 and finally integrated and welded with the bimetallic sheet assembly that has been assembled on the bimetallic bracket to form a complete SEMW thermal module finished product.

[0027] It should be noted that on the finished product platform 400, the welded bimetallic bracket and the integrated structure of the bimetallic bracket auxiliary material will undergo a stamping separation process to disconnect the two. The moving contact assembly is welded to the bimetallic bracket body and is retained as the main functional component, while the bimetallic bracket auxiliary material is cut into fragments after separation and recycled as waste. This achieves efficient material utilization and clean production line operation, improves product production efficiency, and reduces personnel operation. Example 2

[0028] Reference Figures 1-6 The raw material supply unit 100 includes a stamping mechanism 110 and a coil rack A120 and a coil rack B130 for carrying raw material coils, respectively. In this embodiment, the coil racks A120 and B130 have the same structure, both including a frame 121 and a support plate 122. The frame 121 has an "L"-shaped base structure and is provided with anti-slip pads or fixed feet at the bottom for easy installation on the ground or equipment platform. The upper part of the frame 121 is provided with a bearing seat, and the support plate 122 is rotatably mounted on the frame 121 through the bearing seat. A threaded rod 123 is rotatably mounted at the center of the support plate 122, and a rocker arm is fixedly mounted at the end of the threaded rod 123 away from the support plate 122. 124. A sliding sleeve 125 is threaded onto the threaded rod 123, and an inner liner 126 is slidably mounted on the support plate 122. An adjusting arm 127 is rotatably connected between the inner liner 126 and the sliding sleeve 125. When the material roll is placed on the support plate 122, the axial position of the threaded rod 123 is changed by rotating the rocker arm 124, thereby driving the sliding sleeve 125 to move along the threaded rod 123. Since the sliding sleeve 125 and the inner liner 126 are rotatably connected by the adjusting arm 127, the axial displacement of the sliding sleeve 125 will be converted into an angle change of the adjusting arm 127, which will push or pull the inner liner 126 to slide radially along the support plate 122, changing the inner support diameter.

[0029] The stamping mechanism 110 is equipped with an upper die 140 and a lower die 150 that cooperate with each other. The lower die 150 is a multi-functional integrated progressive die, which integrates a first station 151 for forming the A material from the material roll holder A120, a second station 152 for punching the B material from the material roll holder B130, a third station 153 for riveting the A material and the B material, and a fourth station 154 for bending, shaping and pre-cutting the riveted component. In particular, the first station 151 and the second station 152 are arranged perpendicularly in space so that the A material and the B material are fed in mutually perpendicular directions after entering the lower die 150 and are processed synchronously to form the base component.

[0030] Specifically, the base component consists of an integrally connected bimetallic bracket and a bimetallic bracket auxiliary material. Material A enters the lower mold 150 along the Y direction, while material B is fed in from the side along the X direction. The two are orthogonally superimposed in the intersection area of ​​the lower mold 150, so that material A and material B can complete their independent forming actions in the same stamping cycle, and then enter the third station 153 for riveting.

[0031] Specifically, refer to Figure 2 The stamping mechanism 110 is integrally cast and includes a body 111, a crankshaft 112 mounted on the body 111, and a servo motor. The body 111 has a mounting cavity 101 for placing an upper die 140 and a lower die 150. The lower die 150 is bolted to the bottom surface of the mounting cavity 101. The crankshaft 112 is rotatably supported on the body 111 and driven to rotate by the servo motor. A crank 113 is eccentrically mounted on the crankshaft 112. A connecting column 114 is rotatably mounted on the end of the crank 113 away from the crankshaft 112. The upper die 140 is fixedly connected to the connecting column 114. A vertical slide rail 115 is also provided on the body 111. The connecting column 114 is slidably mounted in the slide rail 115 to convert the rotational motion of the crankshaft 112 into the reciprocating linear motion of the upper die 140.

[0032] When the servo motor is started, the motor drives the crankshaft 112 to rotate. Since the crank 113 on the crankshaft 112 is eccentrically mounted, the rotation of the crankshaft 112 will cause the crank 113 to drive the connecting column 114 to move up and down along the vertical slide rail 115. This movement is directly transmitted to the upper mold 140 fixed on it, so that the upper mold 140 moves up and down relative to the lower mold 150 fixed at the bottom of the mounting cavity 101, thereby completing the stamping action.

[0033] Furthermore, a transmission wheel 116 and a gear set 117 are respectively installed on both sides of the machine body 111. The output end of the servo motor is connected to the transmission wheel 116 via a belt. The transmission wheel 116 and the input end of the gear set 117 are coaxially connected. The crankshaft 112 is fixed to the output end of the gear set 117 so that the rotational power of the servo motor is transmitted to the crankshaft 112 via belt drive and gear reduction, driving the upper mold 140 to perform stamping motion.

[0034] In the hot component stamping process, material A and material B are usually fed in two different directions and simultaneously sent into the lower die 150 for composite processing. Therefore, a channel groove 156 is provided on the lower die 150. Guide blocks 157 are bolted to the lower die 150 on both sides of the channel groove 156, so that the channel groove 156 forms a limiting slide, reducing the material strip from shifting, warping or shaking during high-speed feeding.

[0035] Specifically, the distance between two adjacent guide blocks 157 is less than the width of the strip, thus applying a constraint force to the strip in the vertical direction.

[0036] Reference Figure 4 and Figure 5 The first station 151 includes a first horizontal rod 1511, a first guide rod 142, and a convex block 1512. A first sliding groove 1513 is provided in the lower mold 150 below the channel groove 156. The first horizontal rod 1511 is slidably installed in the first sliding groove 1513 and a spring 1514 is fixedly connected between it and the inner wall of the first sliding groove 1513. The first guide rod 142 is fixedly installed on the upper mold 140 and is arranged perpendicular to the first horizontal rod 1511 in space. Its lower end is provided with an inclined surface. A sloping groove 1515 that cooperates with the inclined surface is provided on the first horizontal rod 1511. The convex block 1512 is rotatably installed in the first sliding groove 1513 by a torsion spring. A through groove 1516 is provided at a corresponding position on the channel groove 156 to allow the convex block 1512 to partially protrude.

[0037] When the upper mold 140 descends, the inclined surface of the first guide rod 142 inserts into the inclined groove 1515 and pushes the first horizontal rod 1511 to move horizontally along the first sliding groove 1513, thereby driving the convex block 1512 to flip and realize the convex forming of material A.

[0038] The second station 152 is provided in two sets, which are used for punching the positioning holes of material A and material B respectively. The two sets of second stations 152 are spatially independent and arranged in the same stamping cycle so that material A and material B can complete their respective punching processes synchronously when they enter the second station 152.

[0039] The third station 153 is located at the junction of material A and material B, and includes a second horizontal rod 1531 and a second guide rod 143. A second sliding groove 1532 is provided in the lower mold 150 below the channel groove 156. The second horizontal rod 1531 is slidably installed in the second sliding groove 1532 and a spring 1533 is fixedly connected between it and the inner wall of the second sliding groove 1532. It also includes a pad 1534 slidably installed in the channel groove 156. When the upper mold 140 and the lower mold 150 are separated, the pad 1534 is flush with the top surface of the channel groove 156.

[0040] Furthermore, a spring 1535 is fixedly connected between the pad block 1534 and the bottom surface of the groove of the second slide 1532. The second guide rod 143 is fixedly installed on the upper mold 140 and is arranged perpendicularly to the second horizontal rod 1531 in space. Its lower end is provided with an inclined surface. The second horizontal rod 1531 is provided with a sloping groove 1536 that cooperates with the inclined surface. A rivet block 144 is installed on the upper mold 140 on one side of the second horizontal rod 1531. The rivet block 144 has a pressure pin 1441 corresponding to the A material protrusion.

[0041] When the upper mold 140 descends, the inclined surface of the second guide rod 143 inserts into the inclined groove 1536 and pushes the second horizontal rod 1531 to move horizontally along the second sliding groove 1532. Then, through the linkage, the pad block 1534 is pushed upward, pushing the A material located on it towards the B material. The protrusion on the A material is embedded in the positioning hole on the B material. At the same time, the pressure pin 1441 on the riveting block 144 faces the protrusion during the downward movement and crushes and deforms it downward, so that the protrusion forms a weldless riveting in the positioning hole.

[0042] Reference Figure 3 Both the first station 151 and the second station 152 have integrated cutting stations 160 at their inlets. The upper mold 140 and the lower mold 150 are respectively equipped with punches 141 and blanking channels 155, which are connected to an external waste collection box.

[0043] In an exemplary embodiment: the raw material supply unit 100 is responsible for the progressive die stamping manufacturing of the bimetallic bracket and its auxiliary materials. The material roll holder A120 carries material A, preferably a thin metal strip, which enters the lower die 150 along the Y direction, while the material roll holder B130 carries material B, preferably a thin metal support strip, which is fed into the lower die 150 along the X direction. The two strips are orthogonally overlapped in the intersection area of ​​the lower die 150, and can complete their independent forming actions within the same stamping cycle, and then be riveted.

[0044] The lower die 150 is a multi-functional integrated progressive die. First, at the cutting station 160, the upper die 140 and the lower die 150 are respectively equipped with a punch 141 and a blanking channel 155. The waste edges of the strip are cut off according to the preset shape, and the waste is discharged into an external waste collection box through the blanking channel 155. Next, material A passes through the first station 151 to form the required convex structure, and material B passes through the second station 152 for punching. Material A and material B converge at the third station 153 according to the stamping cycle, causing material A... The protrusion on the material is embedded in the positioning hole of material B. The pressing pin 1441 of the riveting block 144 on the upper die 140 is directly opposite the protrusion and crushes and deforms it, forming a mechanical locking structure in the hole, thus completing the weldless riveting. Finally, the fourth station 154 performs bending, shaping and pre-cutting on the riveted base component to ensure that its three-dimensional shape meets the design requirements. After the above multi-station continuous stamping, the output is a base component composed of an integrally connected bimetallic bracket and bimetallic bracket auxiliary material.

[0045] It should be noted that before material A is delivered to the third station 153, it will undergo a cutting process to cut the continuous material A into individual metal sheets. Example 3

[0046] Reference Figures 7-14The multi-station continuous welding unit 300 is used to perform multi-stage automated welding of the bimetallic bracket and bimetallic bracket auxiliary material integrated structure output from the previous process, and finally form an integrated semi-finished product containing bimetallic sheet, copper braided wire and infeed plate. Specifically, it includes a first workbench 310, a turntable 320, a bimetallic sheet feeding tray 330, a copper braided wire welding unit 340, an infeed plate feeding tray 350, a welding station 360 and a welding station 370.

[0047] Turntable 320 has a circular structure and is driven by a servo motor. It can rotate intermittently. Clamps 321 are installed at equal angles along the circumference of turntable 320 to stably hold semi-finished products at different stages.

[0048] The bimetallic sheet feeding tray 330, copper braided wire welding unit 340, wire feed tray 350, welding station 360, and welding station 370 are sequentially arranged around the turntable 320 on the first worktable 310. In addition, it also includes a first robot 301 between the bimetallic sheet feeding tray 330 and the turntable 320, a second robot 302 and a third robot 303 between the wire feed tray 350 and the turntable 320, and a fourth robot 304 between the welding station 370 and the turntable 320. In particular, a coil feeder body is provided on one side of the copper braided wire welding unit 340. The copper braided wire is continuously fed by the coil feeder body, and is cut to a fixed length when passing through the copper braided wire welding unit 340 and welded to the bimetallic sheet fed in by the previous station.

[0049] The bimetallic strip is fed by the bimetallic strip feeder 330, automatically sorted and conveyed to the picking position, where it is picked up by the first robot arm 301 and placed in the fixture 321 that rotates with the turntable 320 to the position. The copper braided wire is continuously released from the coil feeder body, enters the position through tension control and guide wheels. When the fixture 321 rotates with the turntable 320 to the copper braided wire welding unit 340, the copper braided wire is fed to the top of the bimetallic strip according to the preset length, welded and fixed to the bimetallic strip, and then cut, forming a reliable electrical connection. After the copper braided wire welding is completed... Turntable 320 continues to rotate, causing clamp 321 to enter the feed plate 350 station. The feed plates are automatically fed by the feed plate 350, sorted, and then picked up by the second robot 302 and placed in clamp 321, which rotates with turntable 320 to this station. The third robot 303 is located downstream of the feed plate 350 and is used to transport the bimetallic strip in clamp 321 to one side of the feed plate. Clamp 321 enters welding station 360, where welding head is used to complete the welding and fixing between the feed plate and the copper braid.

[0050] In an exemplary embodiment, to ensure that the bimetallic strip is correctly placed in the fixture 321, an identification sensor is installed on the worktable below the fixture 321 to detect the installation position and installation direction of the bimetallic strip in real time.

[0051] Specifically, the conveyor track 200 is set on the first worktable 310, located on one side of the turntable 320, and the welding station 370 is located on the extension path of the conveyor track 200, used to receive the base components conveyed by the conveyor track 200 and work in conjunction with the turntable 320.

[0052] Reference Figure 8 The fixture 321 includes a plate 3211, on which a first clamping area 3212, a second clamping area 3213, and a placement groove 3214 are provided. The first clamping area 3212 is used to place the bimetallic strip, and the placement groove 3214 is used to assemble the wire feed piece. After the welding between the bimetallic strip and the copper braided wire is completed, the wire feed piece is picked up by the third robot 303 and placed into the second clamping area 3213. At this time, the copper braided wire is located above the wire feed piece, which facilitates subsequent welding.

[0053] A limit block 3215 is installed on the plate 3211 on one side of the first clamping area 3212 and the second clamping area 3213 by means of an elastic element to fix the position of the bimetallic strip. The elastic element is preferably a spring.

[0054] To prevent stacking of bimetallic sheets during feeding, refer to... Figure 13 A material shifting mechanism 380 is also provided on the first worktable 310 below the first robot arm 301. Specifically, the material shifting mechanism 380 includes a material shifting plate 381, a double metal transition seat 382 is slidably installed on the material shifting plate 381, a double metal positioning plate 383 and a limit seat 384 are fixedly installed on the double metal transition seat 382, ​​and a cylinder 385 is also installed on the material shifting plate 381. The output end of the cylinder 385 is fixedly connected to the double metal transition seat 382.

[0055] The limiting seat 384 faces the side of the first robot arm 301 and is used to stop and position the front end of the bimetallic strip. The cylinder 385 drives the bimetallic transition seat 382 to slide left and right on the material handling plate 381, so that the first robot arm 301 can grab and load materials in sequence.

[0056] In this embodiment, the copper braid welding unit 340 is an integrated automated workstation used to realize continuous feeding, fixed-length cutting, and welding of copper braided wire to bimetallic sheets. It includes an overall support frame 341 and further comprises: The feeding mechanism 343, driven by cylinder 2 344, is slidably mounted on the overall bracket 341. It includes a feeding seat 1 3431 and a cylinder 3 3432 mounted on the feeding seat 1 3431. A clamping plate 3433 is installed at the output end of the cylinder 3 3432. A conveyor frame 3434 is installed on the feeding seat 1 3431. The conveyor frame 3434 has a braided wire groove 3435 corresponding to the clamping plate 3433 to guide the copper braided wire to move along a predetermined path.

[0057] Furthermore, a second feeding seat 3436 and a fourth cylinder 3437 mounted on the second feeding seat 3436 are provided on one side of the feeding mechanism 3433. These are used to work together with the first feeding seat 3431 to complete the feeding and straightening of the copper braided wire. A pressure plate 3438 is fixedly installed at the output end of the fourth cylinder 3437. During feeding, appropriate pressure is applied to the copper braided wire to keep it straight before entering the welding area. The second feeding seat 3436 is also provided with a braided wire groove 3435, so that the copper braided wire can be straightened during feeding. A hot melt clamp 346 that can be brought close to each other is provided on the overall support 341 between the first feeding seat 3431 and the second feeding seat 3436 for hot melt treatment of the copper braided wire to prevent it from scattering.

[0058] A fixed-length cutting module 345 and a laser welding module 342 are provided on the side of the overall support 341 near the turntable 320 and are located at the end of the feeding path. The fixed-length cutting module 345 includes an upper cutter 3451 and a lower cutter 3452, wherein the upper cutter 3451 and the lower cutter 3452 can move relative to each other.

[0059] Specifically, refer to Figure 11 The fixed-length cutting module 345 also includes a cover 3453. An L-shaped swing rod 3454 is rotatably installed inside the cover 3453. A first push rod 3455 and a second push rod 3456 are respectively hinged to both ends of the swing rod 3454. The first push rod 3455 and the second push rod 3456 are perpendicular to each other in spatial arrangement, and both the first push rod 3455 and the second push rod 3456 are slidably connected inside the cover 3453. In particular, the second push rod 3456 has a wedge-shaped part. The upper cutter 3451 is sleeved on the wedge-shaped part of the second push rod 3456. A cylinder 3457 is fixedly installed on the overall bracket 341. A connecting block 3458 is fixedly installed at the output end of the cylinder 3457. The lower cutter 3452 and the first push rod 3455 are both fixedly installed on the connecting block 3458.

[0060] The cylinder 3457 pushes the lower cutter 3452 and the first push rod 3455 to rise. The first push rod 3455 drives the L-shaped swing rod 3454 to rotate, pulling the second push rod 3456 to one side. The wedge-shaped part on the second push rod 3456 pulls the upper cutter 3451 down, thereby completing the cutting action.

[0061] Furthermore, a limit block 306 is fixedly installed on the overall bracket 341, a distance sensor 3459 is installed on both sides of the connecting block 3458, and a cylinder 307 is fixedly installed on the overall bracket 341, with the movable end of the cylinder 307 fixed to the connecting block 3458.

[0062] Reference Figure 12 The laser welding module 342 includes an upper welding part and a lower welding part respectively disposed on both sides of the fixture 321. The upper welding part includes a cylinder 11 3421 and an upper welding head 3422. The upper welding head 3422 is clamped and installed in the upper connecting seat 3423. The upper connecting seat 3423 is elastically connected to the output end of the cylinder 11 3421. The lower welding part includes a cylinder 12 3424 and a lower welding head 3425. The lower welding head 3425 is clamped and installed in the lower connecting seat 3426. In particular, a roller 1 3427 is installed on the lower connecting seat 3426. A slide rail 2 3428 is fixedly installed on the overall bracket 341. A wedge-shaped pad 3429 is slidably connected in the slide rail 2 3428. The output end of the cylinder 12 3424 is fixed to the wedge-shaped pad 3429. The roller 1 3427 slides in contact with the surface of the wedge-shaped pad 3429.

[0063] Fixture 321 rotates with turntable 320 to the laser welding station, where a bimetallic strip is already installed. The copper braided wire, placed above the welding point by the preceding cutting mechanism, is in a ready-to-weld state. Cylinder 3421 is activated, pushing the upper connecting seat 3423 downward. Since the upper connecting seat 3423 and the cylinder output end are elastically connected, like a spring buffer, the upper welding head 3422 first gently contacts the surface of the copper braided wire, applying a preload. The elastic structure can absorb workpiece height tolerances or slight warping of the copper braided wire, avoiding rigid impacts that could cause component displacement or welding head collision damage. Cylinder 12 3424 starts synchronously, pushing the wedge-shaped pad 3429 to move horizontally along slide rail 2 3428. Roller 1 3427 installed on the lower connecting seat 3426 always maintains rolling contact with the inclined surface of the wedge-shaped pad 3429. As the wedge-shaped pad 3429 moves horizontally, its inclined surface decomposes the horizontal thrust into a vertically upward component, pushing roller 1 3427 and the entire lower connecting seat 3426 to rise smoothly. The lower welding head 3425 moves upward accordingly, forming a clamping state with the upper welding head 3422, tightly welding the bimetallic strip to the copper braid wire.

[0064] After the bimetallic strip and the copper braided wire are welded, the third robot 303 picks up the component from the first clamping area 3212 and transfers it to the second clamping area 3213 in the fixture 321 for positioning. At this time, the copper braided wire is located above the wire feed piece, which prepares for the reliable connection between the wire feed piece and the copper braided wire in the subsequent welding station 360. Before entering the welding station 360, in order to further ensure the correctness of the assembly state, a detection device 305 is provided on the first workbench 310 between the third robot 303 and the welding station 360. This device is used to confirm the position and pre-inspect the contact state of the semi-finished product that has been transferred to the second clamping area 3213. Specifically, it includes a detection frame 3051 fixed on the first workbench 310, a cylinder 3052 installed on the detection frame 3051, and a detection plate 3053 connected to the output end of the cylinder 3052. The detection plate 3053 integrates an infrared sensor 3054 and an elastic probe 3055.

[0065] During operation, when fixture 321 rotates with turntable 320 to the inspection station, cylinder 3052 drives inspection plate 3053 to move downward, causing elastic probe 3055 to lightly touch the surface of bimetallic plate. If the bimetallic plate is located within the second clamping area 3213, elastic probe 3055 will generate slight compression, and infrared sensor 3054 will receive a stable reflected signal. The system will determine it as "qualified". If it is missing, elastic probe 3055 will not respond, and the system will mark it as "abnormal".

[0066] Furthermore, an inspection camera 390 is installed downstream of welding station 360 for online visual inspection of the quality of the welding points.

[0067] Specifically, refer to Figure 23 The detection camera covers the welded area in fixture 321 with a field of view of 390. First, the outlines of the two sides of the copper braid are identified and their spatial direction in the image is extracted. At the same time, a set auxiliary line is called in the preset feed piece model, and the intersection point of the two sides of the copper braid with the set auxiliary line is calculated. The vertical distance from the vertex of the copper braid to the set auxiliary line is further determined and denoted as H. According to the process specification, this distance H must meet the preset tolerance range. If the measured value exceeds the threshold, it is judged that the copper braid is offset, raised, or not properly attached to the feed piece, which is a welding defect. If the H value is qualified, it is allowed to proceed to the next process. Example 4

[0068] Reference Figures 15-23 The finished product platform 400 is used to complete the final assembly and welding of the thermal components, including a second workbench 410, a turntable 420, a fixture 421, a moving contact component feeding track 430, a bimetallic bracket component unloading and handling module 440, a welding station 450, and a material unloading channel 460.

[0069] Specifically, turntable 420 is positioned above the second worktable 410 and is driven by a servo motor, allowing for intermittent rotation. Clamps 421 are installed at equal angular intervals along the circumference of turntable 420. A moving contact assembly feeding track 430, a bimetallic support assembly unloading and handling module 440, a welding station 450, and a discharge channel 460 are sequentially arranged around turntable 420 on the second worktable 410. Additionally, a fifth robotic arm 401 is positioned corresponding to the moving contact assembly feeding track 430, and a sixth robotic arm 402 is positioned between the discharge channel 460 and turntable 420. The fifth robotic arm 401 picks up the moving contact assembly and loads it into clamps 421, while the sixth robotic arm 402 removes the welded finished thermal assembly from clamps 421 and outputs it through the discharge channel 460.

[0070] The moving contact assembly is continuously conveyed from the preceding unit to the picking position via the moving contact assembly feeding track 430. The fifth robot arm 401 picks up a single moving contact assembly and rotates it into the fixture 421 below this station. At the next station, the bimetallic bracket assembly unloading and handling module 440 cuts the bimetallic bracket strip from the stamping process, separates individual bracket units, and transfers them to the fixture 421 via the built-in transfer unit for spatial alignment with the already installed moving contact assembly. In some embodiments, refer to Figure 20 and Figure 21 The second fixture 421 includes a second plate 4211, on which a third clamping area 4212 and a moving contact assembly placement area 4215 are provided. A limit block 4213 is installed on the second plate 4211 on one side of the third clamping area 4212 via an elastic element. Specifically, a blind hole is opened on the second plate 4211 near the feed side of the production line in the third clamping area 4212. An elastic element, preferably a compression spring, is embedded in the blind hole, and the bottom end of the elastic element abuts against the bottom surface of the blind hole. The top end is fixedly connected to the second limiting block 4213. A positioning pin 4214 is installed in the moving contact assembly placement area 4215. The positioning pin 4214 is a stepped cylindrical pin, with the upper section being the guide section and the lower section being the positioning section. The bottom end of the positioning pin 4214 is inserted into the pin hole of the second plate 4211 through an interference fit, and the top end protrudes above the upper surface of the second plate 4211. This is used to precisely limit the rotational freedom of the moving contact assembly and ensure the relative positional accuracy between the silver contact and the moving contact during welding.

[0071] Fixture 2 421 also includes a limiting seat 2 4216 fixedly installed on plate 2 4211. Two symmetrically arranged irregularly shaped plates 4217 are slidably installed in the limiting seat 2 4216. The irregularly shaped plates 4217 are L-shaped. The structure has a horizontal section located within the second limiting seat 4216, and a vertical section that passes through the guide groove of the second plate 4211 and extends to the front side of the moving contact assembly placement area 4215. Two irregular plates 4217 are located outside the second limiting seat 4216, each passing through the second plate 4211 and equipped with a clamping block 4218. An inclined groove 405 is provided on the irregular plate 4217. A drive rod 4219 is slidably installed inside the second limiting seat 4216. A pin 406 is fixedly installed on the drive rod 4219 and is fitted into the inclined groove 405. A spring 407 is sleeved on the drive rod 4219, and the two ends of the spring 407 are fixed to the drive rod 4219 and the bottom surface of the second limiting seat 4216, respectively.

[0072] The feeding robot on the production line delivers the bimetallic support assembly of the miniature circuit breaker into the third clamping area 4212. The side wall of the bimetallic support assembly presses against the limiting block 4213, compressing the elastic element. Under the action of elastic force, the limiting block 4213 tightly adheres to the surface of the bimetallic sheet assembly, completing the elastic pre-positioning of the bimetallic support assembly. Simultaneously, the fifth robot 401 places the assembled moving contact assembly in the moving contact assembly placement area 4215. The positioning hole of the moving contact assembly slides down the guide section of the positioning pin 4214, eventually engaging with the positioning section to achieve free translation and rotation of the moving contact assembly along the X and Y axes. Due to the degree limitation, precise pre-positioning is achieved. After the turntable 420 transports the fixture 421 to the welding station, the fixture 421 rotates with the turntable 420 to the welding station 450. Under the pre-tightening force of the spring 407, the two clamping blocks 4218 move closer to each other, positioning and clamping the copper braided wire to be welded. Then, the key connection point between the moving contact assembly and the bimetallic bracket is finally welded. Finally, the fixture 421 rotates to the unloading station, and the sixth robot 402 takes the finished thermal assembly out of the fixture 421 and transfers it to the unloading channel 460, completing the output of this unit.

[0073] It should be noted that a pneumatic push rod is installed on the second workbench 410. The pneumatic push rod releases the pressure on the drive rod 4219 upward. The spring 407 is compressed and pushes the drive rod 4219 to slide upward along the central guide hole. The pin 406 moves upward with the drive rod 4219. Under the guidance of the inclined groove 405, it pulls the two irregular plates 4217 to slide back and forth along the guide hole of the limit seat 4216. The clamping block 4218 moves away from the copper braid wire and releases the clamping constraint.

[0074] Reference Figures 17-19The bimetallic bracket assembly unloading and handling module 440 includes a cutting station 470 and a seventh robot arm 403. The seventh robot arm 403 is arranged colinearly with the cutting station 470 and is located on the extension path of the cutting station 470. It is used to receive the semi-finished products conveyed by the cutting station 470 and work in coordination with the turntable 420.

[0075] Specifically, the cutting station 470 includes a cutting frame 471 fixedly installed on the second workbench 410. The cutting frame 471 is equipped with an upper cutting die 472 and a lower cutting die 473. Specifically, the lower cutting die 473 is fixed to the bottom of the cutting frame 471 and has a cavity that matches the shape of the bimetallic bracket. The upper cutting die 472 is installed on a vertically movable slider and is driven by a servo mechanism. It can reciprocate vertically relative to the lower cutting die 473 to cut the bimetallic bracket strip output from the previous process to a fixed length, separate individual bimetallic bracket components, and place them on the second fixture 421.

[0076] During the punching process of bimetallic support components, after the continuous metal strip is punched at the cutting station 470, the individual bimetallic support components are separated and taken away by the seventh robot 403. The remaining metal support strip still maintains a continuous strip structure. If this waste strip is not treated, it will entangle and accumulate, which will not only affect the operation of the equipment, but also be detrimental to material recycling and on-site management. Therefore, in the bimetallic support component unloading and handling module 440, a waste recycling station 480 is further set downstream of the cutting station 470 to guide, cut and collect the continuous waste strip after punching in an orderly manner, so as to realize automated waste treatment.

[0077] Specifically, it includes a waste rack 481, a support rail 482, and a discharge chute 483. The support rail 482 is fixedly installed on the waste rack 481 to guide the waste strip. A cutting mechanism 484 is provided on the side of the support rail 482 away from the cutting station 470. In some preferred embodiments, the cutting mechanism 484 is a pneumatic shearing device. When the continuous waste strip is conveyed forward along the support rail 482 to a preset length, the waste cutting mechanism 484 is activated to cut the waste strip into short segments that are easy to collect, and then they fall into the discharge chute 483.

[0078] During operation, the waste strip after punching is naturally drawn out from below the lower cutting die 473 of the cutting station 470 and enters the support rail 482. The support rail 482 is provided with guide guards on both sides to prevent the waste strip from shifting or tilting. When the waste strip moves synchronously with the main cycle, the waste cutting mechanism 484 performs one cut to complete the waste segmentation. The segmented waste slides into the discharge chute 483 to achieve automatic waste removal.

[0079] Reference Figures 22-23Welding station 3 450 includes a support frame 451 mounted on the second workbench 410. A cylinder 13 452 is fixedly mounted on the support frame 451. A push block 453 is mounted on the output end of the cylinder 13 452 via a coupling. An upper dynamic plate 454 is bolted to the push block 453. A fixing rod 455 is clamped and mounted on the side of the upper dynamic plate 454 near the fixture 2 421. It also includes a lower dynamic plate 456, which is hinged to the upper dynamic plate 454. A welding rod 457 is clamped and mounted on the lower dynamic plate 456. The fixing rod 455 and the welding rod 457 are located on the upper and lower sides of the weld point, respectively. A cylinder 14 458 is fixedly mounted on the support frame 451. A top block 459 is elastically mounted on the output end of the cylinder 14 458. A shock-absorbing block 408 is correspondingly mounted on the lower dynamic plate 456.

[0080] Furthermore, a tension spring 409 is fixedly connected between the upper dynamic plate 454 and the lower dynamic plate 456.

[0081] Specifically, the support frame 451 includes a base plate 4511 and at least two sets of vertically arranged guide columns 4512. The bottom end of each guide column 4512 is fixedly connected to the upper surface of the base plate 4511. A horizontal plate 4513 is fixedly installed at the other end of the guide column 4512. A slide rail 4514 is fixedly installed on the horizontal plate 4513. A push block 453 is installed in the slide rail 4514. A slide table 4515 is fixedly installed on the second worktable 410. The side of the base plate 4511 away from the guide columns 4512 is installed in conjunction with the slide table 4515. A cylinder mounting hole 4516 is opened on the base plate 4511 for fixing the cylinder 458.

[0082] When turntable 2 420 drives fixture 2 421 to rotate directly below welding station 3 450, cylinder 13 452 is activated. Its output end pushes push block 453 to move horizontally forward along slide rail 3 4514 via coupling. Push block 453 drives upper dynamic plate 454, which is bolted to it, to move forward synchronously. When the fixing rod 455 installed at the front end of upper dynamic plate 454 contacts the welding point, the force applied by tension spring 409 presses and fixes the bimetallic bracket above the welding point. As cylinder 14 458 rises, its output end pushes top block 459 upward through elastic element, such as spring. Top block 459 abuts against the shock absorber 408 at the bottom of lower dynamic plate 456, providing controllable upward support force so that welding rod 457 welds the welding point.

[0083] On the second workbench 410 between the fifth robotic arm 401 and the bimetallic bracket assembly unloading and handling module 440, a detection device 490 is also provided to confirm the position and attitude of the moving contact assembly that has been installed in the fixture 421, thereby further improving the overall assembly reliability and yield.

[0084] Reference Figure 29An inspection camera 3404 is installed upstream of the material feeding channel 460 for visual inspection of finished thermal components. Example 5

[0085] Reference Figure 15 , Figure 16 and Figure 24 and Figure 25 The multi-station continuous welding unit 2500 is used to complete the assembly and connection of the moving contact, moving contact support and copper braid wire in the thermal assembly, forming a hot melt semi-finished product with complete electrical contact function.

[0086] Specifically, it includes a third worktable 510, a turntable 520 mounted above the third worktable 510, driven by a high-precision servo motor and capable of intermittent rotation, with clamps 521 installed at equal angular intervals along its circumferential direction, and a moving contact feeding plate 530, a moving contact support feeding plate 540, a copper braided wire welding unit 550, a hot melt unit 560, and an eighth robotic arm 501 sequentially arranged around the turntable 520 on the third worktable 510. It also includes components corresponding to the moving contact feeding plate 530 and... The ninth robot 502 between turntable 3 520, the tenth robot 503 between moving contact support feeding tray 540 and turntable 3 520, and the eleventh robot 504 between copper braid welding unit 2 550 and hot melt unit 560 are used to pick up the moving contact and load it into fixture 3 521. The tenth robot 503 is used to place the moving contact support in the designated area of ​​fixture 3 521. The eleventh robot 504 is used to transfer the moving contact with the copper braid welded to the position where it is assembled with the support.

[0087] In detail, the moving contacts are automatically sorted and transported to the picking position by the moving contact feeder 530. The ninth robot arm 502 grasps them and places them in the fixture 521. Subsequently, the moving contact support is fed by the moving contact support feeder 540, grasped by the tenth robot arm 503, and also placed in the fixture 521, maintaining spatial separation from the moving contacts. A coil feeder is provided on one side of the copper braided wire welding unit 550, and the copper braided wire is continuously fed by the coil feeder. When passing through the copper braided wire welding unit 550, it is cut to a fixed length. The copper braided wire is cut and welded to the moving contact fed in from the previous station. After the copper braided wire welding is completed, the fixture 3 521 continues to rotate to the eleventh robot 504 station. The eleventh robot 504 picks up the moving contact with the welded copper braided wire and transfers it to the moving contact support, where it is fitted into place. Then, the fixture 3 521 enters the hot melt unit 560 to apply heat and pressure to the connection area between the moving contact and the support, softening the local material and forming a metallurgical bond or mechanical interlocking structure, thereby achieving a high-strength, low-resistance permanent connection.

[0088] Finally, the semi-finished product that has completed the hot melting is rotated by turntable 3 520 to the eighth robot arm 501 station. The eighth robot arm 501 takes the hot-melted semi-finished product out of fixture 3 521 and transfers it to the moving contact assembly feeding track 430, completing the output of this unit.

[0089] Reference Figure 24 The fixture 521 includes a plate 5211, on which a fourth clamping area 5212 and a fifth clamping area 5213 are provided. The fourth clamping area 5212 is used to clamp the moving contact, and the fifth clamping area 5213 is used to assemble the moving contact bracket and perform final assembly with the moving contact with the welded copper braid wire. A limit block 5214 is installed on the plate 5211 on one side of the fourth clamping area 5212 and the fifth clamping area 5213 via an elastic element, preferably a spring. When the moving contact is picked up from the moving contact feed tray 530 by the ninth robot arm 502 and placed in the fourth clamping area 5212, the limit block 5214 stably fixes the moving contact in the predetermined position. Subsequently, the fixture 521... 21 rotates with turntable 3 520 to copper braid wire welding unit 2 550 for fixed-length cutting and laser welding of copper braid wire. After the copper braid wire welding is completed, fixture 3 521 rotates with turntable 3 520 to the eleventh robot arm 504 station. The eleventh robot arm 504 picks up the moving contact located in the fourth clamping area 5212 and transfers it to the fifth clamping area 5213, so that it fits into the pre-placed moving contact bracket. Fixture 3 521 continues to rotate to the hot melt unit 560. Here, the hot melt welding head 5632 applies heat and pressure to the connection area between the moving contact and the bracket, softening the local material and forming a metallurgical bond or mechanical interlocking structure, thereby achieving a high-strength, low-resistance permanent connection.

[0090] In some embodiments, the hot melt unit 560 includes a hot melt frame 561, on which a cylinder 562 is fixedly mounted, and the output end of the cylinder 562 is connected to a hot melt pressure head assembly 563.

[0091] Reference Figure 25 The hot melt pressure head assembly 563 includes a mounting plate 5631, a hot melt welding head 5632 embedded in the lower end of the mounting plate 5631, and a guide rail 5633 fixedly mounted on the hot melt frame 561. The mounting plate 5631 slides on the guide rail 5633 and is elastically connected to the output end of the cylinder 562.

[0092] Preferably, the hot melt welding head 5632 can be any one of an ultrasonic welding head, a high-frequency induction heating head, or a resistance hot riveting head. It integrates a heating element and a temperature sensor, and can apply controllable heat energy to the connection area between the moving contact and the moving contact support according to preset process parameters. When the fixture 3 521 rotates with the turntable 3 520 to the hot melt station, the cylinder 6 562 drives the hot melt pressure head assembly 563 to move downward, so that the hot melt welding head 5632 presses against the joint between the already assembled moving contact and the support. After the hot melt connection is completed within the set time, the cylinder 6 562 retracts, the hot melt pressure head assembly 563 resets, and the fixture 3 521 continues to rotate to the next station.

[0093] During the hot-melting process, the assembly of the moving contact and the moving contact support needs to withstand the vertical pressure applied by the hot-melt welding head 5632. If there is a lack of lateral restraint, the material is prone to slight displacement or warping due to heat softening, resulting in hot-melt position deviation, insufficient connection strength, or even component failure. Therefore, clamping rods 564 that can approach each other are also installed on the hot-melt frame 561.

[0094] Specifically, clamping rods 564 are symmetrically arranged on both sides of the hot melt welding head 5632, and are driven by cylinders 7 565 and 8 566 respectively. Mounting plates 5631 that can slide on the hot melt frame 561 are also installed on the movable ends of cylinders 7 565 and 8 566. The clamping rods 564 are also mounted on the mounting plates 5631. When the fixture 3 521 rotates to the hot melt station and completes positioning, cylinders 7 565 and 8 566 move synchronously, driving the two clamping rods 564 to move towards each other in the vertical direction, clamping the non-functional area of ​​the moving contact bracket, forming a three-point positioning constraint, effectively suppressing deformation and displacement during the hot melt process. After the hot melt is completed, the clamping rods 564 return to their original position, making room for the rotation of fixture 3 521.

[0095] To further save installation space and improve structural compactness, cylinder 8 566 and cylinder 7 565 are perpendicular to each other in spatial position. A wedge block 567 is fixedly installed at the output end of cylinder 8 566. The wedge block 567 slides within the horizontal rail set on the hot melt frame 561. A roller 2 568 is rotatably installed on the corresponding mounting plate 5631. The outer circumferential surface of roller 2 568 abuts against the inclined surface of wedge block 567. When cylinder 8 566 extends, wedge block 567 advances horizontally, and its inclined surface pushes roller 2 568 upward, thereby driving the entire mounting plate 5631 and the clamping rod 564 connected to it to rise synchronously. Conversely, when cylinder 8 566 retracts, wedge block 567 retracts, and under the action of return spring 569, roller 2 568 falls back along the inclined surface, causing clamping rod 564 to return to its original position.

[0096] A second inspection camera 570 is installed on the third worktable 510 between the hot-melt unit 560 and the eighth robot arm 501. It is used to make a final quality judgment on the moving contact assembly that has completed the hot-melt connection to ensure that it meets the subsequent assembly and functional requirements.

[0097] Specifically, refer to Figure 27 The detection camera 2570 first identifies the central axis of the copper braid wire and its relative relationship with the edge of the moving contact solder joint, determining its position and vertical angle. If the copper braid wire tilts beyond a set threshold or deviates from the center of the solder joint beyond the allowable tolerance, it is determined to be a soldering misalignment or a raised copper braid wire. Next, for the elastic reset component integrated in the moving contact assembly, its outer contour shape and closure are identified through an edge extraction algorithm. If the contour is missing, broken, or the position is abnormal, it is determined to be a missing or deformed spring. The system pre-stores a standard product that is fully installed as a reference template. During the inspection process, the image of the current workpiece is matched with the template using normalized cross-correlation to calculate the similarity score. If the similarity score is lower than the set threshold or in key areas, such as the moving contact latch or the bracket mating surface, and there are obvious differences, it is determined that the moving contact is not fully embedded in the bracket or the assembly is misaligned. If all features meet the requirements, the eighth robot arm 501 is allowed to take it away normally and enter the downstream process. If any item is unqualified, it is marked as an abnormal product, and the eighth robot arm 501 is controlled to divert it to the scrap channel to achieve automatic rejection.

[0098] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely preferred examples and are not intended to limit the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. An integrated online stamping and welding production line for miniature circuit breakers, used for continuous processing and forming of hot component raw material strips, characterized in that: It includes a raw material supply unit (100), a conveying track (200), a multi-station continuous welding unit one (300) and a multi-station continuous welding unit two (500) arranged sequentially along the conveying direction of the material belt, and a finished product platform (400) is provided between the multi-station continuous welding unit one (300) and the multi-station continuous welding unit two (500). The first multi-station continuous welding unit (300) is used to perform preliminary welding on the strip formed by the stamping of the raw material supply unit (100). The second multi-station continuous welding unit (500) is used for subsequent multiple welding processes. The finished product platform (400) is used to temporarily store the semi-finished products processed by the first multi-station continuous welding unit (300) for the second multi-station continuous welding unit (500) to continue processing.

2. The integrated online stamping and welding production line for miniature circuit breakers according to claim 1, characterized in that: The raw material supply unit (100) includes a stamping mechanism (110) and a material roll holder A (120) and a material roll holder B (130) for carrying raw material rolls, respectively. The stamping mechanism (110) is equipped with an upper die (140) and a lower die (150) that cooperate with each other. The lower die (150) integrates a first station (151) for forming the A material from the material roll holder A (120), a second station (152) for punching the B material from the material roll holder B (130), a third station (153) for riveting the A material and the B material, and a fourth station (154) for bending, shaping and pre-cutting the riveted components. The first station (151) and the second station (152) are arranged vertically in space so that material A and material B are fed in mutually perpendicular directions after entering the lower mold (150) and are processed synchronously to form the base component.

3. The integrated online stamping and welding production line for miniature circuit breakers according to claim 2, characterized in that: The first station (151) and the second station (152) are equipped with cutting parts at their inlets. The upper mold (140) and the lower mold (150) are respectively provided with punches (141) and material discharge channels (155). The material discharge channels (155) are connected to an external waste collection box.

4. The integrated online stamping and welding production line for miniature circuit breakers according to claim 1, characterized in that: The multi-station continuous welding unit 1 (300) includes a first workbench (310), a turntable 1 (320) disposed above the first workbench (310), and clamps 1 (321) spaced apart on the turntable 1 (320). The bimetallic sheet feeding tray (330), copper braided wire welding unit one (340), wire feed tray (350), welding station one (360) and welding station two (370) are arranged sequentially around the turntable one (320) on the first worktable (310). It also includes a first robot (301) corresponding to the bimetallic sheet feeding tray (330) and the turntable one (320), a second robot (302) and a third robot (303) corresponding to the wire feed tray (350) and the turntable one (320), and a fourth robot (304) corresponding to the welding station two (370) and the turntable one (320). The copper braid welding unit (340) is provided with a coil feeder on one side. The copper braid is continuously fed by the coil feeder. When it passes through the copper braid welding unit (340), it is cut to a fixed length and welded to the bimetallic sheet fed in by the previous station.

5. The integrated online stamping and welding production line for miniature circuit breakers according to claim 4, characterized in that: The conveying track (200) is set on the first workbench (310) and located on one side of the turntable (320). The welding station (370) is located on the extension path of the conveying track (200) and is used to receive the base components conveyed by the conveying track (200) and work together with the turntable (320).

6. The integrated online stamping and welding production line for miniature circuit breakers according to claim 4, characterized in that: The clamp (321) includes a plate (3211), on which a first clamping area (3212), a second clamping area (3213), and a placement groove (3214) are provided. A limit block (3215) is installed on the plate (3211) on one side of the first clamping area (3212) and the second clamping area (3213) by means of an elastic element.

7. The integrated online stamping and welding production line for miniature circuit breakers according to claim 1, characterized in that: The finished product table (400) includes a second workbench (410), a turntable (420) disposed above the second workbench (410), and clamps (421) spaced apart on the turntable (420). The moving contact assembly feeding track (430), the bimetallic bracket assembly unloading and handling module (440), the welding station three (450) and the unloading channel (460) are arranged sequentially around the turntable two (420) on the second worktable (410). It also includes a fifth robot (401) corresponding to the moving contact assembly feeding track (430) and a sixth robot (402) located between the unloading channel (460) and the turntable two (420).

8. The integrated online stamping and welding production line for miniature circuit breakers according to claim 7, characterized in that: The bimetallic support assembly unloading and handling module (440) includes a cutting station (470) and a seventh robot (403). The seventh robot (403) is arranged colinearly with the cutting station (470) and is located on the extension path of the cutting station (470). It is used to receive the semi-finished products conveyed by the cutting station (470) and work in cooperation with the turntable (420). The cutting station (470) includes a cutting frame (471) fixedly installed on the second workbench (410). The cutting frame (471) is equipped with an upper cutting die (472) and a lower cutting die (473). The upper cutting die (472) is driven by a servo stamping structure and can reciprocate vertically relative to the lower cutting die (473) to cut the bimetallic bracket strip output from the previous process and separate individual bimetallic bracket assemblies.

9. The integrated online stamping and welding production line for miniature circuit breakers according to claim 1, characterized in that: The multi-station continuous welding unit two (500) includes a third workbench (510), a turntable three (520) disposed above the third workbench (510), and fixtures three (521) are installed at intervals on the turntable three (520). The moving contact feeding plate (530), the moving contact support feeding plate (540), the copper braided wire welding unit (550), the hot melt unit (560), and the eighth robot (501) are arranged sequentially around the turntable three (520) on the third worktable (510). It also includes the ninth robot (502) between the moving contact feeding plate (530) and the turntable three (520), the tenth robot (503) between the moving contact support feeding plate (540) and the turntable three (520), and the eleventh robot (504) between the copper braided wire welding unit two (550) and the hot melt unit (560). The copper braided wire welding unit 2 (550) is provided with a coil feeder on one side. The copper braided wire is continuously fed by the coil feeder. When it passes through the copper braided wire welding unit 2 (550), it is cut to a fixed length and welded to the moving contact fed in by the previous station.

10. The integrated online stamping and welding production line for miniature circuit breakers according to claim 9, characterized in that: The fixture three (521) includes a plate three (5211), on which a fourth clamping area (5212) and a fifth clamping area (5213) are provided. A limit block three (5214) is installed on the plate three (5211) on one side of the fourth clamping area (5212) and the fifth clamping area (5213) by means of an elastic element. When the moving contact in the fourth clamping area (5212) is processed by the copper braid welding unit two (550), it is transferred by the eleventh robot (504) to the fifth clamping area (5213) and assembled with the moving contact bracket.

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