Processing die and method for a soldering positioning boss of a special-shaped copper bar

Abstract

This invention relates to the field of metal component welding and mold forming technology, and discloses a processing mold for a brazing positioning boss of an irregular copper busbar, including a matching upper mold and a lower mold. A punch is detachably installed on the upper mold, and the lower mold has a mold cavity that cooperates with the punch. This processing mold and method for a brazing positioning boss of an irregular copper busbar utilizes a combination of weld joint enlargement forming and boss positioning. Relying on the inherent perforated characteristics of the copper busbar and copper block, the original hole structure is first optimized through a hole enlargement process. Then, combined with the geometric principle that two points determine a straight line, a positioning boss is set when the number of holes is met, allowing the copper busbar components to achieve precise docking during the brazing process. This completely solves the core problems of inaccurate positioning and weld joint alignment deviation in traditional butt welding processes. At the same time, it significantly improves processing efficiency, enhances the stability of the production process, ensures the consistency of product quality, and effectively saves production costs compared to traditional bulge positioning methods.

Description

Technical Field

[0001] This invention relates to the field of metal component welding and mold forming technology, specifically to a processing mold and method for brazing positioning bosses on irregularly shaped copper busbars. Background Technology

[0002] In power transmission and distribution systems, copper busbars serve as core conductive components, and their structural forming precision and connection reliability directly determine the operating efficiency, conductivity stability, and safety of the entire power system. With the rapid development of power electrical equipment towards high density, integration, and miniaturization, the application scenarios for irregularly shaped copper busbar assemblies are becoming increasingly widespread. These assemblies are typically composed of multiple copper busbar sub-components that are processed separately and then assembled through a brazing process. The relative positioning precision of each copper busbar sub-component during brazing is crucial for ensuring the quality of the weld formation, the conductivity of the assembly, and its structural strength.

[0003] However, existing technologies mainly employ two types of positioning processing methods. The first is to use mechanical cutting to create process holes and positioning bosses on the copper busbar components, using the engagement of the bosses and process holes to achieve positioning. Although this method can guarantee positioning accuracy to a certain extent, the mechanical cutting process is cumbersome, the processing cycle is long, and a large processing allowance needs to be reserved before processing the copper busbar components, resulting in high material loss and high processing costs. In mass industrial production, the processing efficiency is low and it is difficult to meet production capacity requirements. The second method is to use special tooling fixtures to braze and position the copper busbar components. Although this method can improve the convenience of assembly and positioning, the design and manufacturing costs of special tooling fixtures are high, and the structural adaptability of the fixtures is poor. They can only correspond to non-standard copper busbar components of a single specification and structure, and cannot flexibly switch between copper busbar products of different structures and sizes. The process versatility is insufficient, and additional storage and maintenance costs of tooling fixtures are added, which also restricts the flexible production of copper busbar processing.

[0004] Therefore, a processing mold and method for brazing positioning bosses on irregularly shaped copper busbars are proposed to solve the problems mentioned above. Summary of the Invention

[0005] (a) Technical problems to be solved To address the shortcomings of existing technologies, this invention provides a processing mold and method for brazing positioning bosses on irregularly shaped copper busbars. This solves the problems of high process complexity, difficulty in controlling positioning accuracy, easy alignment deviations at the weld joints, low processing efficiency, high manufacturing costs, poor versatility of positioning molds and processes, and difficulty in adapting to the flexible mass production of various specifications of irregularly shaped copper busbars.

[0006] (II) Technical Solution To achieve the above objectives, the present invention provides the following technical solution: A processing mold for brazing positioning bosses on irregularly shaped copper busbars includes an upper mold and a lower mold. A punch is detachably mounted on the upper mold, and the lower mold has a cavity that mates with the punch. The punching end of the punch adopts a stepped forming structure, which can simultaneously punch process holes, positioning bosses, and recesses on the back of the positioning bosses on the copper busbar components. The fit tolerance between the positioning bosses and the process holes meets the accuracy requirements for brazing positioning of the copper busbar components. The mold can be adapted to the processing needs of irregularly shaped copper busbar components with different structures and sizes by changing punches of different specifications and adjusting the dimensional parameters of the mold cavity.

[0007] Preferably, the diameter of the punch is consistent with the design diameter of the process hole to be processed. The stepped forming structure of the punch is divided into a blanking section and a forming section. The blanking section is used to form the process hole on the copper busbar component, and the forming section is used to form the positioning boss and the recess on the back of the positioning boss.

[0008] Preferably, the inner wall contour of the mold cavity matches the outer contour of the punch forming section to define the forming size of the positioning boss.

[0009] Preferably, both the upper mold and the lower mold are provided with a positioning and guiding structure. The positioning and guiding structure includes at least two sets of guide posts and guide sleeves. The guide posts are fixed to the lower mold, and the guide sleeves are correspondingly provided to the upper mold. The guide posts and guide sleeves are in clearance fit.

[0010] Preferably, the punch is fixed to the upper die by bolt connection or quick-release snap-fit, and the mounting end of the punch is provided with a positioning flange, and the upper die is provided with a corresponding mounting groove adapted to the positioning flange.

[0011] Preferably, the bottom of the mold cavity of the lower mold is provided with an ejector assembly, the ejector assembly including an ejector rod and a reset elastic element, the ejector rod passing through the bottom of the mold cavity, and the reset elastic element being sleeved outside the ejector rod and abutting against the inside of the lower mold.

[0012] Preferably, the stamping end edge of the upper die and the forming surface edge of the punch are provided with rounded corner transition structures, and the rounded corner transition structures are arranged in a continuous ring along the corresponding edges.

[0013] Preferably, both the upper and lower dies are made of high-strength wear-resistant alloy material, and the punch is made of cemented carbide material.

[0014] Preferably, the lower mold has a waste discharge port, which is connected to the mold cavity, and the cross-sectional dimension of the waste discharge port is larger than the cross-sectional dimension of the mold cavity.

[0015] A method for processing a brazing positioning boss on an irregularly shaped copper busbar further includes the following steps: Step 1: First, based on the design drawings of the irregular copper busbar, process two copper busbar components to be welded, ensuring that the external dimensions and material properties of the copper busbar components meet the design standards; Step 2: At the preset welding position of one of the copper busbar components, process round holes are machined using drilling technology. The diameter and tolerance of the process round holes must not exceed the specified values. According to the specifications of the process round holes, the appropriate punch is replaced for the processing mold, the mold cavity size is adjusted, and the coaxiality of the upper and lower molds is calibrated through the positioning guide structure to complete the mold debugging. Step 3: Place another copper busbar component in the positioning position of the lower mold, drive the upper mold to close the mold downwards, and the punch and the mold cavity work together to simultaneously punch out the positioning boss on the process hole at the corresponding position of the copper busbar component. The positioning boss is also integrally formed with a recess on the back of the positioning boss. After the stamping is completed, the material is unloaded through the ejector assembly, and the waste is discharged from the waste discharge port. The stamped positioning boss is embedded into the process round hole to achieve the initial positioning of the two copper busbar components. Silver-based brazing filler is filled into the joint area. The tooling fixture is used to help to align and apply slight pressure to ensure that the components are aligned correctly before brazing. Step 4: After welding is completed, according to the final design drawings of the irregular copper busbar, the process holes are enlarged to achieve the final forming size of the product, thus completing the processing of the entire irregular copper busbar assembly.

[0016] (III) Beneficial Effects Compared with the prior art, the present invention provides a processing mold and method for brazing positioning bosses on irregularly shaped copper busbars, which has the following beneficial effects: 1. The processing mold and method for the positioning boss of the irregular copper busbar brazing utilize a combination scheme of weld joint enlargement forming and boss positioning. Relying on the inherent hole characteristics of the copper busbar and copper block, the original hole structure is first optimized through hole enlargement process. Then, combined with the geometric principle that two points determine a straight line, the positioning boss is set when the hole quantity requirement is met, so that the copper busbar components can achieve precise docking during the brazing process. This completely solves the core problems of inaccurate positioning and weld joint alignment deviation in the traditional butt welding process. At the same time, it greatly improves processing efficiency, enhances the stability of the production process, ensures the consistency of product quality, and effectively saves production costs compared with the traditional bulge positioning method.

[0017] 2. The processing mold and method for the brazing positioning boss of the irregular copper busbar utilizes a structure setting for synchronous forming by mold stamping. Through the coordinated operation of a dedicated stamping mold, the stamping operation is completed at the designated position of the copper busbar component. The positioning boss and process hole can be formed in one processing, and a recess can be formed simultaneously on the other side of the corresponding component of the boss. No additional processing steps are required, freeing the positioning boss processing from the constraints of traditional cutting processes, eliminating cumbersome cutting procedures, significantly saving processing time, improving the overall processing efficiency from a process perspective, reducing the waste of processing allowance, and further reducing various costs in the production process.

[0018] 3. The processing mold and method for the brazing positioning boss of the irregular copper busbar utilizes the adjustable structure of a general-purpose stamping mold. The stamping mold adopts an adjustable punch and die cavity design, eliminating the need to design and manufacture special molds for irregular copper busbar products with different structures. Simply adjust the size of the punch and die cavity according to the positioning requirements of different products to adapt to the processing requirements of various copper busbar components. This significantly reduces the design, manufacturing and maintenance costs of tooling fixtures, enhances the versatility and flexibility of the process, meets the high-efficiency and flexible manufacturing requirements of copper busbar components, and is particularly suitable for large-scale industrial production scenarios, thereby improving overall production efficiency. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the upper mold structure of a processing mold for a brazing positioning boss on a non-circular copper busbar, as proposed in this invention. Figure 2 This is a schematic diagram of the lower mold structure for processing a special-shaped copper busbar brazing positioning boss proposed in this invention; Figure 3 This is a schematic diagram of the mold guide structure for processing a brazing positioning boss for an irregularly shaped copper busbar, as proposed in this invention.

[0020] In the diagram: 1. Upper die; 2. Lower die; 3. Punch; 4. Mold cavity; 5. Guide structure; 7. Scrap outlet. 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] Please see Figure 1 - Figure 3 A processing mold for brazing positioning bosses on irregularly shaped copper busbars includes an upper mold 1 and a lower mold 2. A punch 3 is detachably mounted on the upper mold 1, and a mold cavity 4 that mates with the punch 3 is provided on the lower mold 2. The punching end of the punch 3 adopts a stepped forming structure, which can simultaneously punch process holes, positioning bosses, and recesses on the back of the positioning bosses on the copper busbar components. The fit tolerance between the positioning bosses and the process holes meets the accuracy requirements for brazing positioning of the copper busbar components. The mold can be adapted to the processing needs of irregularly shaped copper busbar components with different structures and sizes by replacing the punch 3 of different specifications and adjusting the dimensional parameters of the mold cavity 4.

[0023] First, the diameter of punch 3 is consistent with the design diameter of the process hole to be processed. The stepped forming structure of punch 3 is divided into a blanking section and a forming section. The blanking section is used to form the process hole on the copper busbar component, and the forming section is used to form the positioning boss and the recess on the back of the positioning boss. Through the precise matching of punch 3 with the design diameter of the process hole, the size compatibility between the process hole and the positioning boss is achieved. With the help of the segmented operation design of the stepped forming structure, the integrated forming of the process hole, positioning boss and recess can be completed simultaneously in a single stamping, without the need for multiple processing steps, effectively simplifying the processing flow, greatly improving the processing efficiency of the positioning structure, and ensuring the relative positional accuracy between the blanking and forming structures, laying the structural foundation for the accuracy of subsequent brazing positioning of the copper busbar component.

[0024] Secondly, the inner wall contour of the mold cavity 4 matches the outer contour of the forming section of the punch 3 to limit the forming size of the positioning boss. Through the precise fit between the mold cavity 4 and the outer contour of the forming section of the punch 3, the dimensional rigidity of the positioning boss forming process is achieved, effectively avoiding the problem of boss size deviation caused by material deformation during the stamping process, ensuring the forming accuracy and dimensional consistency of the positioning boss, and at the same time, effectively controlling the surface flatness of the boss forming, ensuring the fitting accuracy between the positioning boss and the process round hole, and meeting the accuracy requirements of the brazing positioning of the copper busbar.

[0025] Furthermore, both the upper mold 1 and the lower mold 2 are equipped with positioning guide structures 5. The positioning guide structure 5 includes at least two sets of guide pillars and guide sleeves. The guide pillars are fixed to the lower mold 2, and the guide sleeves are correspondingly set on the upper mold 1. The guide pillars and guide sleeves are in clearance fit. By setting at least two sets of positioning guide structures 5 in the upper and lower molds and adopting the clearance fit method between the guide pillars and guide sleeves, the precise guidance and coaxiality calibration of the upper mold 1 and the lower mold 2 during mold closing and stamping are achieved. This effectively prevents the punch 3 from deviating or skewing during stamping, ensures the precise alignment of the punch 3 and the mold cavity 4, and avoids processing defects of the copper busbar parts caused by mold deviation. At the same time, the clearance fit design can reduce the wear of the guide structure 5, improve the service life of the positioning guide structure 5, and ensure the accuracy and stability of the mold during long-term continuous processing.

[0026] Furthermore, the punch 3 is fixed to the upper die 1 by bolt connection or quick-release snap-fit. The mounting end of the punch 3 is provided with a positioning flange, and the upper die 1 is provided with a corresponding mounting groove that matches the positioning flange. Through the precise engagement of the positioning flange and the mounting groove of the upper die 1, the punch 3 can be quickly positioned and its coaxiality can be guaranteed during the installation process. Combined with the fixing method of bolt connection or quick-release snap-fit, the punch 3 and the upper die 1 are firmly connected to prevent the punch 3 from loosening or shifting during the stamping process. At the same time, the punch 3 can be quickly disassembled and replaced, which is convenient for adapting punches 3 of different sizes according to the processing requirements of different specifications of process round holes, improving the versatility of the mold and the mold changing efficiency, and meeting the processing requirements of multi-specification irregular copper busbars.

[0027] Furthermore, an ejector assembly is provided at the bottom of the cavity 4 of the lower mold 2. The ejector assembly includes an ejector rod and a reset elastic element. The ejector rod passes through the bottom of the cavity 4, and the reset elastic element is sleeved on the outside of the ejector rod and abuts against the inside of the lower mold 2. The elastic reset driving force of the reset elastic element drives the ejector rod to move up and down reciprocally, realizing automatic ejection and unloading of the copper busbar after stamping. There is no need for manual removal of parts, which improves the automation level and production efficiency of the processing. At the same time, it avoids the collision and damage to the positioning boss after forming during the manual removal of parts, ensuring the product processing quality. It can also effectively prevent the copper busbar from sticking to the cavity 4 after stamping, ensuring continuous and stable processing of the mold.

[0028] Furthermore, the stamping end edge of the upper die 1 and the forming surface edge of the punch 3 are both provided with rounded corner transition structures. The rounded corner transition structures are arranged in a continuous ring along the corresponding edges. By setting the continuous ring rounded corner transition structures on the stamping end edge of the upper die 1 and the forming surface edge of the punch 3, flexible contact processing of the copper busbar is achieved during the stamping process. This effectively avoids the material stress concentration problem caused by sharp corner stamping, prevents processing defects such as edge cracking and warping of the copper busbar, reduces the stamping friction between the punch 3 and the copper busbar, reduces the wear rate of the punch 3, extends the service life of the punch 3, and makes the edges of the process holes and bosses after forming smoother, improving the processing appearance and structural integrity of the product.

[0029] Furthermore, both the upper die 1 and the lower die 2 are made of high-strength wear-resistant alloy materials, while the punch 3 is made of hard alloy material. By selecting high-strength wear-resistant alloy materials for the upper die 1 and the lower die 2, the main structure of the mold is made of high rigidity and wear resistance, which can withstand the mechanical load of long-term continuous stamping, prevent the mold from deforming and wearing, and ensure the overall structural accuracy of the mold. The punch 3 is made of hard alloy material, which achieves ultra-high hardness, wear resistance and impact resistance, effectively meeting the stamping processing requirements of copper busbar materials, avoiding chipping and wear of the punch 3 during the blanking and forming process, ensuring the forming accuracy of the punch 3, greatly improving the service life of the entire mold, and adapting to the production needs of large-scale continuous industrial processing.

[0030] Finally, the lower die 2 has a waste discharge outlet 7, which is connected to the die cavity 4. The cross-sectional size of the waste discharge outlet 7 is larger than that of the die cavity 4. By connecting the waste discharge outlet 7 to the die cavity 4, the waste generated by the stamping process hole can be discharged in a directional manner. With the help of the larger cross-sectional size design of the waste discharge outlet 7, blockage and jamming problems during the discharge process are avoided, ensuring the smooth discharge of waste and preventing waste from accumulating in the die cavity 4, which would affect the accuracy and efficiency of subsequent stamping processes. At the same time, there is no need for frequent manual cleaning of waste in the die cavity 4, further improving the continuity and automation of the processing.

[0031] A method for processing a brazing positioning boss on an irregularly shaped copper busbar further includes the following steps: Step 1: First, based on the design drawings of the irregular copper busbar, process two copper busbar components to be welded, ensuring that the external dimensions and material properties of the copper busbar components meet the design standards; Step 2: At the preset welding position of one of the copper busbar components, process round holes are machined using drilling technology. The diameter and tolerance of the process round holes must not exceed the specified values. According to the specifications of the process round holes, the appropriate punch 3 is replaced for the processing mold, the size of the mold cavity 4 is adjusted, and the coaxiality of the upper mold 1 and the lower mold 2 is calibrated through the positioning guide structure 5 to complete the mold debugging. Step 3: Place another copper busbar component in the positioning position of the lower mold 2, drive the upper mold 1 to close the mold downwards, and the punch 3 and the mold cavity 4 work together to simultaneously punch out the positioning boss on the process hole at the corresponding position of the copper busbar component, and form an integrally formed recess on the back of the positioning boss. After the stamping is completed, the material is unloaded through the ejector assembly, and the waste is discharged from the waste discharge outlet 7. The stamped positioning boss is embedded into the process round hole to achieve the initial positioning of the two copper busbar components. Silver-based brazing filler is filled into the joint area, and the tooling fixture is used to assist in the alignment and apply slight pressure to ensure that the components are aligned correctly before brazing. Step 4: After welding is completed, according to the final design drawings of the irregular copper busbar, the process holes are enlarged to achieve the final forming size of the product, thus completing the processing of the entire irregular copper busbar assembly.

[0032] Working principle: The upper mold 1 and lower mold 2 of this processing mold are compatible core forming structures. The upper mold 1 can be detachably installed with the punch 3 by bolt connection or quick-release snap-fit. The positioning flange at the mounting end of the punch 3 is precisely matched with the mounting groove of the upper mold 1 to ensure the coaxiality and stability of the punch 3 installation. The lower mold 2 has a mold cavity 4 that matches the punch 3. The inner wall contour of the mold cavity 4 is precisely matched with the outer contour of the forming section of the punch 3, providing a dimensional basis for the forming of the positioning boss. The positioning guide structure 5 set in the upper mold 1 and the lower mold 2 is clearance fit. During the mold closing process, the guide post and the guide sleeve form a precise guide, effectively ensuring the coaxiality of the upper mold 1 and the lower mold 2, avoiding misalignment during punching and forming, and ensuring stamping accuracy. The punching end of punch 3 has a stepped forming structure, divided into a blanking section and a forming section. When the mold is closed, the upper mold 1 is driven downward. The blanking section of punch 3 first completes the blanking forming of the process hole at the preset position of the copper busbar. As the upper mold 1 continues to move downward, the forming section of punch 3 works in conjunction with the mold cavity 4 to simultaneously punch out the positioning boss at the process hole and integrally form the recess on the other side of the copper busbar. This achieves simultaneous forming of the process hole, positioning boss, and recess in one punching, eliminating the need for multiple processing steps. After the stamping is completed, the ejector assembly at the bottom of the mold cavity 4 of the lower mold 2 drives the ejector rod upward through the elastic reset of the reset elastic element, ejecting the processed copper busbar from the mold cavity 4 and achieving automatic unloading. The waste generated by blanking is discharged through the waste discharge outlet 7 on the lower mold 2, which is connected to the mold cavity 4. The cross-sectional size of the waste discharge outlet 7 is larger than that of the mold cavity 4 to ensure smooth waste discharge and avoid waste blockage affecting continuous processing. Meanwhile, the continuous annular rounded corner transition structure of the stamping end edge of the upper die 1 and the forming surface edge of the punch 3 can effectively avoid stress concentration and edge cracking of the copper busbar parts during the stamping process, thus improving the product processing quality. Furthermore, the upper die 1 and lower die 2 are made of high-strength wear-resistant alloy materials, and the punch 3 is made of hard alloy material, which greatly improves the wear resistance and service life of each component of the mold, making it suitable for the needs of large-volume continuous processing.

[0033] Based on the positioning boss formed by the above-mentioned die stamping, combined with the combination scheme of weld joint expansion forming and boss positioning, the precise positioning of the brazing of irregular copper busbar components is achieved by relying on the geometric principle of "two points determine a straight line". First, two copper busbar components to be welded are processed according to the design drawings. After processing the process round hole at the preset welding position of one of the copper busbar components, the mold is adjusted according to the specifications of the process round hole by changing the appropriate punch 3 and adjusting the size of the mold cavity 4. The coaxiality is calibrated by the positioning guide structure 5 to complete the mold debugging. Then, the other copper busbar component is placed in the positioning position of the lower mold 2. The process hole + positioning boss are integrated by the above-mentioned die stamping principle. The stamped positioning boss is embedded in the process round hole of the other copper busbar component. The precise fit tolerance between the boss and the process hole forms the initial positioning of the copper busbar component. If the number of preset holes of the copper busbar component is ≥2, two positioning bosses are stamped at the corresponding positions by the die. The straight line constraint formed by the two points can completely avoid the problems of circumferential deviation and weld joint alignment deviation during the brazing of the copper busbar component, and achieve precise docking of the components. After positioning, silver-based brazing filler is applied to the joint. The tooling fixture is used to help align the parts and apply slight pressure to ensure that there is no relative displacement of the sub-parts before brazing. The mating structure of the boss and the process hole provides natural space for the brazing filler, which is beneficial to weld formation and weld strength improvement.

[0034] After welding, the original circular holes are enlarged according to the final design drawings of the irregular copper busbar to achieve the final product dimensions, thus completing the processing of the entire irregular copper busbar assembly. Furthermore, this mold can be adapted to the processing needs of irregular copper busbar sub-parts with different structures and sizes by changing the punches 3 of different specifications and adjusting the dimensions of the mold cavity 4. When changing processed products in the future, only the matching adjustment of the punches 3 and the mold cavity 4 needs to be completed to achieve rapid switching, ensuring the versatility and flexibility of the processing technology.

[0035] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

Claims

1. A machining mold for brazing positioning bosses on irregularly shaped copper busbars, comprising a matching upper mold (1) and a lower mold (2), characterized in that: The upper mold (1) is detachably mounted with a punch (3), and the lower mold (2) has a mold cavity (4) that cooperates with the punch (3). The punching end of the punch (3) adopts a stepped forming structure, which can simultaneously punch out process holes, positioning bosses and recesses on the back of the positioning bosses on the copper busbars. The fit tolerance between the positioning bosses and the process holes meets the accuracy requirements of the brazing positioning of the copper busbars. The mold can be adapted to the processing needs of different structures and different sizes of irregular copper busbars by replacing punches (3) of different specifications and adjusting the size parameters of the mold cavity (4).

2. The processing mold for brazing a positioning boss on a non-circular copper busbar according to claim 1, characterized in that: The diameter of the punch (3) is consistent with the design diameter of the process hole to be processed. The stepped forming structure of the punch (3) is divided into a blanking section and a forming section. The blanking section is used to form the process hole on the copper busbar, and the forming section is used to form the positioning boss and the recess on the back of the positioning boss.

3. The processing mold for brazing a positioning boss on a non-circular copper busbar according to claim 1, characterized in that: The inner wall contour of the mold cavity (4) matches the outer contour of the forming section of the punch (3) to define the forming size of the positioning boss.

4. The processing mold for brazing a positioning boss on a non-circular copper busbar according to claim 1, characterized in that: Both the upper mold (1) and the lower mold (2) are provided with positioning guide structures (5). The positioning guide structures (5) include at least two sets of guide posts and guide sleeves. The guide posts are fixed to the lower mold (2), and the guide sleeves are correspondingly provided to the upper mold (1). The guide posts and guide sleeves are in clearance fit.

5. The processing mold for brazing a positioning boss on a non-circular copper busbar according to claim 1, characterized in that: The punch (3) is fixed to the upper die (1) by bolt connection or quick-release snap-fit. The mounting end of the punch (3) is provided with a positioning flange, and the upper die (1) is provided with a mounting groove that matches the positioning flange.

6. The machining mold for brazing a positioning boss on a non-circular copper busbar according to claim 1, characterized in that: The bottom of the cavity (4) of the lower mold (2) is provided with an ejector assembly. The ejector assembly includes an ejector rod and a reset elastic element. The ejector rod passes through the bottom of the cavity (4), and the reset elastic element is sleeved outside the ejector rod and abuts against the inside of the lower mold (2).

7. The processing mold for brazing a positioning boss on a non-circular copper busbar according to claim 1, characterized in that: The upper die (1) and the forming surface edge of the punch (3) are both provided with rounded corner transition structures, and the rounded corner transition structures are arranged in a continuous ring along the corresponding edges.

8. The machining mold for brazing a positioning boss on a non-circular copper busbar according to claim 1, characterized in that: The upper die (1) and lower die (2) are both made of high-strength wear-resistant alloy material, and the punch (3) is made of hard alloy material.

9. The machining mold for brazing a positioning boss on a non-circular copper busbar according to claim 1, characterized in that: The lower mold (2) has a waste discharge port (7), which is connected to the mold cavity (4). The cross-sectional dimension of the waste discharge port (7) is larger than that of the mold cavity (4).

10. A method for processing a brazed positioning boss on an irregularly shaped copper busbar, characterized in that: The processing mold for the brazing positioning boss of the irregular copper busbar according to any one of claims 1-9 further includes the following steps: Step 1: First, based on the design drawings of the irregular copper busbar, process two copper busbar components to be welded, ensuring that the external dimensions and material properties of the copper busbar components meet the design standards; Step 2: At the preset welding position of one of the copper busbar parts, process round holes are processed by drilling. The diameter and tolerance of the process round holes must not exceed the specified values. According to the specifications of the process round holes, the appropriate punch (3) is replaced for the processing mold, the size of the mold cavity (4) is adjusted, and the coaxiality of the upper mold (1) and the lower mold (2) is calibrated by the positioning guide structure (5) to complete the mold debugging. Step 3: Place another copper busbar component in the positioning position of the lower mold (2), drive the upper mold (1) to close the mold downwards, and the punch (3) and the mold cavity (4) work together to simultaneously punch out the positioning boss on the process hole at the corresponding position of the copper busbar component, and form an integrally formed pit on the back of the positioning boss. After the punching is completed, the material is unloaded through the ejector assembly, and the waste is discharged from the waste discharge outlet (7). The stamped positioning boss is embedded into the process round hole to achieve the initial positioning of the two copper busbar components. Silver-based brazing filler is filled into the joint, and the tooling fixture is used to assist in the alignment and apply slight pressure. After ensuring that the components are aligned correctly, brazing is performed. Step 4: After welding is completed, according to the final design drawings of the irregular copper busbar, the process holes are enlarged to achieve the final forming size of the product, thus completing the processing of the entire irregular copper busbar assembly.

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