Single-knife multi-wire sleeve type shearing limiting structure, cold heading equipment and shearing blanking method thereof

Abstract

This invention proposes a single-blade, multi-line sleeve-type shearing and limiting structure, including a cutter motion assembly and a distance adjustment assembly. The cutter motion assembly contains a slidable slider and a pre-upsetting needle, with a follower on the side of the slider. The distance adjustment assembly is fixed to the equipment and has limiting step surfaces of varying heights along the cutter's lateral movement path. During operation, the cutter's lateral movement drives the follower to move along the step surfaces, forcibly adjusting the axial position of the pre-upsetting needle to form a rigid, variable-depth blind hole for stopping material. Combined with the overfeeding and slippage elimination strategies of the wire feeding mechanism, the pre-upsetting needle acts as a stop to eliminate feeding errors. This invention solves the problems of poor accuracy and unstable product volume caused by traditional cold heading machines relying on feeding pulse control for length. It achieves high-precision shearing and automatic avoidance ejection with a single blade and multi-line, significantly improving the forming quality of composite contacts.

Description

Technical Field

[0001] This invention belongs to the technical field of precision cold heading equipment, specifically relating to a single-blade multi-line sleeve-type shearing and limiting structure, cold heading equipment and its shearing and blanking method. Background Technology

[0002] In the low-voltage electrical appliance industry, riveted electrical contacts (especially triple-composite contacts) are typically manufactured using a cold heading process. Existing cold heading machines for contacts usually employ a single sleeve cutter in conjunction with a wire feeding mechanism during the wire cutting process. The workflow is as follows: the wire feeding mechanism feeds silver or copper wire into the sleeve cutter hole, the cutter moves laterally to cut the wire, and then the wire is transported to the fixed mold station for ejection and shaping.

[0003] However, existing shearing and feeding mechanisms have the following significant technical drawbacks: Limited feeding accuracy: Traditional feeding length depends entirely on the feeding stroke accuracy of the wire feeding mechanism (such as a servo motor or mechanical cam). Due to the slippage of the wire surface, the inertia of the wire feeding wheel, and the mechanical transmission clearance, the feeding length error is usually around ±0.04mm.

[0004] Unstable product quality: Fluctuations in the blanking length directly lead to unstable volume of the cut wire material segments. In the subsequent cold heading process, if the material segment volume is too small, it will result in "material shortage" in the product, leading to insufficient bonding strength or substandard dimensions; if the material segment volume is too large, it will cause "burrs" or "flash" to be generated when the mold closes, seriously affecting the appearance and dimensional stability of the contact points.

[0005] Poor adaptability to multi-wire materials: When producing multi-layer composite contacts (such as those requiring one section of silver and one section of copper), the required lengths of the material segments differ depending on the material. Existing equipment struggles to achieve rapid, precise switching and rigid limiting of different material segment lengths within a single cutting blade using purely mechanical structures.

[0006] Therefore, there is an urgent need to develop an innovative structure that can break free from the dependence on the precision of the wire feeding mechanism, achieve high-precision rigid positioning through mechanical structure, and adapt to the needs of single-blade multi-wire shearing. Summary of the Invention

[0007] To address the aforementioned technical problems in the existing technology, this invention proposes a single-blade multi-line sleeve-type shearing limiting structure, a cold heading device, and a shearing and blanking method thereof, in order to solve the above-mentioned technical problems.

[0008] According to a first aspect of the present invention, a single-blade multi-line sleeve-type shearing limiting structure is provided, comprising a cooperating cutter motion assembly and a distance adjustment assembly; the cutter motion assembly includes a sleeve cutter seat, a slider slidably disposed within the sleeve cutter seat, a pre-upsetting needle fixed on the slider, and a follower disposed on the side of the slider; the distance adjustment assembly is configured to be fixedly mounted on a cold heading machine, and has at least two limiting step surfaces of different heights along the lateral movement path of the cutter motion assembly; when the cutter motion assembly moves laterally relative to the distance adjustment assembly, the follower abuts against the limiting step surfaces of different heights, driving the slider and the pre-upsetting needle to generate axial displacement within the sleeve cutter seat, so as to lock the axial stop position of the pre-upsetting needle at different lateral positions. By coordinating the relative motion of the cutter motion component and the fixed-distance adjustment component, the lateral transport motion of the cutter is creatively transformed into the axial position adjustment motion of the pre-upsetting needle. Rigid limiting is achieved by using the follower and the limiting step surface, which enables a single cutter to automatically and accurately switch the pre-upsetting needle's stopping depth at different workstations. This solves the problem of unstable material length (large error) caused by the reliance on the feeder's accuracy in traditional equipment, and achieves precise control of each material segment with fixed length by mechanical stops.

[0009] In some specific embodiments, the distance adjustment component includes multiple limit adjustment blocks fixed to the cold heading machine bed; the limit adjustment blocks are arranged sequentially along the moving direction of the cutting blade motion component, each corresponding to a different wire cutting station. The use of a split design with adjustment blocks arranged along the moving direction enables modular management; when debugging the equipment or changing product specifications, the corresponding adjustment blocks can be independently adjusted or replaced for each specific cutting station, reducing processing difficulty and maintenance costs, and improving the versatility and adjustment flexibility of the mold.

[0010] In some specific embodiments, multiple limit adjustment blocks are connected by guide ramps. The guide ramps eliminate abrupt height changes between steps, ensuring a smooth transition for the follower when switching stations at high speeds, avoiding mechanical impact, vibration, or jamming, thereby ensuring the stability of the equipment during high-speed operation and extending the service life of the follower and adjustment blocks.

[0011] In some specific embodiments, the height difference between adjacent limit adjustment blocks is set as the axial length of the material segment cut by the previous station. When the cutter moves to the second station, the pre-upsetting needle automatically retracts to accommodate the material segment cut by the previous station. This allows for the tight arrangement of multi-layer composite materials (such as silver / copper composites) within the cutter using only mechanical structures, without the need for complex electronic control programming, ensuring that the cutting length reference for the second segment remains accurate.

[0012] In some specific embodiments, the distribution area of ​​the distance adjustment component along the lateral movement path is configured such that the distance adjustment component covers the lateral path segment where the shearing station is located, and is disconnected or missing in the lateral path segment where the ejection station is located. This ensures that when the cutter motion component moves laterally to the ejection station, the follower loses the support of the limiting step surface, and the slider is in a free state that can be pushed by an external mechanism. This setting allows the slider to automatically switch from a locked state to an axially floating free state, providing the necessary movement space for the subsequent intervention of the moving die extrusion rod and preventing mechanical interference or jamming of the mechanism.

[0013] In some specific embodiments, the lower end face of the slider is provided with a force-bearing area for receiving the thrust and a mounting area for mounting the follower; on the projection plane perpendicular to the slider axis, the projection of the force-bearing area and the projection of the follower do not overlap; the pushing end face of the external moving mold extrusion rod only covers the projection range of the force-bearing area. By staggering the force-bearing area and the follower in the spatial layout at the bottom of the slider, it is ensured that when the moving mold extrusion rod applies a large force to push the slider, it will not accidentally collide with the precision follower (such as a roller), protecting the precision transmission components from damage by the ejection impact force and ensuring the long-term accuracy maintenance.

[0014] In some specific embodiments, the follower includes a roller shaft and a roller; the roller shaft is fixedly connected to the side wall of the slider; the roller is rotatably mounted on the roller shaft; the roller is configured to extend radially outward from the inside of the sleeve cutter holder to abut against the limiting step surface of the distance adjustment assembly. The roller significantly reduces motion resistance and wear on the limiting step surface, thereby maintaining the limiting height accuracy during long-term production and avoiding material size drift due to wear.

[0015] In some specific embodiments, a balance return spring is provided inside the cutter motion assembly. This spring is located between the slider and the rear end cover of the sleeve cutter holder, and constantly applies a preload force to the slider in the direction of the distance adjustment assembly to maintain the contact between the follower and the limiting step surface. This arrangement ensures that the follower is tightly fitted to the limiting step surface, preventing the pre-upsetting needle position from floating due to vibration, and further ensuring the repeatability of the limiting position.

[0016] In some specific embodiments, the sleeve cutter holder has an axially extending mounting cavity inside, and a pre-upsetting needle fixing sleeve, which is housed within the mounting cavity, is fixedly connected to the slider; the pre-upsetting needle is coaxially fixed to the pre-upsetting needle fixing sleeve; the cutter motion assembly also includes a return spring, which is disposed within the mounting cavity, with its two ends respectively abutting against the sleeve cutter holder and the pre-upsetting needle fixing sleeve. The fixing sleeve protects the vulnerable pre-upsetting needle, facilitating quick disassembly and replacement; integrating the return spring into the mounting cavity makes the internal structure of the cutter motion assembly more compact, saving space and optimizing the force transmission path, resulting in a more stable structure.

[0017] In some specific embodiments, the pre-upsetting pin is configured to move synchronously axially within the sleeve cutter holder, following the slider, to change the axial depth position of the pre-upsetting pin's front end face within the cutter hole. As the final actuating element, the pre-upsetting pin ensures that the slider's displacement is accurately translated into changes in the stop depth within the cutter hole, thereby forming a rigid blind hole of variable depth, providing a physical reference for the precision shearing of wires of different lengths.

[0018] According to a second aspect of the present invention, a cold heading apparatus is provided, comprising a frame, a wire feeding mechanism, a moving die extrusion rod, and a sleeve-type shearing limiting structure as described above. A distance adjustment assembly is fixedly mounted on the frame. The wire feeding mechanism is configured to feed wire into the cutting motion assembly corresponding to the shearing station. The moving die extrusion rod is configured to push a slider axially at the ejection station corresponding to the ejection station. This apparatus can directly produce composite contact products with consistent volume and height, significantly improving the yield rate.

[0019] According to a third aspect of the present invention, a shearing and blanking method using the above-described cold heading equipment is provided, comprising the following steps: Step S1: Drive the cutting blade motion assembly to move laterally, so that the follower abuts against the first limiting step surface of the corresponding first station, and rigidly lock the pre-upsetting needle in the first axial position; Step S2: Control the wire feeding mechanism to perform overfeeding, set the feeding stroke to be greater than the target material length, use the locked pre-upsetting needle as a stop to block the wire, and eliminate the stroke margin by wire feeding slippage to complete the first wire cutting; Step S3: Drive the cutting motion assembly to move laterally to the second station, and use the second limiting step surface with different heights to force the slider and pre-upsetting needle to retract, leaving room for the first wire; Step S4: Control the wire feeding mechanism again to perform overfeeding to complete the second wire shearing; Step S5: Drive the cutting blade motion assembly to move to the ejection station, and use the moving mold extrusion rod to push the slider to eject all material segments.

[0020] This invention provides a single-blade, multi-line sleeve-type shearing and limiting structure, which has significant advantages over existing technologies: This invention employs an overfeeding strategy combined with rigid limiting, utilizing physical limits instead of electrical stroke control to eliminate errors caused by wire slippage and mechanical transmission backlash. For the production of precious metal (such as silver) contacts, this not only significantly improves the consistency of product size and volume but also effectively reduces the waste of expensive raw materials.

[0021] By employing a mechanical logic that automatically switches the height of the cam step during lateral movement, this invention enables a single cutter to continuously and precisely cut wires of different materials and lengths, such as silver and copper wires, without stopping the machine or changing molds. It features a compact structure, high production efficiency, and is suitable for manufacturing processes involving multi-layer composite electrical contacts.

[0022] This invention ingeniously designs a state-switching mechanism that switches between locking during shearing and avoiding during ejection. Utilizing the clutch (contact / disengagement) and projected misalignment design of the rollers, it ensures both absolute rigidity during shearing and smooth, interference-free ejection. Compared to complex sensors and pneumatic locking mechanisms, the purely mechanical structure of this application has an extremely low failure rate and exceptional durability.

[0023] The design of the split adjustable cam block and modular slider assembly allows the equipment to be changed simply by adjusting the screws or replacing the module when changing product models. This eliminates the need to reprocess the complex overall mold, greatly shortens the setup time, and lowers the technical threshold for operators. Attached Figure Description

[0024] The accompanying drawings are included to provide a further understanding of the embodiments and are incorporated in and constitute a part of this specification. The drawings illustrate embodiments and, together with the description, serve to explain the principles of the invention. Other embodiments and many anticipated advantages of the embodiments will be readily recognized as they become better understood through reference to the following detailed description. Elements in the drawings are not necessarily to scale. The same reference numerals refer to corresponding similar parts.

[0025] Figures 1a-1f This is a schematic diagram of the sleeve-type cutting mechanism of a bimetallic composite contact cold heading machine in the prior art; Figures 2a-2e This is a front view of a single-blade multi-line sleeve-type shearing limiting structure according to a specific embodiment of the present invention; Figures 3a-3l This is a cross-sectional view AA in Figure 2 according to a specific embodiment of the present invention; Figure 4 This is a flowchart of a cutting and blanking method according to an embodiment of the present invention.

[0026] The meanings of the numbers in the diagram are as follows: 1. Fixed template; 2. Silver wire shearing seat; 3. Silver wire; 4. Copper wire shearing seat; 5. Copper wire; 6. Fixed platform; 7. Fixed mold ejector pin; 8. Tool holder; 9. Sleeve seat; 10. Slider guide sleeve; 11. Nut cap; 12. Screw plug; 13. Pre-upsetting pin fastening slide bar; 14. Pre-upsetting pin; 15. Return spring; 16. Sleeve cutter; 17. Moving mold extrusion rod; 21. Fixed template; 22. Wire A shearing seat; 23. Wire A; 24. Wire B shearing seat; 25. Wire B; 26. Wire C; 27. Wire C shearing seat; 28. 29. Fixed mold ejector pin; 30. Fixed table; 31. Cutter mounting base; 32. Cutter bar; 33. Bolt; 34. Cutter mounting base rear cover; 35. Bolt; 36. Roller; 37. Limit block fixing plate; 38. Moving mold assembly; 39. Moving mold extrusion rod; 40. Material section A limit adjustment block; 41. Material section B limit adjustment block; 42. Material section C limit adjustment block; 43. Sleeve cutter; 44. Return spring; 45. Pre-upsetting pin fixing sleeve; 46. Pre-upsetting pin; 47. Slider; 48. Pre-upsetting pin pad; 49. Roller shaft; 50. Balance return spring; 51. Machine tool bed. Detailed Implementation

[0027] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, only the parts relevant to the invention are shown in the accompanying drawings.

[0028] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0029] The specific embodiments of the present invention have been described above, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

[0030] Figures 1a-1f This diagram illustrates a sleeve-type cutting mechanism in a prior art bimetallic composite contact cold heading machine, wherein... Figure 1a This is a schematic diagram of a sleeve cutter at the silver wire shearing station, as shown below. Figure 1aAs shown in the figure, the shearing mechanism of the cold heading machine is in the first position. The silver wire shearing seat 2, mounted on the fixed template 1, guides the feeding of the silver wire 3. Driven by the cutter bar 8, the sleeve seat 9 and the sleeve cutter 16 fixed at its front end move to the axial position of the silver wire shearing seat 2, so that the shearing hole of the sleeve cutter 16 is aligned with the silver wire shearing seat 2. At this time, the feeding mechanism pushes the silver wire 3 through the silver wire shearing seat 2 into the inner hole of the sleeve cutter 16, preparing for the shearing of the first section of material (silver material section). Figure 1b for Figure 1a The enlarged view at point E shows a schematic diagram illustrating the positional relationship between the silver wire feeding termination end and the front end face of the pre-upsetting needle, as shown below. Figure 1b As shown in the figure, the internal assembly structure and feeding state of the sleeve assembly are illustrated. A slider guide sleeve 10 is installed inside the sleeve base 9, and a nut cap 11 is threadedly connected to the rear end of the sleeve base 9. A pre-upsetting needle fastening slide rod 13 is slidably disposed within the slider guide sleeve 10, and a pre-upsetting needle 14 is fastened to the front end of the pre-upsetting needle fastening slide rod 13 via a screw plug 12. A return spring 15 is disposed between the pre-upsetting needle fastening slide rod 13 and the nut cap 11, providing a return spring force for the pre-upsetting needle 14. In this prior art, the silver wire 3 enters the sleeve cutter 16, and its feeding length is entirely controlled by the stroke of the external feeding mechanism. As shown in the figure, there is often an uncertain free space (i.e., no rigid contact) between the front end of the silver wire 3 and the front end face of the pre-upsetting needle 14, causing the feeding length to depend entirely on the feeding accuracy, which is prone to errors.

[0031] Figure 1c This is a schematic diagram of a sleeve cutter at the copper wire shearing station, as shown below. Figure 1c As shown, after the silver wire is cut, the cutter bar 8 drives the sleeve seat 9 and the sleeve cutter 16 to move laterally to the second position, namely the position of the copper wire cutting seat 4. The copper wire cutting seat 4 is installed on the fixed template 1 to guide the copper wire 5. At this time, the sleeve cutter 16 has already contained the cut silver material segment and is aligned with the feed path of the copper wire 5, ready for feeding and cutting the second segment (copper material segment). Figure 1d for Figure 1c The enlarged view at point F shows a schematic diagram illustrating the positional relationship between the copper wire feeding termination end, the silver segment, and the front end face of the pre-upsetting needle; as shown... Figure 1d As shown, the feeding mechanism pushes the copper wire 5 into the sleeve cutter 16, and the front end of the copper wire 5 pushes against the previously cut silver material segment. Under the action of the return spring 15, the silver material segment pushes the pre-upsetting needle 14 and the pre-upsetting needle fastening slide bar 13 backward. In this state, the pre-upsetting needle 14 is passively retracted, and there may still be gaps or positional uncertainties between the copper wire 5, the silver material segment and the pre-upsetting needle 14 due to feeding errors (as marked "gap" in the figure). Moreover, due to the lack of an active rigid limit adjustment mechanism, the cutting length of the copper wire 5 is also limited by the accuracy of the feeding mechanism, resulting in an unstable total volume of the final composite material segment.

[0032] Figure 1e This is a schematic diagram of the sleeve cutter at the fixed table position, as shown below. Figure 1e As shown, after all the wires have been cut, the cutter bar 8 drive assembly continues to move laterally to the fixed platform 6 (i.e., the ejection / forming station). The fixed platform 6 is mounted on the fixed template 1, and its center is provided with a fixed mold ejector pin 7 and a fixed mold cavity for forming. At this time, the axis of the sleeve cutter 16 coincides with the axis of the fixed platform 6 and the axis of the moving mold extrusion bar that will subsequently move, ready for the ejection operation. Figure 1f for Figure 1e The enlarged view at point G shows a schematic diagram of how the pre-upsetting needle pushes the copper and silver material segments out of the sleeve cutter for pre-forming, as shown below. Figure 1f As shown, during the ejection stage, the external moving mold extrusion rod 17 moves forward axially, passing through the nut cover 11 (or related pusher components) and directly pushing the pre-upsetting pin fastening slide rod 13 and the pre-upsetting pin 14 forward. The pre-upsetting pin 14 acts as an ejector rod, forcibly pushing out the silver and copper material segments inside the sleeve cutter 16 and sending them into the mold cavity of the fixed platform 6 to cooperate with the fixed mold ejector pin 7 for subsequent cold upsetting.

[0033] In the aforementioned single-blade sleeve-type shearing method, the shearing length of the silver and copper segments depends entirely on the wire feeding accuracy of the wire feeding mechanism in the cold heading equipment. However, the wire feeding mechanism often experiences fluctuations in wire feeding length due to inherent phenomena such as wear and clearance of parts, which in turn leads to large changes in the volume of the contact material at the shearing point, affecting the forming quality and stability of the contact.

[0034] To address the problems existing in the prior art, this application proposes a single-blade, multi-line sleeve-type shearing limiting structure. Figures 2a-2e A front view of a single-blade, multi-line sleeve-type shearing limiting structure according to a specific embodiment of the present invention is shown; wherein, Figure 2a This is a top-view sectional view of a sleeve cutter cutting wire at the A-stage shearing station. Figure 2b for Figure 2a The AA section diagram in the figure is as follows: Figure 2a and 2bAs shown, the single-blade multi-line sleeve-type shearing and limiting structure of this embodiment mainly consists of a cutting blade moving component and a cutting blade limiting component. The figure shows the state in which the blade holder 31 drives the cutting blade mounting base 30 to move to the position of the wire A cutting seat 22. At this time, the wire A 23 passes through the cutting seat mounted on the fixed template 21 and enters the sleeve cutting blade 42. The sleeve cutting blade 42 is fastened between the cutting blade mounting base 30 and the cutting blade mounting base rear cover 33 on its rear side by its own mounting platform and bolts 34. The cutting blade mounting base rear cover 33 contains a slider 46, which is constrained in the rear cover and can slide back and forth. A pre-upsetting needle pad 47 is provided inside the slider 46. The pre-upsetting needle 45 is fastened to the slider 46 through the pre-upsetting needle fixing sleeve 44, and the front end of the pre-upsetting needle 45 can slide smoothly in the hole of the sleeve cutting blade 42. To eliminate gaps, a balance return spring 49 is provided between the slider 46 and the cutter mounting base 30, and a return spring 43 is also provided between the pre-upsetting needle fixing sleeve 44 and the sleeve cutter 42. A follower is provided on the side of the slider 46, configured to follow the external contour. This follower is specifically a roller assembly, including a roller shaft 48 fixed to the side wall of the slider and a roller 35 rotatably mounted on the shaft. Under the action of the spring force, the roller 35 protrudes from the base and abuts tightly against the front end face of the material segment A limit adjustment block 39, achieving rigid limitation of the cutting length of wire A. It should be noted that although this embodiment shows a roller structure, the follower in this application is not limited to this. In other alternative embodiments, the follower can also be designed as a sliding contact with a wear-resistant coating, a ball plunger, a rigid ejector pin, or any other mechanical following component capable of abutting against the limit step surface and transmitting displacement; these variations all fall within the protection scope of this invention.

[0035] Figure 2c This is a schematic diagram of the combination of the limiting fixing plate and its limiting adjustment block, as shown below. Figure 2cAs shown, a distance adjustment assembly is fixedly installed on the frame to provide a guide trajectory for the height variation along the transverse movement path of the cutter. In a specific embodiment, the distance adjustment assembly is specifically constructed as a combination structure formed by splicing multiple split limit adjustment blocks (segment A limit adjustment block 39, segment B limit adjustment block 40, and segment C limit adjustment block 41) transversely. The main body of the cutter limiting component is a limit block fixing plate 36, which is fastened to the machine bed 50 by bolts and pins to form a stable reference. On the limit block fixing plate 36, each station adjustment block that can be quickly replaced is arranged sequentially along the movement path of the cutter: segment A limit adjustment block 39 corresponding to wire A 23, segment B limit adjustment block 40 corresponding to wire B 25 (passing through wire B shear seat 24), and segment C limit adjustment block 41 corresponding to wire C 26 (passing through wire C shear seat 27). During the wire cutting process, the front end faces of these adjustment blocks form a tight rigid contact with the rollers 35 of the cutting blade moving parts to limit the cutting length at different workstations. Figure 2d for Figure 2c Enlarged view at point M, as shown Figure 2d As shown, the positional difference S1 between the limit adjustment block 39 of section A and the limit adjustment block 40 of section B corresponds to the length of section B cut from wire B (i.e., the distance the slider retracts is equal to the length of the previous section). Similarly, the positional difference S2 between the limit adjustment block 40 of section B and the limit adjustment block 41 of section C corresponds to the length of section C cut from wire C. The length of section A is determined by the thickness of the limit adjustment block 39 of section A and the length of the pre-upsetting needle 45. By adjusting the position of the contact surface between the limit adjustment block 39 of section A and the roller 35, corresponding to the material feeding length adjustment range δ, the required length of section A can be obtained: increasing the thickness shortens the material feeding length, and decreasing the thickness increases the material feeding length.

[0036] Figure 2e This is a schematic diagram showing the positional relationship between the sleeve-type shearing limiting structure and the moving die extrusion rod, as shown below. Figure 2eAs shown, at this time, the axis of the sleeve cutter 42 coincides with the axis of the fixed mold ejector pin 28 at the center of the fixed table 29. The outer edge of the roller 35 on the slider 46 is a certain distance σ higher than the rear force-bearing surface (i.e., surface P) of the slider 46. This design is to ensure that when the roller 35 contacts the cutter limiting component, the surface P of the slider 46 will not interfere with the limiting component. At the same time, the axial height of the pre-upsetting pin 45 in the slider 46 (this height is basically consistent with the axial height of the moving mold extrusion rod 38 in the subsequent station) needs to be offset by a certain distance H in the vertical direction from the upper end surface of the roller 35 in the slider 46. This staggered design (distance H) allows the cutter limiting component and the roller to effectively avoid the moving mold moving device composed of the moving mold assembly 37, the moving mold extrusion rod 38, and other parts, thereby reserving the necessary moving position space for the intervention of the moving mold components during the operation of the cold heading equipment. At this station, the roller 35 has disengaged from the limit adjustment block (or is in the avoidance area), and the moving mold extrusion rod 38 can move towards the cold heading mold closing direction, directly and rigidly contacting the P surface of the slider 46. Subsequently, the moving mold extrusion rod 38 pushes the slider 46 and the pre-heading pin 45 forward, ejecting all the material segments in the sleeve cutter 42 to the fixed table 29 for pre-forming.

[0037] Figures 3a-3l Figure 2 shows a cross-sectional view of section AA according to a specific embodiment of the present invention. Figure 3a This is a schematic diagram of the sleeve cutter at the wire A shearing station, as shown. Figure 3a As shown, the blade holder 31 drives the cutter mounting base 30 to move laterally, causing the sleeve cutter 42 to be positioned on the axis of the wire A shearing seat 22. At this time, the slider 46 is in the first axial position inside the cutter mounting base rear cover 33, and the balance return spring 49 keeps the slider stable. The wire A 23 (such as silver wire) passes through the shearing seat and is ready to enter the inner hole of the sleeve cutter 42. In this state, the roller 35 on the slider 46 is in rigid contact with the external limiting component. Figure 3b for Figure 3a The enlarged view at point M1 shows a schematic diagram of the positional relationship between the feeding termination end of wire A and the front end face of the pre-upsetting needle. The external wire feeding mechanism feeds wire A 23 into the sleeve cutter 42, and its front end directly abuts against the front end face of the pre-upsetting needle 45. The pre-upsetting needle 45 is fastened to the slider 46 by the pre-upsetting needle fixing sleeve 44. This embodiment adopts an overfeed strategy, that is, the feeding stroke of wire A is greater than the predetermined length of the material segment A. When the front end of wire A is stuck on the pre-upsetting needle 45, the pre-upsetting needle 45 acts as a rigid stop to prevent the wire from continuing to advance. The excess feeding stroke is eliminated by the slippage of the wire feeding mechanism, thereby ensuring accurate cutting length. Figure 3c for Figure 3aThe enlarged view at point N1 shows a schematic diagram of the relative positional relationship between the roller and the limiting adjustment block of the limiting structure. Under the preload of the return spring 43 and the balance return spring 49, the roller 35 on the side of the slider 46 is tightly pressed against the stepped surface of the limiting adjustment block 39 of section A. The thickness of the limiting adjustment block 39 of section A directly determines the extension depth of the pre-upsetting needle 45 in the sleeve, thereby accurately defining the cutting length of wire A.

[0038] Figure 3d This is a schematic diagram of the sleeve cutter at the wire B shearing station, as shown. Figure 3d As shown, after cutting wire A, segment A is retained inside the sleeve cutter 42. The assembly moves laterally to the wire B cutting seat 24, ready to receive wire B 25 (such as copper wire). During this process, as it moves laterally, the limiting structure drives the slider 46 to undergo axial displacement. Figure 3e for Figure 3d The enlarged view at point M2 shows a schematic diagram of the positional relationship between the feeding termination end of wire B, material segment A, and the front end face of the pre-upsetting needle. Wire B 25 enters the sleeve cutter 42, pushing the previously sheared material segment A backward, so that material segment A is in close contact with the front end face of the pre-upsetting needle 45. At this time, a rigid force transmission chain is formed between wire B, material segment A, and pre-upsetting needle 45. Similarly, by using an overfeed strategy, after wire B presses against material segment A and the pre-upsetting needle, the feeding error is eliminated, ensuring the accurate effective shearing length of wire B. Figure 3f for Figure 3d The enlarged view at point N2 shows a schematic diagram of the relative positional relationship between the roller and the limiting adjustment block of the limiting structure. Roller 35 has transitioned onto the limiting adjustment block 40 of material segment B. The limiting adjustment block 40 of material segment B has a positional height difference relative to the limiting adjustment block 39 of material segment A (i.e., Figure 2c The drop S1 is equal to the length of material segment A. This allows the slider 46 and the pre-upsetting needle 45 to retract precisely under the action of the spring force, making room to accommodate material segment A, while limiting the shearing space of wire B.

[0039] Figure 3g This is a schematic diagram of the sleeve cutter at the wire C shearing station, as shown below. Figure 3g As shown, the assembly continues to move to the wire C shearing seat 27 position. At this time, the sleeve cutter 42 has already accommodated material segments A and B, ready to receive wire C 26. Figure 3h for Figure 3g The enlarged view at point M3 shows the positional relationship between the feeding termination end of wire C and the front end faces of material segments A, B, and the pre-upsetting needle. After wire C 26 is fed in, it pushes material segments B and A backward in sequence, eventually locking onto the pre-upsetting needle 45. At this point, a rigid chain is formed: wire C - material segment B - material segment A - pre-upsetting needle 45. Through the rigid reaction force of the pre-upsetting needle 45, wire C is forced to slip during feeding, achieving precise length setting of the third segment. Figure 3i for Figure 3g The enlarged view at point N3 shows a schematic diagram of the relative positional relationship between the roller and the limiting adjustment block of the limiting structure. Roller 35 abuts against the limiting adjustment block 41 of material section C. The positional difference between this adjustment block and the adjustment block at the previous station ( Figure 2c S2 in the figure is equal to the length of material segment B. Through three independently adjustable limit blocks (39, 40, 41), a single cutter achieves continuous and precise control over three different length material segments.

[0040] Figure 3j This is a schematic diagram of the sleeve cutter at the fixed table position, as shown below. Figure 3j As shown, after all shearing processes are completed, the cutter mounting base 30, carrying the sleeve cutter 42 filled with material, moves to the axis of the fixed platform 29 (i.e., the fixed mold station). The fixed platform 29 has a fixed mold ejector pin 28 at its center, ready for ejection pre-forming. Figure 3k for Figure 3j The enlarged view at M4 shows a schematic diagram of the pre-upsetting needle ejecting multiple material segments from the sleeve cutter for pre-forming. The pre-upsetting needle 45 moves forward under the drive of the slider, and smoothly pushes material segments C, B and A out of the inner hole of the sleeve cutter 42 in sequence and into the mold cavity of the fixed table 29. Figure 3l for Figure 3j The enlarged view at point N4 shows a schematic diagram of the relative positional relationship between the moving mold extrusion rod and the slider during preforming. At this position, roller 35 has passed the end of the limit adjustment block 41 of material segment C and is in a suspended or unsupported state (i.e., out of the limit). The moving mold extrusion rod 38, which belongs to the moving mold moving device, extends axially. Because the outer edge of roller 35 is higher than the P surface of slider 46 by a distance σ, and the upper end face of roller is offset from the axis of pre-upsetting pin by a distance H (refer to...). Figure 2e (Note:) The moving die extrusion rod 38 can bypass the roller 35 and directly and rigidly contact and push the force-bearing surface (P-surface) of the slider 46. This design ensures that at the ejection station, the slider 46 switches from a passive limiting state to a passive die active driving state to complete the ejection of the material segment.

[0041] As shown in the foregoing figures, the present invention also provides a cold heading device that utilizes the aforementioned sleeve-type shearing and limiting structure. This device mainly consists of a frame (machine bed 50), a wire feeding mechanism, a transverse shearing drive mechanism, and a longitudinal cold heading forming mechanism. The machine bed 50 serves as the rigid base of the device, on which a fixed template 21 is fixedly mounted. In front of the fixed template 21, corresponding to the positions of wire A shearing seat 22, wire B shearing seat 24, and wire C shearing seat 27, independent wire feeding mechanisms are respectively provided. These wire feeding mechanisms are configured to have servo control or mechanical cam adjustment functions, enabling independent setting of the feeding length for each wire and supporting the aforementioned "overfeeding" strategy (i.e., the output torque allows slippage under the obstruction of the stop block). The cutter limiting component (i.e., the limiting block fixing plate 36 and its adjusting blocks 39, 40, and 41) is rigidly fixed to the side of the machine bed 50 by high-strength bolts, forming a static measurement reference. A transverse shearing drive mechanism (such as a cam linkage or servo module) is connected to the cutter bar 31, driving the cutter's moving parts to perform transverse reciprocating motion on the frame, allowing the roller 35 to sequentially sweep past each limit adjustment block. The longitudinal cold heading mechanism includes a moving module 37 (main slide block) and a moving die extrusion rod 38 mounted thereon. The moving module 37 is driven by the machine's main crankshaft, performing reciprocating impact motion along the axial direction (Z-axis). The machine's operating sequence is configured as follows: Shearing stage: The moving module 37 is in the retracted position, and the transverse shearing drive mechanism drives the cutting blade moving parts to move between various shearing stations, and works with the wire feeding mechanism to complete the accumulation of multiple segments of material; Ejection Stage: When the cutting blade moving parts move to the fixed table 29 (ejection station) and stop lateral movement, the moving die 37 moves forward. At this time, the moving die extrusion rod 38, using the missing space (i.e., the clearance area) of the cutting blade limiting parts in the ejection station, directly inserts into the slide groove of the cutting blade mounting base rear cover 33, rigidly pushing the slider 46 to push the multi-layer composite material segment in the sleeve cutting blade 42 into the female die of the fixed table 29. Subsequently, it cooperates with the main punch to complete the upsetting process. Through the precise coordination of the above mechanisms, this cold heading equipment realizes fully automated high-precision production from multi-wire feeding to fixed-length shearing to composite ejection.

[0042] Figure 4 A flowchart of a shearing and blanking method according to an embodiment of the present invention is shown, as follows: Figure 4 As shown, the shearing and blanking method includes the following steps: Step S1: Drive the cutting blade motion assembly to move laterally, so that the follower abuts against the first limiting step surface of the corresponding first station, and rigidly lock the pre-upsetting needle in the first axial position; Step S2: Control the wire feeding mechanism to perform overfeeding, set the feeding stroke to be greater than the target material length, use the locked pre-upsetting needle as a stop to block the wire, and eliminate the stroke margin by wire feeding slippage to complete the first wire cutting; Step S3: Drive the cutting motion assembly to move laterally to the second station, and use the second limiting step surface with different heights to force the slider and pre-upsetting needle to retract, leaving room for the first wire; Step S4: Control the wire feeding mechanism again to perform overfeeding to complete the second wire shearing; Step S5: Drive the cutting blade motion assembly to move to the ejection station, and use the moving mold extrusion rod to push the slider to eject all material segments.

[0043] The core innovation of the above-mentioned shearing and blanking process lies in its complete transformation of the control logic for wire length determination in cold heading, namely, shifting from the traditional active precision control relying on the feeding mechanism to a passive rigid control relying on the mechanical limit structure. Specifically, throughout the process, the wire feeding mechanism no longer undertakes the task of precise measurement, but only needs to provide sufficient excess stroke and torque maintenance. By setting the feeding stroke S to always be greater than the target length L, and using the pre-heading pin 45 as an absolute physical stop, the wire is forced to absorb all the accumulated errors of the feeding system (including slippage, gear backlash, motor pulse fluctuations, etc.) the moment it contacts the stop. Especially in the multi-wire continuous shearing stage (steps S3-S4), the material segment cut in the previous step (such as material segment A) is essentially transformed into an extension stop for the subsequent wire (such as wire B) after the slider retracts, forming a rigid force transmission chain. This cascaded limiting method, combined with the temporal and spatial separation of the rollers and limiting steps at the ejection station (i.e., time-based process switching and spatial mechanical avoidance), ensures that multi-layer metal composite material segments with consistent volume and height can be continuously and frequently produced within a single cycle, without the need for a complex closed-loop feedback control system.

[0044] This invention discloses a single-blade, multi-wire sleeve-type shearing and limiting structure and its cold heading equipment, solving the industry pain points of poor blanking accuracy and low product consistency in the production of multi-layer metal composite contacts (such as silver / copper / silver). The core of this application lies in replacing traditional servo pulse control with mechanical rigid limiting. By setting a sliding pre-heading pin assembly within the cutter holder, and utilizing rollers on the side of the slider in conjunction with externally arranged stepped distance adjustment components, the lateral position switching action of the cutter is transformed into the axial depth adjustment action of the pre-heading pin. During shearing, an overfeed + slippage error elimination strategy is used to ensure the wire is locked onto the cam-locked pre-heading pin, achieving micron-level length control. During ejection, the disengagement of the rollers from the cam and the spatial misalignment with the moving die extrusion rod enable the slider to automatically switch from rigid locking to free floating. This structure enables a single cutter to continuously and precisely cut and accumulate multiple sections of wire of different materials and lengths, significantly improving the volume consistency and forming quality of composite contacts. It also has the significant advantages of compact structure, convenient adjustment and low failure rate.

[0045] In the description of this invention, it should be understood that the terms "upper," "lower," "inner," "outer," etc., indicating orientation or positional relationships based on the orientation or positional relationships shown in the accompanying drawings, are only for the convenience of describing the 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, and therefore should not be construed as a limitation of the invention. The word "comprising" does not exclude the presence of elements or steps not listed in the claims. The word "a" or "an" preceding an element does not exclude the presence of a plurality of such elements. The simple fact that certain measures are recited in mutually different dependent claims does not indicate that combinations of these measures cannot be used for improvement. Any reference signs in the claims should not be construed as limiting the scope.

Claims

1. A single-blade, multi-line sleeve-type shearing and limiting structure, characterized in that, The device includes a cooperating cutting motion assembly and a distance adjustment assembly. The cutting motion assembly includes a sleeve cutting blade seat, a slider slidably disposed within the sleeve cutting blade seat, a pre-upsetting needle fixed on the slider, and a follower disposed on the side of the slider. The distance adjustment assembly is configured to be fixedly mounted on a cold heading machine and has at least two limiting step surfaces of different heights along the lateral movement path of the cutting motion assembly. When the cutting motion assembly moves laterally relative to the distance adjustment assembly, the follower abuts against the limiting step surfaces of different heights, driving the slider and the pre-upsetting needle to generate axial displacement within the sleeve cutting blade seat, thereby locking the axial stop position of the pre-upsetting needle at different lateral positions.

2. The single-blade multi-line sleeve-type shearing limiting structure according to claim 1, characterized in that, The distance adjustment assembly includes multiple limit adjustment blocks fixed on the cold heading machine bed; the limit adjustment blocks are arranged sequentially along the moving direction of the cutting blade motion assembly, and each corresponds to a different wire cutting station.

3. The single-blade multi-line sleeve-type shearing limiting structure according to claim 2, characterized in that, The multiple limit adjustment blocks are connected by guide ramps.

4. The single-blade multi-line sleeve-type shearing limiting structure according to claim 2, characterized in that, The height difference between adjacent limit adjustment blocks is set as the axial length of the shearing section of the preceding station.

5. The single-blade multi-line sleeve-type shearing limiting structure according to claim 1, characterized in that, The distribution area of ​​the fixed-distance adjustment component along the lateral movement path is configured such that the fixed-distance adjustment component covers the lateral path segment where the shearing station is located, and is in a disconnected or missing state in the lateral path segment where the ejection station is located, so that when the cutter motion component moves laterally to the ejection station, the follower loses the support of the limiting step surface, and the slider is in a free state that can be pushed by an external mechanism.

6. The single-blade multi-line sleeve-type shearing limiting structure according to claim 5, characterized in that, The lower end face of the slider is provided with a force-bearing area for receiving the thrust and an installation area for mounting the follower; on the projection plane perpendicular to the slider axis, the projection of the force-bearing area and the projection of the follower do not overlap; the pushing end face of the external moving mold extrusion rod only covers the projection range of the force-bearing area.

7. The single-blade multi-line sleeve-type shearing limiting structure according to claim 1, characterized in that, The follower includes a roller shaft and a roller; the roller shaft is fixedly connected to the side wall of the slider; the roller is rotatably mounted on the roller shaft; the roller is configured to extend radially outward from the inside of the sleeve cutter seat to abut against the limiting step surface of the distance adjustment assembly.

8. The single-blade multi-line sleeve-type shearing limiting structure according to claim 1, characterized in that, The cutter motion assembly is equipped with a balance return spring; the balance return spring is located between the slider and the rear end cover of the sleeve cutter seat, and always applies a preload force to the slider in the direction of the fixed distance adjustment assembly to keep the follower in contact with the limiting step surface.

9. The single-blade multi-line sleeve-type shearing limiting structure according to claim 1, characterized in that, The sleeve cutter holder has an axially extending mounting cavity inside, and a pre-upsetting needle fixing sleeve that is housed in the mounting cavity is fixedly connected to the slider; the pre-upsetting needle is coaxially fixed to the pre-upsetting needle fixing sleeve; the cutter movement assembly also includes a return spring, which is disposed in the mounting cavity and its two ends respectively abut against the sleeve cutter holder and the pre-upsetting needle fixing sleeve.

10. The single-blade multi-line sleeve-type shearing limiting structure according to claim 9, characterized in that, The pre-upsetting needle is configured to move synchronously axially within the sleeve cutter holder following the slider, so as to change the axial depth position of the front end face of the pre-upsetting needle within the cutter hole.

11. A cold heading device, characterized in that: The device includes a frame, a wire feeding mechanism, a moving die extrusion rod, and a sleeve-type shearing limiting structure as described in any one of claims 1-10. The distance adjustment assembly is fixedly installed on the frame. The wire feeding mechanism is set to correspond to the shearing station and is configured to feed wire into the cutter motion assembly. The moving die extrusion rod is set to correspond to the ejection station and is configured to push the slider axially at the ejection station.

12. A shearing and blanking method using the cold heading equipment of claim 11, characterized in that, Includes the following steps: Step S1: Drive the cutting blade motion assembly to move laterally, so that the follower abuts against the first limiting step surface of the corresponding first station, and rigidly lock the pre-upsetting needle in the first axial position; Step S2: Control the wire feeding mechanism to perform overfeeding, set the feeding stroke to be greater than the target material length, use the locked pre-upsetting needle as a stop to block the wire, and eliminate the stroke margin by wire feeding slippage to complete the first wire cutting; Step S3: Drive the cutting motion assembly to move laterally to the second station, and use the second limiting step surface with different heights to force the slider and pre-upsetting needle to retract, leaving room for the first wire; Step S4: Control the wire feeding mechanism again to perform overfeeding and complete the second wire cutting; Step S5: Drive the cutting blade motion assembly to the ejection station, and use the moving mold extrusion rod to push the slider to eject all material segments.

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