A plug-in shaping device

Abstract

This invention discloses a plug-in shaping device for shaping plug-ins that have not fully cooled after injection molding. It includes: a mounting frame; a conveying unit comprising a chain that circulates along a closed-loop path; a positioning unit comprising multiple moving plates connected to the chain, each moving plate having a fixed positioning fixture with a positioning groove and insertion holes at the bottom for the plug-in's pins to be inserted; and a shaping unit located above the conveying unit, comprising a first press and a second press arranged sequentially. The first press is used to extrude, shape, and hold pressure on the plug-in while it still has residual heat. The second press has a cooling structure for cooling and holding pressure to solidify the initially shaped plug-in. This invention utilizes the residual heat after plug-in molding for shaping and eliminates internal stress through an independent cooling and pressure-holding process, avoiding cold-press damage and springback deformation. Simultaneously, the closed-loop conveying system enables continuous automated production, improving shaping efficiency and dimensional stability.

Description

Technical Field

[0001] This invention relates to the field of plastic part shaping technology, and more specifically to a plug-in shaping device. Background Technology

[0002] Automotive connectors are fundamental components in automotive circuits, connecting various electrical devices. The stability and reliability of their connection directly affect the safety of the entire vehicle's electrical system. The plastic insert used for connection is one of the core components of the connector, typically featuring a square body and multiple pins extending from one end face. These inserts are mostly integrally injection molded.

[0003] During injection molding, due to factors such as material shrinkage and demolding stress, newly molded inserts inevitably experience slight deformations such as skewing and warping, especially in the pin portion, where positional accuracy and straightness tend to deviate from design standards. This deformation can lead to difficulties in insertion or even complete failure to insert when mating with the opposite connector, severely impacting product yield and assembly efficiency.

[0004] In existing technologies, the common method for shaping plastic parts is to wait until the workpiece has completely cooled and solidified before processing it using specialized hot shaping or cold pressing straightening equipment. This method has the following significant drawbacks: 1. Cold shaping usually requires reheating the workpiece to soften it, or applying extreme pressure to force plastic deformation. This not only increases the additional heating process and energy consumption, but also results in a long shaping cycle, which cannot match the high-speed injection molding production cycle. 2. Forcibly applying pressure to straighten a completely cooled plastic part, due to the material's high rigidity and brittleness at this point, easily causes micro-cracks, whitening, or even fracture at stress concentration points such as the pin roots, resulting in irreversible damage and reducing the product's structural strength and service life. 3. After cold pressing shaping, significant internal stress remains inside the plastic part. During subsequent storage or use, especially in high-temperature environments, the slow release of this internal stress causes the workpiece to slowly spring back, losing its original dimensional accuracy again, resulting in poor durability of the shaping effect. Therefore, how to efficiently, stably, and without damage reshape newly formed connector plugs to ensure that their dimensional accuracy meets the requirements is a technical problem that urgently needs to be solved in this field.

[0005] It should be noted that the above description of the technical background is only for the purpose of providing a clear and complete explanation of the technical solutions of the present invention and facilitating understanding by those skilled in the art. It should not be assumed that the above technical solutions are known to those skilled in the art simply because they have been described in the background section of this invention. Summary of the Invention

[0006] To overcome the shortcomings of the prior art, the present invention aims to provide a plug-in shaping device.

[0007] To achieve the above and other related objectives, the technical solution provided by the present invention is: a plug-in shaping device for shaping plug-ins that have not yet fully cooled after injection molding, wherein the plug-in has a body and pins disposed on one side of the body, and the device includes: Mounting rack; A conveying unit, mounted on the mounting frame, includes a chain that circulates along a closed-loop path; The positioning unit includes multiple motion plates connected to the chain and moving synchronously therewith. Each motion plate is fixed with at least one positioning fixture. The positioning fixture has a positioning groove adapted to the shape of the plug body. The bottom of the positioning groove has a socket for the plug pins of the plug to be inserted one by one. The positioning groove limits the insertion of the plug in the horizontal direction and keeps the inserted plug pins in a vertical state. The shaping unit, located above the closed-loop path of the conveying unit, includes a first press and a second press arranged sequentially along the conveying direction of the moving plate; the first press is used to extrude, shape, and hold pressure on the plug-in (still hot) carried on the positioning fixture from the previous station; the second press is provided with a cooling structure for cooling and holding pressure to fix the plug-in after preliminary shaping by the first press.

[0008] In this design, the device utilizes the residual heat after injection molding of the inserts. A closed-loop conveyor unit sequentially passes the inserts through hot forming and cooling / pressure holding for shaping. High-precision correction is achieved while the material is still in a hot state with low yield stress, avoiding damage from cold pressing. Simultaneously, an independent cooling / pressure holding station forces the inserts to cool under constraint, eliminating internal stress and achieving stable final dimensions. The device itself forms a continuous production line, allowing each station to operate in parallel, significantly improving production efficiency.

[0009] Furthermore, the conveying unit also includes a mounting chassis fixed within the mounting frame. A drive sprocket and a driven sprocket are rotatably mounted at both ends of the mounting chassis. A closed-loop chain is tensioned and wrapped around the drive sprocket and the driven sprocket. The drive sprocket is connected to a driving device. In this design, a sprocket and chain mechanism is used as the cyclic traction mechanism, which has strong load-bearing capacity and reliable transmission. It can drive multiple moving plates and fixtures to achieve precise intermittent cyclic movement under large loads, meeting the needs of multi-station heavy-duty transmission.

[0010] Furthermore, the mounting chassis is provided with a closed-loop annular track along its circumference, the annular track being wound around the outside of the chain; the back of the motion plate is provided with a guide assembly that rolls in cooperation with the annular track. In this design, the guiding function of the motion plate is separated from the traction function of the chain, and the annular track provides independent precision guidance and support for the motion plate, avoiding the influence of chain polygonal effects and vibrations on positioning accuracy, so that the motion plate and its positioning fixture maintain high positional accuracy throughout the cyclic movement.

[0011] Furthermore, the guide assembly includes a mounting base fixed to the back of the moving plate. The mounting base is equipped with an upper row of rollers and a lower row of rollers. The edge of the annular track is embedded between the upper and lower rollers, forming a rolling friction engagement. In this design, the upper and lower rows of rollers clamp the edge of the annular track, constituting an omnidirectional limiting rolling guide. This results in minimal frictional resistance, smooth and stable movement, and effectively resists the overturning moment generated when the press is applied, preventing the moving plate from deflecting and ensuring stability during the pressure holding process.

[0012] Furthermore, a ring track is symmetrically arranged on both sides of the mounting chassis, and guide components are respectively arranged on the back of the moving plate corresponding to the ring tracks on both sides. In this solution, the double-sided tracks and double-sided guide components form a symmetrical high-rigidity support structure, which greatly enhances the anti-tilting and anti-torsion capabilities of the moving plate, and is especially suitable for working conditions where the first press and the second press apply large holding pressure, ensuring that the positioning accuracy does not decrease over long-term operation.

[0013] Furthermore, a positioning and locking mechanism is also included, comprising: a limiting seat fixed to the moving plate; a rotating shaft rotatably connected to the mounting chassis or mounting frame; and a limiting clip fixed to the rotating shaft. The rotating shaft is connected to a driving component, which drives the rotating shaft to rotate, causing the limiting clip to engage or disengage from the limiting seat on the moving plate as it moves to the pressure-holding position. In this solution, before the press presses down, the moving plate is rigidly connected to the mounting frame or mounting chassis by mechanical locking, eliminating any possibility of micro-displacement of the moving plate under pressure-holding action. This ensures that the relative positions of the insert and the press head are absolutely consistent each time the press presses down, thereby significantly improving the repeatability and consistency of the forming dimensions.

[0014] Furthermore, at least two limiting clips are spaced apart along the axial direction on the rotating shaft, including at least limiting clips corresponding to the pressure-holding positions directly below the first and second presses. In this design, one rotating shaft can simultaneously drive multiple limiting clips, enabling simultaneous locking and releasing of multiple moving plates at different pressure-holding positions. This simplifies the structure and control logic of the locking mechanism, and improves response speed and system reliability. The engaging end of the limiting clip is a freely rotatable guide wheel. In this design, the guide wheel automatically guides and slides into the limiting holder through rolling contact, ensuring a smooth and impact-free engagement process. Simultaneously, it transforms the sliding friction during engagement into rolling friction, significantly reducing wear on the contact surface and extending the service life of the limiting structure.

[0015] Furthermore, the cooling structure within the second press is either a water-cooled circulation structure or an air-cooled structure. In this solution, the active cooling method can quickly remove heat from the inserts, significantly shortening the cooling and shaping time and improving production efficiency; simultaneously, uniform cooling under continuous pressure constraint more effectively releases and freezes internal stress, ensuring long-term dimensional stability of the finished product without rebound.

[0016] Furthermore, the system also includes a detection unit located behind and above the shaping unit along the conveying direction. The detection unit comprises a light source board and a CCD vision inspection module. The light source board has apertures for light to pass through during vision inspection, and the CCD vision inspection module is located above these apertures for inspecting the appearance and dimensions of the cooled and shaped inserts. This solution enables online automated quality inspection of the shaped inserts, allowing for real-time assessment of the shaping effect and data recording. It eliminates the need for manual sampling, providing timely and objective feedback for product grading and process parameter optimization, thus ensuring product quality before shipment.

[0017] Furthermore, it also includes a feeding unit, located behind the detection unit along the conveying direction and above the conveying unit. The feeding unit includes a movable seat capable of horizontal and vertical reciprocating motion. A mounting plate is mounted on the movable seat, and the lower end of the mounting plate is equipped with feeding grippers that match the number and layout of the positioning slots of the positioning fixture on the movable plate. In this solution, the shaped and inspected inserts are automatically and accurately removed from the positioning fixture and transferred to a designated position, achieving unmanned feeding operation synchronized with the conveying unit's cycle time. This eliminates the uncertainty caused by manual material handling and improves the automation level and cycle time of the entire line.

[0018] Furthermore, it also includes a feeding unit, which is located in front of and above the forming unit along the conveying direction. The feeding unit includes a docking plate connected to a robotic arm, and the docking plate is equipped with feeding grippers that match the number and layout of the positioning slots of the positioning fixture on the moving plate. In this solution, it can seamlessly cooperate with the injection molding machine's part-removing robotic arm to automatically grab and precisely load freshly demolded and still-warm inserts into the positioning fixture, maximizing the preservation of the insert's initial temperature and providing ideal thermal conditions for subsequent hot-forming, while simultaneously improving the automation level and efficiency of feeding.

[0019] Furthermore, each moving plate is fixed with multiple positioning fixtures, and the number of pressing heads and the pressing area of ​​the first and second presses of the shaping unit are matched with the number and layout of the positioning fixtures. In this solution, multiple inserts can be processed simultaneously in a single conveying cycle, significantly increasing the production capacity of the device. Moreover, the simultaneous cooperation of the press heads and multiple fixtures ensures uniform and consistent downward pressure on each insert, achieving efficient and high-quality batch shaping.

[0020] Due to the application of the above technical solution, the beneficial effects of this invention compared with the prior art are as follows: 1. This invention performs shaping directly while the workpiece is still hot after injection molding, making full use of the residual heat of the workpiece itself. No additional heating process is required, greatly shortening the production cycle and reducing energy consumption. Simultaneously, through a closed-loop conveyor unit, the entire process of feeding, shaping, cooling, inspection, and unloading is automated, allowing each station to operate in parallel, resulting in a fast production cycle and significantly improved efficiency.

[0021] 2. This invention performs extrusion shaping when the plug-in has not completely cooled down and the material is still in the high elasticity or viscous flow transition zone. The material has low yield stress and high elongation, and only a small amount of pressure is needed to achieve precise correction. This avoids secondary damage such as microcracks and whitening caused by forced cold pressing, and ensures the structural integrity of the product.

[0022] 3. This invention separates the "shaping" and "cooling and setting" processes by setting up independent cooling and pressure holding stations. After the insert is initially shaped by the first press, it immediately enters the second press with a cooling structure, where it is cured and set under continuous pressure and forced cooling. This controlled cooling method maximizes the release and elimination of internal stress in the workpiece, effectively preventing subsequent springback deformation and achieving long-term stable dimensional accuracy.

[0023] 4. The moving plate of this invention clamps the annular track through a guide assembly with upper and lower rows of rollers, achieving stable, low-friction, and low-backlash rolling motion, providing a foundation for high-precision shaping. Simultaneously, the cooperation of the limiting clip and the limiting seat enables secondary mechanical locking of the moving plate and positioning fixture at the pressure holding station, ensuring absolute precision in the insertion position during pressdown and further guaranteeing the consistency of shaping. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the three-dimensional structure of the plug-in of the present invention; Figure 2 This is a schematic diagram of the overall structure of the plug-in shaping device of the present invention; Figure 3 This is a partial structural diagram of the plug-in shaping device of the present invention; Figure 4 This is a schematic diagram of the feeding unit structure of the present invention; Figure 5 This is a schematic diagram of the positioning fixture and related structures of the present invention; Figure 6 This is a schematic diagram of the detection unit and the feeding unit of the present invention; In the above attached figures, 100. Plugin; 101. Main body; 102. Pin; 1. Mounting bracket; 2. Feeding unit; 21. Connecting plate; 22. Feeding gripper; 3. Positioning unit; 31. Motion plate; 311. Mounting base; 312. Upper row of rollers; 313. Lower row of rollers; 314. Limiting bracket; 32. Positioning fixture; 321. Positioning groove; 322. Insertion hole; 4. Conveying unit; 41. Mounting chassis; 42. Drive sprocket; 43. Driven sprocket; 44. Chain; 45. Circular track; 46. Drive unit; 5. Shaping unit; 51. First press; 52. Second press; 6. Detection unit; 61. Light source board; 62. CCD vision inspection module; 7. Unloading unit; 71. Movable seat; 72. Mounting plate; 73. Unloading gripper; 8. Positioning and locking mechanism; 81. Rotating shaft; 82. Limiting clip; 821. Guide wheel; 83. Linear cylinder. Detailed Implementation

[0025] The following specific embodiments illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification.

[0026] It should be noted that in the description of this invention, the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product is in use. These terms are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," and "third," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance. The terms "horizontal," "vertical," and "suspended," etc., do not indicate that the component must be absolutely horizontal or suspended, but rather that it can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal than "vertical," and does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0027] In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0028] In the description of this application, it should be understood that the orientation or positional relationship indicated by directional terms such as "front, back, up, down, left, right", "horizontal, vertical, horizontal" and "top, bottom" is usually based on the orientation or positional relationship shown in the accompanying drawings, and is only for the convenience of describing this application and simplifying the description. Unless otherwise stated, these directional terms 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 on the scope of protection of this application; the directional terms "inner" and "outer" refer to the inner and outer contours relative to the outline of each component itself.

[0029] The preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings, so that the advantages and features of the present invention can be more easily understood by those skilled in the art, thereby providing a clearer and more explicit definition of the scope of protection of the present invention.

[0030] Example: like Figure 1The diagram shows a three-dimensional structural schematic of the plug-in 100 in this case. The plug-in 100 is a one-piece injection-molded plastic part, and its structure includes an approximately square body 101 and four pins 102 extending vertically from one side of the body 101. It is understood that the number and arrangement of the pins 102 may vary depending on the specifications of different connectors. This embodiment uses four pins 102 arranged in a matrix as an example. When the plug-in 100 is freshly molded and demolded, its temperature is still high (e.g., 60°C to 80°C), and both the body 101 and the pins 102 may have slight skewing or warping due to uneven material shrinkage.

[0031] like Figure 2 and Figure 3 As shown, the plug-in shaping device provided in this embodiment mainly includes a mounting frame 1 that provides overall support and installation, and a conveying unit 4, a positioning unit 3, and a shaping unit 5 integrated on the mounting frame 1. In a preferred embodiment, the device also includes a feeding unit 2, a detection unit 6, and a discharging unit 7 to form a complete, highly automated production line.

[0032] Conveying unit 4 is the core of the cyclic conveying system of this device. Specifically, as shown in... Figure 3 As shown, it includes a mounting base 41 fixedly installed inside the mounting frame 1. In this embodiment, the mounting base 41 is a vertically arranged elliptical disc, with a driving sprocket 42 and a driven sprocket 43 rotatably mounted at its two ends. The driving sprocket 42 is connected to a drive device 46 (such as a servo motor or stepper motor) via a coupling or gearbox, serving as a power source. A closed-loop chain 44 is tensioned and wound between the driving sprocket 42 and the driven sprocket 43. When the drive device 46 drives the driving sprocket 42 to rotate, the driving sprocket 42 drives the chain 44 to move through meshing, thereby driving the driven sprocket 43 to rotate synchronously, realizing the closed-loop cyclic movement of the chain 44. This sprocket-chain transmission method has a simple structure, strong load-bearing capacity, and can meet the cyclic transportation needs of multi-station heavy loads.

[0033] The positioning unit 3 is the component that directly supports and precisely positions the plug-in 100, following the chain 44 in a cyclical motion to ensure continuous operation of the device. The positioning unit 3 includes multiple moving plates 31 and positioning fixtures 32 fixed thereon. Each moving plate 31 is fixedly connected to a link or specific connector of the chain 44, thus becoming an "accessory" to the chain 44, moving with it. The number of moving plates 31 can be determined based on the total demand of the working stations and the return buffer stations, and is usually an even number to ensure that the entire closed-loop path is filled, achieving smooth circulation.

[0034] The positioning fixture 32 is a component that directly contacts the plug-in 100 and determines its shaping reference. In this embodiment, four positioning fixtures 32 are provided on each motion plate 31, and each positioning fixture 32 has at least one positioning groove 321 whose shape is adapted to the body 101 of the plug-in 100. In this embodiment, in order to increase the single processing capacity, two positioning grooves 321 are provided side by side on each positioning fixture 32, so there are a total of eight positioning grooves 321. At the bottom of the positioning groove 321, corresponding to the position of the plug pin 102 of the plug-in 100, through holes 322 are provided. When the hot plug-in 100 to be shaped is placed in the positioning groove 321 with its plug pin 102 facing down, the side wall of the body 101 will be limited by the horizontal direction of the inner wall of the positioning groove 321, so that it cannot wobble; at the same time, its slightly skewed plug pin 102 will be guided and constrained in the corresponding hole 322, and forcibly corrected to a vertical downward state. The socket 322 not only serves as a guide, but also, together with the extrusion surface of the subsequent press, forms a precise constraint "mold" for the shape of the pin 102, ensuring the positional accuracy and straightness after shaping.

[0035] To achieve high-precision, low-friction cyclic motion of the motion plate 31, a closed-loop annular track 45 is also provided on the mounting chassis 41. This annular track 45 is elliptical in shape and is wound around the outside of the chain 44's path. A guide assembly that rolls with the annular track 45 is provided on the back of the motion plate 31. This structure separates transmission from guidance; the chain 44 only provides traction, while the motion accuracy and load support of the motion plate 31 are entirely borne by the annular track 45. This avoids the polygonal effect and vibration caused by the chain 44 being stretched, thus ensuring the positional accuracy and stability of the positioning fixture 32 during cyclic motion.

[0036] As a better option, such as Figure 3 As shown, parallel annular tracks 45 are symmetrically arranged on both sides of the mounting chassis 41. Correspondingly, two sets of symmetrical guide components are also provided on the back of the motion plate 31, which cooperate with the annular tracks 45 on both sides respectively. This double-track, double-support structure is like creating a highly rigid "guide bridge" for the motion plate 31, enabling it to maintain excellent flatness and stability during movement and under stress, and almost no tilting or torsion.

[0037] Furthermore, such as Figure 3 and Figure 5As shown, each guide assembly specifically includes a mounting base 311 fixed to the back of the motion plate 31, located on the outer side of the annular track 45. At least two rows of rollers, upper and lower, are arranged on the mounting base 311 along a direction perpendicular to the edge of the annular track 45, namely an upper row of rollers 312 and a lower row of rollers 313. The outer peripheral edge of the annular track 45 forms a straight guide flange, which fits precisely into the gap between the upper row of rollers 312 and the lower row of rollers 313. The upper row of rollers 312 and the lower row of rollers 313 clamp the guide flange of the annular track 45 from both upper and lower directions, forming omnidirectional limiting. When the motion plate 31 is driven, the upper row of rollers 312 and the lower row of rollers 313 roll on the upper and lower surfaces of the guide flange, transforming traditional sliding friction into rolling friction. Compared with the method of using a slider to slide on a slide rail, rolling friction has extremely low resistance, less wear, longer life, smoother movement, and is not sensitive to dimensional changes, and is less prone to jamming. This is especially important for pressure holding stations that require frequent starts and stops and precise positioning.

[0038] When the moving plate 31, carrying the insert 100, precisely stops directly below the first press 51 and the second press 52 to perform the pressing and holding operation, relying solely on the braking force of the drive device 46 (servo motor) and the rigidity of the chain to maintain the position is insufficient. Under the enormous continuous pressure of the presses, any slight displacement will lead to damage to the shaping accuracy. Therefore, this device is specially designed with a positioning and locking mechanism 8 to perform secondary mechanical locking of the moving plate 31 at the holding pressure station.

[0039] like Figure 3 and Figure 5 As shown, the positioning and locking mechanism 8 includes a limiting seat 314 disposed on the motion plate 31, and a rotatable component disposed at a corresponding fixed position on the mounting chassis 41 or mounting bracket 1. The rotatable component includes a horizontally arranged rotating shaft 81 and one or more limiting clips 82 fixed to the rotating shaft 81. The rotating shaft 81 is driven to rotate by an actuator such as a cylinder, hydraulic cylinder, or motor. In this embodiment, a linear cylinder 83 (such as a telescopic cylinder) is used as the actuator. The cylinder body of the linear cylinder 83 is fixed to the mounting chassis 41, and the end of its piston rod is hinged to a crank fixed to the rotating shaft 81, thereby converting the linear telescopic motion of the piston rod into the rotational motion of the rotating shaft 81.

[0040] The distal end of the limiting clamp 82 is the insertion end, and its shape and size match the groove on the limiting clamp seat 314. When the moving plate 31 reaches the preset pressure holding position, the control system issues a command, the piston rod of the linear cylinder 83 extends, and pushes the rotating shaft 81 to rotate at an angle, so that the insertion end of the limiting clamp 82 accurately engages in the groove of the limiting clamp seat 314 on the moving plate 31. At this time, the moving plate 31 is physically locked in the conveying direction, and a rigid connection is formed between it and the mounting chassis 41 or mounting frame 1. Even under the pressure of tens or even hundreds of kilograms of the press, it can remain motionless, ensuring the ultimate stability of the forming dimensions. When the pressure holding process is completed, the piston rod of the linear cylinder 83 retracts, and drives the limiting clamp 82 to rotate in the opposite direction through the rotating shaft 81, disengaging it from the limiting clamp seat 314, releasing the lock, and the moving plate 31 can continue to move forward under the drive of the chain 44.

[0041] To reduce impact and wear during the locking process and to make the locking action smoother, the locking end of the limiting latch 82 is specially designed as a freely rotating guide wheel 821. When the curved surface of the guide wheel 821 contacts the inclined surface of the slot of the limiting latch 314, it will produce an automatic guiding sliding effect, while the rolling friction will protect the contact surface to the greatest extent and extend the service life of the mechanism.

[0042] In this embodiment, three limiting clips 82 are spaced apart along the axial direction on a rotating shaft 81. Their positions correspond to the pressure holding station below the first press 51, the pressure holding station below the second press 52, and a detection waiting station (or standby station) behind both. In this way, only one rotating shaft and one driver are needed to simultaneously lock or release all moving plates 31 reaching these three key stations, resulting in a clever and efficient structure.

[0043] like Figure 2 and Figure 3 As shown, the shaping unit 5 is mounted above the conveying unit 4, and its core consists of two presses with the same specifications but different functions: the first press 51 and the second press 52. They are mounted along the conveying direction of the moving plate 31. Figure 3 Arranged in a clockwise direction as indicated by the middle arrow.

[0044] The first press 51 is located near the feeding unit 2, and its main task is "hot-pressing". After the feeding is completed and the moving plate 31 of the insert 100, which still has residual heat, moves to the underside of the first press 51 and stops, the positioning and locking mechanism 8 locks it. The press head of the first press 51 presses down. The lower surface of the press head is a high-flatness, high-gloss forming surface, and its shape matches the expected upper surface contour of the insert 100. The press head presses down on the upper surface of the body 101 of the insert 100 with a preset pressure (which is much less than the force required for cold pressing), squeezing it so that the body 101 and the pins 102, which are still in a plastic state, undergo a small amount of plastic flow and deformation in the closed mold cavity formed by the positioning groove 321, the insertion hole 322 and the lower surface of the press head, thereby being precisely corrected. After the press head reaches the lower stop point, it will maintain the pressure for a period of time (i.e., holding pressure) to allow the deformation of the material to become uniform.

[0045] The second press 52 is located near the unloading unit 7, and its main task is "cooling and shaping". The second press 52 has a built-in cooling structure. In this embodiment, the cooling structure is a circulating water-cooled channel that surrounds or is embedded inside the press head of the second press 52. The channel is connected to an external chiller unit through pipes to form a water-cooled circulation system. As an alternative, the cooling structure can also use semiconductor cooling chips or forced air cooling, all of which are within the scope of protection of this invention. After the insert 100, which has completed the initial shaping, moves with the moving plate 31 to directly below the second press 52 and is locked, the press head of the second press 52, which has a cooling function, presses down to maintain pressure on the insert 100. At this time, the low-temperature press head will quickly absorb the heat on the insert 100 and carry it away through the water-cooling system. Under continuous pressure constraint and forced cooling, the material of the insert 100 changes from a highly elastic state to a glassy state and solidifies and shapes. The residual stress generated by the initial shaping and cooling shrinkage is fully released and eliminated. Therefore, the insert 100 coming out of the second press 52 is not only accurate in shape, but also has excellent dimensional stability and will not spring back during subsequent room temperature placement.

[0046] To achieve fully automated closed-loop control and quality traceability, this device also integrates a detection unit 6, a feeding unit 7, and a loading unit 2.

[0047] like Figure 2As shown, the detection unit 6 is located behind the second press 52 along the conveying direction. Its core is a CCD vision inspection module 62 and a light source plate 61 that provides illumination. The light source plate 61 is horizontally positioned above the conveying unit 4, and has one or more openings for the camera lens to pass through. The lens of the CCD vision inspection module 62 faces downwards, taking pictures of the shaped and cooled inserts 100 below it through the openings. Through the image processing system, it can quickly detect defects such as scratches and dents on the upper surface of the insert body 101. Simultaneously, it can accurately measure key dimensions such as the spacing and position of the pins 102, determine their qualification, and record the data to provide a basis for subsequent sorting or process adjustments.

[0048] like Figure 2 As shown, the unloading unit 7 is located behind the detection unit 6, and includes a crossbeam spanning above the conveying unit 4. Specifically, as shown... Figure 6 As shown, a movable seat 71 can reciprocate horizontally on the crossbeam, and a mounting plate 72 can reciprocate vertically on the movable seat 71. The lower end face of the mounting plate 72 is equipped with unloading grippers 73, the number and layout of which perfectly match the positioning grooves 321 of the positioning fixture 32 on the movable plate 31. That is, in this embodiment, there are eight unloading grippers 73, which can grip eight inserts 100 at a time. When a qualified insert 100 needs to be conveyed to the unloading position, the unloading unit 7 operates to remove it and place it into the finished product collection box.

[0049] like Figure 2 As shown, the feeding unit 2 is located in front of the first press 51 along the conveying direction. It is linked to the robotic arm of the injection molding machine. Specifically, as... Figure 4 As shown, the loading unit 2 includes a docking plate 21, which is connected to the end flange of the injection molding machine's part-retrieving robot. The docking plate 21 is also equipped with loading grippers 22, the number and layout of which match the positioning slots 321 of the positioning fixture 32 on the motion plate 31. After the injection molding machine opens the mold, the part-retrieving robot, carrying the loading grippers 22, removes the freshly injection-molded, still-warm insert 100 and quickly moves it to the loading station of this device. The loading grippers 22 precisely place and press the hot insert 100 into the positioning slots 321 and insertion holes 322 of the empty positioning fixture 32 waiting at this station, completing the automatic loading.

[0050] Plugin shaping method: When the device is started, the drive device 46 of the conveying unit 4 continues to work, driving the chain 44 and all the moving plates 31 on it to move clockwise along the elliptical path. Figure 3The intermittent cyclical motion (clockwise as indicated by the middle arrow) is as follows. A complete cycle contains multiple pauses, each corresponding to the working time of one or more workstations. The following uses the motion trajectory of a motion plate A as an example to illustrate the complete cycle of the plug-in 100 within the device.

[0051] 1. Loading: The moving plate A runs unloaded to... Figure 2 The loading station (at the very front) is shown and then stops. At this time, the docking plate 21 of the loading unit 2, driven by the external robot, carries eight still-heated inserts 100 taken from the injection molding exit station and precisely moves them to directly above the positioning fixture 32 on the motion plate A. Then, the docking plate 21 descends, and the loading gripper 22 smoothly presses the inserts 100 into the positioning groove 321 with the pins 102 facing downwards, ensuring that each pin 102 slides smoothly into the corresponding insertion hole 322. After placement, the loading gripper 22 releases and retracts with the docking plate 21, completing the loading. This step utilizes the high elasticity of the inserts 100 after demolding, which has not yet cooled down. At this time, posture constraint and pin guidance are performed, and the relatively flexible pins 102 can be easily inserted into the insertion hole 322 without damage.

[0052] 2. First Forming: The moving plate A, carrying the hot insert 100, continues to move one station with the chain, reaching the pressure-holding and forming station directly below the first press 51, and stops precisely. After receiving the arrival signal, the control system immediately drives the linear cylinder 83 of the positioning and locking mechanism 8 to rotate the rotating shaft 81. The three limit clamps 82 simultaneously engage with the limit clamps 314 of the corresponding stations of the moving plate A, achieving high-rigidity locking. Immediately afterwards, the first press 51 starts, and its hot or room-temperature pressure head presses down at a uniform speed according to the set program, applying pressure to the upper surface of the body 101 of the insert 100. Since the temperature of the insert 100 is still relatively high at this time, and the material yield limit is low, under the joint constraint of the pressure head, the positioning groove 321, and the insertion hole 322, its skewed body 101 is flattened, and the bent insertion pins 102 are forcibly straightened. After the pressure head descends to its designated position, the pressure holding stage begins. The duration of this stage can be preset, for example, 2-5 seconds, allowing the material to undergo sufficient stress relaxation and deformation redistribution under pressure. After the pressure holding stage ends, the pressure head of the first press 51 lifts up, the positioning and locking mechanism 8 unlocks, and the moving plate A completes the first stage of shaping.

[0053] 3. Cooling and Shaping: The moving plate A continues forward, carrying the initially shaped but not yet stable insert 100 to the cooling and pressure-holding station directly below the second press 52, where it is locked again by the positioning and locking mechanism 8. The cooling structure built into the second press 52 continues to operate, keeping its pressure head at a low temperature (e.g., 5°C to 15°C). The cold pressure head of the second press 52 presses down and holds pressure at the same or slightly higher pressure as the first press 51. During this process, the cold pressure head comes into close contact with the hot insert 100, forming an efficient heat exchange. The heat of the insert 100 is quickly absorbed by the pressure head and carried away by the cooling structure. Its body 101 and pins 102 are forcibly, rapidly, and uniformly cooled to room temperature or near room temperature under pressure constraints. In this "quenching" pressure cooling process, the material undergoes solidification and shaping from a highly elastic state to a glassy state, and its molecular chain segments are "frozen" in the ideal constrained position, thereby fundamentally eliminating the source of internal stress. The holding time in this step is usually longer than a single shaping step, for example, 5-15 seconds, depending on the plug-in wall thickness and cooling efficiency. After the holding time is complete, the pressure head is lifted, the lock is released, and the plug-in 100 achieves its final stable and precise shape.

[0054] 4. Inspection and Unloading: After cooling and shaping, the motion plate A continues forward, first reaching the inspection station. Under the illumination of the light source plate 61, the CCD vision inspection module 62 takes high-definition photos and analyzes the two inserts 100 below, recording their size and appearance data. Then, the motion plate A enters the unloading station. The moving seat 71 of the unloading unit 7 moves above this station, the mounting plate 72 descends, the unloading gripper 73 clamps eight finished inserts 100 and moves upward, then the moving seat 71 moves horizontally above the finished product collection box, the gripper releases, and the inserts 100 fall into the qualified product area. The coordinated actions of the positioning and locking mechanism 8, the inspection unit 6, and the unloading unit 7 ensure the automation of the entire process.

[0055] Finally, the unloaded moving plate A returns along the bottom of the closed-loop path, repeating the cycle to start a new round of feeding.

[0056] It is important to emphasize that while moving plate A is undergoing prolonged cooling and pressure holding at the second press 52, another moving plate B is simultaneously moving to the first press 51 for shaping and pressure holding. Meanwhile, another moving plate C is loading materials at the loading station, and another moving plate D is unloading materials at the unloading station. The five main stations on the entire conveyor line—loading, primary shaping, cooling and setting, inspection, and unloading—operate in parallel within the same timeframe. This assembly line-style parallel work mode eliminates the limitation of production efficiency on the longest-running cooling process, maximizing the production cycle time. For example, if cooling and setting takes 10 seconds and the first press shaping takes 3 seconds, the theoretical cycle time of the entire system can be shortened to 10 seconds or less, far exceeding any production method that requires manual transfer and single-machine processing.

[0057] The above embodiments are only for illustrating the technical concept and features of the present invention. Their purpose is to enable those skilled in the art to understand the content of the present invention and implement it. They should not be used to limit the scope of protection of the present invention. All equivalent changes or modifications made in accordance with the spirit and essence of the present invention should be covered within the scope of protection of the present invention.

Claims

1. A plug-in shaping device for shaping a plug-in (100) that has not fully cooled after injection molding, the plug-in (100) having a body (101) and pins (102) disposed on one side of the body (101), characterized in that, The device includes: Mounting bracket (1); The conveying unit (4) is mounted on the mounting frame (1) and includes a chain (44) that moves cyclically along a closed-loop path. The positioning unit (3) includes multiple motion plates (31) connected to the chain (44) and moving synchronously therewith. Each motion plate (31) is fixed with at least one positioning fixture (32). The positioning fixture (32) is provided with a positioning groove (321) adapted to the shape of the body (101) of the plug (100). The bottom of the positioning groove (321) is provided with a socket (322) for the pins (102) of the plug (100) to be inserted one by one. The shaping unit (5) is located above the closed-loop path of the conveying unit (4) and includes a first press (51) and a second press (52) arranged sequentially along the conveying direction of the moving plate (31). The first press (51) is used to extrude and shape the plug-in (100) from the previous station and carried on the positioning fixture (32) and hold it under pressure. The second press (52) is provided with a cooling structure for cooling and holding pressure to shape the plug-in (100) after it has been initially shaped by the first press (51).

2. The plug-in shaping device according to claim 1, characterized in that: The conveying unit (4) also includes a mounting chassis (41) fixed in the mounting frame (1). The two ends of the mounting chassis (41) are respectively rotatably provided with a drive sprocket (42) and a driven sprocket (43). The closed-loop chain (44) is tensioned around the drive sprocket (42) and the driven sprocket (43). The drive sprocket (42) is connected to a drive device (46) for transmission.

3. The plug-in shaping device according to claim 2, characterized in that: The mounting chassis (41) is provided with a closed-loop annular track (45) along its circumference, and the annular track (45) is wrapped around the outside of the chain (44); the back of the motion plate (31) is provided with a guide component that rolls with the annular track (45).

4. The plug-in shaping device according to claim 3, characterized in that: The guide assembly includes a mounting base (311) fixed to the back of the motion plate (31), and an upper row of rollers (312) and a lower row of rollers (313) are provided on the mounting base (311). The edge portion of the annular track (45) is embedded between the upper row of rollers (312) and the lower row of rollers (313) to form a rolling friction fit.

5. The plug-in shaping device according to claim 3, characterized in that: A ring track (45) is symmetrically arranged on both sides of the mounting chassis (41), and the guide components are respectively arranged on the back of the motion plate (31) corresponding to the ring tracks (45) on both sides.

6. The plug-in shaping device according to claim 1, characterized in that: It also includes a positioning and locking mechanism (8), which includes: a limiting seat (314) fixed on the motion plate (31); a rotating shaft (81) rotatably connected to the mounting chassis (41) or mounting bracket (1); and a limiting member (82) fixed on the rotating shaft (81); the rotating shaft (81) is connected to a driving member, which drives the rotating shaft (81) to rotate, so that the limiting member (82) engages or disengages from the limiting seat (314) on the motion plate (31) that has moved to the pressure holding position.

7. The plug-in shaping device according to claim 6, characterized in that: At least two limiting clips (82) are provided on the rotating shaft (81) at intervals along its axial direction, including at least the limiting clips (82) corresponding to the pressure holding positions directly below the first press (51) and the second press (52); the snap-in end of the limiting clip (82) is a freely rotatable guide wheel (821).

8. The plug-in shaping device according to claim 1, characterized in that: It also includes a detection unit (6), which is located behind the shaping unit (5) along the conveying direction and above the conveying unit (4); the detection unit (6) includes a light source plate (61) and a CCD vision inspection module (62), the light source plate (61) has a hole for light to pass through for vision inspection, and the CCD vision inspection module (62) is located above the hole and is used to inspect the appearance and size of the plug-in (100) after cooling and shaping.

9. The plug-in shaping device according to claim 8, characterized in that: It also includes a feeding unit (7), which is located behind the detection unit (6) along the conveying direction and above the conveying unit (4); the feeding unit (7) includes a movable seat (71) capable of horizontal and vertical reciprocating motion, and a mounting plate (72) is provided on the movable seat (71). The lower end of the mounting plate (72) is provided with feeding grippers (73) that match the number and layout of the positioning grooves (321) of the positioning fixture (32) on the moving plate (31).

10. The plug-in shaping device according to claim 1, characterized in that: It also includes a feeding unit (2), which is located in front of the shaping unit (5) along the conveying direction and above the conveying unit (4); the feeding unit (2) includes a docking plate (21) connected to the robot arm, and the docking plate (21) is provided with feeding grippers (22) that match the number and layout of the positioning grooves (321) of the positioning fixture (32) on the motion plate (31).

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