A new energy automobile high-voltage wire harness copper-aluminum composite terminal automatic pressing and shearing equipment

Abstract

This invention discloses an automatic copper-aluminum composite terminal crimping and cutting device for high-voltage wiring harnesses in new energy vehicles, relating to the field of automotive high-voltage wiring harness processing technology. It includes an automatic wire stripping machine for new energy vehicles, a conveyor belt, a terminal socket assembly, and a terminal crimping assembly. By integrating the automatic wire stripping machine, conveyor belt, gantry-type three-axis robotic arm assembly, terminal socket assembly, and terminal crimping assembly, this invention constructs a complete automated production line from wiring harness feeding, stripping, transfer, terminal socketing, direction adjustment, crimping, to finished product unloading, significantly improving production efficiency. Furthermore, by designing a conical rotating cylinder, a semi-conical pressing block, a positioning pressing groove, a second directional motor, and a gear transmission mechanism in the terminal crimping assembly, the terminal can be rotated to any angle set in the engineering process. This function ensures precise matching of the spatial orientation of the crimped terminal with the overall high-voltage wiring harness layout of the vehicle, effectively avoiding wiring harness twisting, installation difficulties, or stress concentration problems caused by terminal orientation deviations.

Description

Technical Field

[0001] This invention relates to the field of automotive high-voltage wiring harness processing technology, specifically an automatic crimping and shearing device for copper-aluminum composite terminals of high-voltage wiring harnesses for new energy vehicles. Background Technology

[0002] As the "high-voltage artery" of new energy vehicles, high-voltage wiring harnesses are the core carrier connecting the three-electric system (battery, motor, and electronic control system) and transmitting high voltage and high current. The automatic crimping and shearing process for copper-aluminum composite terminals of new energy high-voltage wiring harnesses mainly includes the following steps:

[0003] 1. Terminal processing: The tube blank is flattened, punched and trimmed using stamping or hydraulic equipment to form the initial shape of the terminal. For copper-aluminum composite terminals, the copper and aluminum materials are connected by welding (ultrasonic welding, friction welding) or metallurgical bonding process (brazing, explosive welding) to form a strong bonding interface.

[0004] 2. Wire harness processing: The feeding system feeds the coiled wires into the equipment and precisely positions them to start processing. High-precision servo cutting is used (common dimensional deviation ≤ ±0.2 mm). After cutting, a rotating blade is used to spin-cut and pull to remove part of the outer insulation of the wire harness (the maximum stripping length for high-voltage large wire harness processing is 100 mm).

[0005] Subsequently, the aluminum foil layer is precisely cut and peeled using a laser or rotary cutter to ensure zero damage to the inner insulation layer. Similarly, the metal braided shielding mesh is cut using a laser or mechanical method, and the cut shielding layer is flipped over to the outer layer of the wire harness. Finally, the insulation layer of the inner core of the wire harness is peeled off to expose the aluminum conductor so as to achieve reliable contact with the terminal.

[0006] 3. Connector Assembly and Post-processing: Insert the treated aluminum core into the copper-aluminum composite terminal. Use a servo crimping machine to precisely control the pressure (the crimping tensile strength standard for reliable connections is typically ≥200 N) and crimping depth, causing the metal to undergo plastic deformation under pressure, forming an airtight cold welded connection. The crimping die cavity commonly uses a hexagonal or W-shaped indentation structure.

[0007] For high-voltage wiring harnesses for new energy vehicles, the direction of the terminals at both ends needs to be flexibly designed according to the actual layout of the vehicle and the installation point, and a precise specific angle should be adopted. The core principle is to ensure that the wiring harness is in a natural and untwisted state, and that both ends are precisely aligned with the interface.

[0008] Therefore, when crimping wire harness terminals, it is necessary to adjust the terminal angle and rotate it to the precise angle set by the engineering (e.g., the terminals at both ends of the wire harness are offset by 90°). Based on the above process requirements, an automatic crimping and cutting device for copper-aluminum composite terminals of high-voltage wire harnesses for new energy vehicles is provided. Summary of the Invention

[0009] The purpose of this invention is to provide an automatic crimping and shearing device for copper-aluminum composite terminals of high-voltage wiring harnesses for new energy vehicles in order to solve the problems mentioned above.

[0010] To achieve the above objectives, the present invention provides the following technical solution: an automatic copper-aluminum composite terminal crimping and cutting device for high-voltage wiring harnesses of new energy vehicles, comprising an automatic wire stripping machine for new energy vehicles, a conveyor belt, a terminal socket assembly, and a terminal crimping assembly. The conveyor belt and the automatic wire stripping machine are laid in a straight line, and the terminal socket assembly and the terminal crimping assembly are laid in a straight line and are arranged parallel to the conveyor belt.

[0011] A gantry-type three-axis robotic arm assembly is provided in the area where the conveyor belt, terminal socket assembly, and terminal pressing assembly are located. The gantry-type three-axis robotic arm assembly is used to clamp and transfer the terminal pressing assembly on the conveyor belt, so as to realize the displacement of the terminal pressing assembly in the three work positions of the conveyor belt, terminal socket assembly, and terminal pressing assembly.

[0012] The conveyor belt protrudes from both ends into the working area of ​​the gantry-type three-axis robotic arm assembly, used to receive wire harnesses from the new energy automatic wire stripping machine, and at the same time, to transport the wire harnesses with pressed terminals to the next process.

[0013] As a further embodiment of the present invention: the gantry-type three-axis robotic arm assembly includes a gantry-type three-axis slide, a connecting seat, a rotating seat, a two-finger parallel gripper, a worm gear gearbox, a horizontal gear shaft, a side plate, a first directional motor, and a vertical gear shaft;

[0014] Two sets of transverse moving seats are symmetrically installed on the transverse arm of the gantry-type three-axis slide table. The connecting seat is installed at the bottom of the vertical lifting toothed arm on the transverse moving seat. The two-finger parallel pneumatic gripper is rotatably installed on the connecting seat through the rotating seat.

[0015] The worm gearbox is mounted on the front end of the frame of the transverse moving seat. The horizontal gear shaft passes horizontally through the worm in the two worm gearboxes and is slidably connected to the worm. The side plates are symmetrically fixed at both ends of the transverse arm of the gantry-type three-axis slide table. The two ends of the horizontal gear shaft are respectively rotatably connected to the two side plates.

[0016] The first directional motor is mounted on the end face of a side plate and the output end of the first directional motor is connected to a horizontal gear shaft;

[0017] The vertical gear shaft extends vertically through the worm gear in the worm gearbox and is rotatably connected to the worm gear. The bottom of the vertical gear shaft is connected to the top of the two-finger parallel pneumatic gripper housing.

[0018] As a further embodiment of the present invention: the terminal socket assembly includes a first workstation, a vertical guide frame, a first cylinder, a horizontal plate, and a pusher head;

[0019] The vertical guide rack is provided in two sets, and the two sets of vertical guide racks are symmetrically installed on the top of the first workstation. The terminals are arranged vertically and placed inside the vertical guide rack. The inner space of the vertical guide rack matches the shape of the terminals. The bottom front end of the vertical guide rack has a notch for the terminals to be removed.

[0020] The first cylinder is installed on the top of the first workstation and distributed between the two sets of vertical guide frames. The output end of the first cylinder extends backward and connects to the horizontal plate.

[0021] The horizontal plate is distributed at the rear end of two sets of vertical guide frames, and the pusher head is symmetrically fixed at the front end of the horizontal plate, with the two pusher heads respectively aligned with the notches of the vertical guide frames.

[0022] As a further embodiment of the present invention: the terminal pressing assembly includes a second workbench, a servo-type terminal pressing machine, a hexagonal pressing mold, a support shaft seat, a rotating cylinder, a C-shaped guide bar, a semi-conical pressing block, a positioning pressing groove, and a C-shaped guide groove;

[0023] The servo terminal crimping machine is provided in two sets, and the two sets of servo terminal crimping machines are symmetrically installed on the top of the second workbench. The hexagonal crimping mold is installed on the output end of the servo terminal crimping machine.

[0024] The support shaft seat is installed inside the frame of the servo terminal crimping machine and is located behind the hexagonal crimping mold. The rotating cylinder is rotatably installed inside the support shaft seat and extends towards the front end close to the servo terminal crimping machine.

[0025] The inner cavity of the rotating cylinder has a conical structure, and the inner diameter decreases from back to front. The C-shaped guide bar is symmetrically fixed to the conical inner wall side of the rotating cylinder.

[0026] Two semi-conical pressure blocks are symmetrically arranged. The positioning pressure groove is formed on the side of the two semi-conical pressure blocks that are close to each other. The C-shaped guide groove is opened on the outer side of the semi-conical pressure blocks that are far apart from each other. The two semi-conical pressure blocks are slidably installed on the inner side of the rotating cylinder through the C-shaped guide groove and the C-shaped guide bar.

[0027] When the terminal passes through the hexagonal crimping mold, the end of the terminal is inserted into the inside of the rotating cylinder. The two semi-conical pressing blocks move forward along the inner wall of the rotating cylinder, approach each other, and are pressed against the outside of the end of the terminal through the positioning groove to achieve the directional positioning of the terminal.

[0028] As a further embodiment of the present invention: the terminal press-fit assembly further includes a T-shaped annular groove, a mating round seat, a connecting rod, a connecting plate, and a second cylinder;

[0029] The T-shaped annular groove is formed on one side of the two semi-conical pressure blocks that are close to each other and extends through the rear end of the semi-conical pressure blocks. The T-shaped annular groove is distributed at the rear end of the positioning pressure groove.

[0030] The docking round seat and the connecting rod are connected and fixed in sequence along the axial direction. The two semi-conical pressure blocks are sleeved on the outside of the docking round seat through T-shaped annular grooves. The connecting rod extends backward to the rear end of the servo terminal crimping machine, and the rear ends of the two connecting rods are connected and fixed to the connecting plate.

[0031] The second cylinder is mounted on the bottom of the second workbench via a bracket and is located between two sets of servo terminal crimping machines. The output axis of the second cylinder extends rearward and is connected and fixed to the connecting plate.

[0032] As a further embodiment of the present invention: the terminal pressing assembly further includes a second directional motor and a drive gear;

[0033] An external gear is formed on the outer side of the portion of the rotating cylinder that protrudes from the rear end of the support shaft seat;

[0034] The second directional motor is mounted behind the support shaft seat, and the drive gear is connected to the output shaft of the second directional motor, and the drive gear meshes with the external gear;

[0035] The second directional motor drives the rotating cylinder and the semi-conical pressure block to rotate as a whole, thereby driving the terminal to rotate and thus adjusting the orientation of the terminal.

[0036] As a further aspect of the present invention: the maximum distance between the two sets of transverse moving seats is greater than the longest processing length of the wire harness;

[0037] The terminal socket assembly and the terminal press assembly are located inside the movable area of ​​the gantry-type three-axis robotic arm assembly.

[0038] The front area of ​​the terminal socket assembly and the terminal press-fit assembly is provided with a platform to support the tail of the wire harness that is bent into a "U" shape.

[0039] As a further aspect of the present invention: the inner diameter of the T-shaped annular groove matches the outer diameter of the mating round seat, and the outer diameter of the mating round seat is greater than the maximum distance between the two semi-conical pressure blocks.

[0040] As a further aspect of the present invention, the helical directions on the two worms in the two worm gearboxes are opposite.

[0041] Compared with the prior art, the beneficial effects of the present invention are:

[0042] 1. By integrating a new energy automatic wire stripping machine, conveyor belt, gantry-type three-axis robotic arm assembly, terminal socket assembly and terminal pressing assembly, a complete automated production line is constructed, from wire harness feeding, wire stripping, transfer, terminal socketing, direction adjustment, pressing to finished product unloading. Throughout the process, the wire harness automatically flows between the conveyor belt picking, terminal socketing, terminal pressing and finished product unloading stations without manual intervention, which significantly improves production efficiency, reduces labor costs and ensures the consistency and repeatability of the process.

[0043] 2. By setting two sets of two-finger parallel pneumatic grippers in the gantry-type three-axis robotic arm assembly, and cooperating with the first directional motor, worm gear gearbox, horizontal gear shaft and worm structure with opposite rotation direction, the synchronous opposite rotation of the two pneumatic grippers is realized. This enables the straight wire harness to bend into a U-shape, so that both ends of the wire harness face the terminal sleeve assembly and the terminal pressing assembly at the same time. Based on this, the equipment can simultaneously perform terminal sleeve and terminal pressing operations on both ends of the wire harness, eliminating the time waste caused by processing both ends separately in the traditional solution. It is especially suitable for mass production scenarios.

[0044] 3. By designing a conical rotating cylinder, a semi-conical pressing block, a positioning pressing groove, a second directional motor, and a gear transmission mechanism in the terminal pressing assembly, when the terminal end is inserted into the rotating cylinder, the second cylinder drives the semi-conical pressing block to move forward and clamp the terminal end, achieving high-precision circumferential positioning. Subsequently, the second directional motor can drive the rotating cylinder and the semi-conical pressing block to rotate as a whole, thereby rotating the terminal to any angle set by the project. This function ensures that the spatial orientation of the terminal after pressing is accurately matched with the layout of the high-voltage wiring harness of the whole vehicle, effectively avoiding wiring harness twisting, installation difficulties, or stress concentration problems caused by terminal orientation deviation. Attached Figure Description

[0045] Figure 1 This is a schematic diagram showing the positional distribution of the new energy automatic wire stripper, conveyor belt, gantry-type three-axis robotic arm assembly, terminal socket assembly, and terminal pressing assembly of the present invention.

[0046] Figure 2 This is a schematic diagram of the gantry-type three-axis robotic arm assembly of the present invention;

[0047] Figure 3 For the present invention Figure 2 Enlarged view of point A in the middle;

[0048] Figure 4 This is a cross-sectional view showing the positional distribution of the horizontal gear shaft, vertical gear shaft, and worm gear transmission of the present invention.

[0049] Figure 5 This is a schematic diagram of the terminal sleeve assembly of the present invention;

[0050] Figure 6This is another structural view of the terminal socket assembly of the present invention;

[0051] Figure 7 This is a schematic diagram of the terminal press-fit assembly of the present invention;

[0052] Figure 8 This is a schematic diagram showing the terminal of the present invention passing through the hexagonal crimping mold;

[0053] Figure 9 This is another structural view of the terminal press-fit assembly of the present invention;

[0054] Figure 10 This is a schematic diagram showing the structural distribution of some parts of the terminal press-fit assembly of the present invention;

[0055] Figure 11 This is a cross-sectional view of the internal structure of the rotating cylinder of the present invention.

[0056] Figure 12 This is a cross-sectional exploded view of the rotating cylinder of the present invention.

[0057] In the diagram: 1. Automatic wire stripping machine for new energy; 2. Conveyor belt; 3. Gantry-type three-axis robotic arm assembly; 4. Terminal socket assembly; 5. Terminal pressing assembly; 6. Wire harness; 7. Terminal;

[0058] 301. Gantry-type three-axis slide table; 302. Lateral moving seat; 303. Vertical lifting gear arm; 304. Connecting seat; 305. Rotating seat; 306. Two-finger parallel pneumatic gripper; 307. Worm gearbox; 308. Horizontal gear shaft; 309. Side plate; 310. First directional motor; 311. Vertical gear shaft;

[0059] 401. First workstation; 402. Vertical guide frame; 403. First cylinder; 404. Horizontal plate; 405. Pusher head;

[0060] 501. Second worktable; 502. Servo-type terminal crimping machine; 503. Hexagonal crimping die; 504. Support shaft seat; 505. Rotating cylinder; 506. C-shaped guide bar; 507. External gear; 508. Semi-conical pressing block; 509. Positioning pressing groove; 510. C-shaped guide groove; 511. T-shaped annular groove; 512. Docking round seat; 513. Connecting rod; 514. Connecting plate; 515. Second cylinder; 516. Second directional motor; 517. Drive gear. Detailed Implementation

[0061] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0062] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance. In the description of this invention, it should be noted that unless otherwise explicitly specified and limited, the terms "installed," "connected," "linked," and "set up" 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 of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances. The following describes embodiments of the invention based on its overall structure.

[0063] Please see Figures 1 to 12 In this embodiment of the invention, an automatic copper-aluminum composite terminal crimping and cutting device for high-voltage wiring harnesses of new energy vehicles includes a new energy automatic wire stripping machine 1, a conveyor belt 2, a terminal socket assembly 4, and a terminal crimping assembly 5. The conveyor belt 2 and the new energy automatic wire stripping machine 1 are laid in a straight line, and the terminal socket assembly 4 and the terminal crimping assembly 5 are laid in a straight line and are arranged parallel to the conveyor belt 2.

[0064] A gantry-type three-axis robotic arm assembly 3 is installed in the area where the conveyor belt 2, terminal socket assembly 4, and terminal pressing assembly 5 are located. The gantry-type three-axis robotic arm assembly 3 is used to clamp and transfer the terminal pressing assembly 5 on the conveyor belt 2, so as to realize the displacement of the terminal pressing assembly 5 in the three work positions of the conveyor belt 2, terminal socket assembly 4, and terminal pressing assembly 5.

[0065] The two ends of the conveyor belt 2 protrude from the working area of ​​the gantry-type three-axis robotic arm assembly 3, which is used to receive the wire harness 6 from the new energy automatic wire stripper 1, and at the same time, to transport the wire harness 6 with the crimped terminals 7 to the next process.

[0066] The gantry-type three-axis robotic arm assembly 3 includes a gantry-type three-axis slide 301, a connecting seat 304, a rotating seat 305, a two-finger parallel gripper 306, a worm gear gearbox 307, a horizontal gear shaft 308, a side plate 309, a first directional motor 310, and a vertical gear shaft 311.

[0067] Two sets of transverse moving seats 302 are symmetrically installed on the transverse arm of the gantry-type three-axis slide table 301. The connecting seat 304 is installed at the bottom of the vertical lifting toothed arm 303 on the transverse moving seat 302. The two-finger parallel pneumatic gripper 306 is rotatably installed on the connecting seat 304 through the rotating seat 305.

[0068] The worm gear transmission 307 is installed at the front end of the frame of the transverse moving seat 302. The horizontal gear shaft 308 horizontally passes through the worms in the two worm gear transmissions 307 and is slidably connected to the worms. The side plates 309 are symmetrically fixed at both ends of the cross arm of the gantry three-axis slide table 301. The two ends of the horizontal gear shaft 308 are rotatably connected to the two side plates 309 respectively.

[0069] The first directional motor 310 is mounted on the end face of a side plate 309 and the output end of the first directional motor 310 is connected to the horizontal gear shaft 308.

[0070] The vertical gear shaft 311 vertically penetrates the worm gear in the worm gear transmission 307 and is rotatably connected to the worm gear. The bottom of the vertical gear shaft 311 is connected to the top of the housing of the two-finger parallel pneumatic gripper 306.

[0071] In this embodiment, it should be noted that both the new energy automatic wire stripping machine 1 and the conveyor belt 2 are existing mature structures, and their internal working principles will not be described in detail here.

[0072] A gantry-type three-axis robotic arm assembly 3 is set up in the area where the conveyor belt 2, terminal socket assembly 4, and terminal pressing assembly 5 are located. It is used to clamp and transfer the wire harness 6, so as to realize the automatic handling of the wire harness 6 between the three stations of "material picking from conveyor belt 2 → terminal socket assembly 4 → terminal pressing assembly 5 → material unloading from conveyor belt 2".

[0073] The core motion of the gantry-type three-axis robotic arm assembly 3 is completed collaboratively by two sets of two-finger parallel grippers 306, and its working principle is as follows:

[0074] Two sets of two-finger parallel pneumatic grippers 306 respectively clamp the two ends of the wire harness 6 (near the stripping end). By moving the two sets of transverse moving seats 302 along the horizontal arm of the gantry three-axis slide table 301, the spacing between the two sets of two-finger parallel pneumatic grippers 306 can be adjusted to match wire harnesses 6 of different lengths.

[0075] In addition, after the vertical lifting gear arm 303 moves upward and drives the wire harness 6 to detach from the conveyor belt 2, the two sets of transverse moving seats 302 can be brought closer to each other, and the first directional motor 310 is started. The first directional motor 310 drives the two worms in the two sets of worm gear gearboxes 307 to rotate synchronously through the horizontal gear shaft 308. The worm drives the worm wheel to rotate, which in turn drives the vertical gear shaft 311 to rotate, so that the two sets of two-finger parallel pneumatic grippers 306 rotate through their respective rotating seats 305. By driving the two sets of pneumatic grippers 306 to rotate and move closer to each other, the middle part of the wire harness 6 hangs down naturally, and the two ends face the same direction, and its whole is in a U-shape.

[0076] In this way, the two ends of the originally straight wire harness 6 are spatially adjusted so that they are simultaneously facing the terminal sleeve assembly 4 and the terminal pressing assembly 5, which facilitates the simultaneous terminal sleeve and terminal pressing operations at both ends.

[0077] By operating the gantry-type three-axis slide 301, the U-shaped wire harness 6 can be transferred as a whole to the working area of ​​the terminal socket assembly 4 and the terminal pressing assembly 5. Then, the terminal socket assembly 4 and the terminal pressing assembly 5 sequentially perform the socketing and pressing operations of the terminal 7 and the wire harness 6.

[0078] After the wire harness 6 is pressed, it is sent back to the conveyor belt 2 so that it can be transported to the next process.

[0079] It should be noted that the gantry-type three-axis slide table 301 has a mature linear motion structure, and its specific drive and control principles will not be elaborated here.

[0080] Please refer to this carefully. Figure 1 , Figure 5 , Figure 6 The terminal socket assembly 4 includes a first workstation 401, a vertical guide frame 402, a first cylinder 403, a horizontal plate 404, and a pusher head 405.

[0081] Two sets of vertical guide racks 402 are provided. The two sets of vertical guide racks 402 are symmetrically installed on the top of the first workstation 401. The terminals 7 are arranged vertically and placed inside the vertical guide racks 402. The inner space of the vertical guide racks 402 matches the shape of the terminals 7. A notch is opened at the bottom front end of the vertical guide racks 402 for the terminals 7 to be removed.

[0082] The first cylinder 403 is installed on the top of the first workstation 401 and distributed between the two sets of vertical guide frames 402. The output end of the first cylinder 403 extends backward and connects to the horizontal plate 404.

[0083] The horizontal plate 404 is distributed at the rear end of two sets of vertical guide frames 402. The pusher head 405 is symmetrically fixed at the front end of the horizontal plate 404, and the two pusher heads 405 are respectively aligned with the notches of the vertical guide frames 402.

[0084] In this embodiment: the terminals 7 are arranged vertically and placed inside the two sets of vertical guide frames 402, and are automatically fed downwards by gravity;

[0085] The gantry-type three-axis slide table 301 moves the U-shaped wire harness 6 to the front of the terminal socket assembly 4, with the two ends of the wire harness 6 aligned with the notches of the two guide frames 402, that is, the two ends of the wire harness 6 are respectively aligned with the two lowest terminals 7.

[0086] At this time, the first cylinder 403 is activated. The first cylinder 403 drives the two push heads 405 to move forward synchronously through the horizontal plate 404, pushing the lowest terminal 7 out of the notch at the bottom front end of the vertical guide frame 402. The pushed-out terminal 7 is aligned with the end of the wire harness 6, completing the automatic connection.

[0087] Please refer to this carefully. Figure 1 , Figures 7 to 12 The terminal pressing assembly 5 includes a second workbench 501, a servo-type terminal pressing machine 502, a hexagonal pressing mold 503, a support shaft seat 504, a rotating cylinder 505, a C-shaped guide bar 506, a semi-conical pressing block 508, a positioning pressing groove 509, and a C-shaped guide groove 510.

[0088] The servo terminal crimping machine 502 is provided in two sets. The two sets of servo terminal crimping machines 502 are symmetrically installed on the top of the second workbench 501, and the hexagonal crimping mold 503 is installed at the output end of the servo terminal crimping machine 502.

[0089] The support shaft seat 504 is installed inside the frame of the servo terminal crimping machine 502 and is located behind the hexagonal crimping mold 503. The rotating cylinder 505 is rotatably installed inside the support shaft seat 504 and extends towards the front end close to the servo terminal crimping machine 502.

[0090] The inner cavity of the rotating cylinder 505 has a conical structure, and the inner diameter decreases from back to front. C-shaped guide bars 506 are symmetrically fixed to the conical inner wall side of the rotating cylinder 505.

[0091] Two semi-conical pressure blocks 508 are symmetrically arranged. The positioning pressure groove 509 is formed on the side of the two semi-conical pressure blocks 508 that are close to each other. The C-shaped guide groove 510 is opened on the outer side of the semi-conical pressure blocks 508 that are far apart from each other. The two semi-conical pressure blocks 508 are slidably installed on the inner side of the rotating cylinder 505 through the C-shaped guide groove 510 and the C-shaped guide bar 506.

[0092] When terminal 7 passes through hexagonal crimping mold 503, the end of terminal 7 is inserted into the inner side of rotating cylinder 505. Two semi-conical pressing blocks 508 move forward along the inner wall of rotating cylinder 505 and approach each other, and are pressed against the outer side of the end of terminal 7 through positioning pressing groove 509 to achieve directional positioning of terminal 7.

[0093] The terminal press-fit assembly 5 also includes a T-shaped annular groove 511, a mating round seat 512, a connecting rod 513, a connecting plate 514, and a second cylinder 515;

[0094] T-shaped annular grooves 511 are formed on the side of the two semi-conical pressure blocks 508 that are close to each other and pass through the rear end of the semi-conical pressure blocks 508. T-shaped annular grooves 511 are distributed at the rear end of the positioning pressure grooves 509.

[0095] The mating round seat 512 and the connecting rod 513 are connected and fixed in sequence along the axial direction. Two semi-conical pressure blocks 508 are sleeved on the outside of the mating round seat 512 through the T-shaped annular groove 511. The connecting rod 513 extends backward to the rear end of the servo terminal crimping machine 502, and the rear ends of the two connecting rods 513 are connected and fixed to the connecting plate 514.

[0096] The second cylinder 515 is mounted on the bottom of the second workbench 501 via a bracket and is located between the two sets of servo terminal crimping machines 502. The output axis of the second cylinder 515 extends backward and is connected and fixed to the connecting plate 514.

[0097] Terminal press-fit assembly 5 also includes a second directional motor 516 and a drive gear 517;

[0098] An external gear 507 is formed on the outer side of the part of the rotating cylinder 505 that protrudes from the rear end of the support shaft seat 504;

[0099] The second directional motor 516 is mounted behind the support shaft seat 504, and the drive gear 517 is connected to the output shaft of the second directional motor 516, and the drive gear 517 meshes with the external gear 507.

[0100] The second directional motor 516 drives the rotating cylinder 505 and the semi-conical pressure block 508 to rotate as a whole, thereby driving the terminal 7 to rotate and thus achieving the orientation adjustment of the terminal 7.

[0101] In this embodiment: when the gantry-type three-axis robotic arm assembly 3 transfers the U-shaped wire harness 6 to the working area of ​​the terminal pressing assembly 5, the two ends of the wire harness 6 are respectively aligned with the entrances of the hexagonal pressing molds 503 of the two sets of servo-type terminal pressing machines 502. At this time, the ends of the wire harness 6 are already fitted with terminals 7, and the ends of the terminals 7 face the back of the pressing molds.

[0102] Terminal 7 moves along with the end of wire harness 6 and passes through hexagonal crimping mold 503, so that its end is inserted into the inside of rotating cylinder 505;

[0103] The inner cavity of the rotating cylinder 505 has a conical structure that is smaller at the front and larger at the back. Two symmetrical semi-conical pressure blocks 508 are slidably installed on its inner side wall through C-shaped guide bars 506. In the initial state, the two semi-conical pressure blocks 508 are back and far apart from each other, which does not affect the insertion of the end of the terminal 7.

[0104] After the position of wire harness 6 is determined, the second cylinder 515 is started. The output shaft of the second cylinder 51 retracts, driving the connecting plate 514 to move. The connecting plate 514 pushes the two connecting rods 513 to move synchronously. The connecting rods 513 push the two semi-conical pressure blocks 508 to move forward along the inner wall of the rotating cylinder 505 through the docking round seat 512. Due to the action of the conical surface, the two semi-conical pressure blocks 508 move closer to each other during the movement.

[0105] Finally, the positioning grooves 509 on the inner side of the two semi-conical pressure blocks 508 clamp the outer contour of the end of the terminal 7 from both sides, realizing the precise circumferential positioning of the terminal 7 before crimping (that is, ensuring that the angle relationship between the terminal 7 and the crimping mold is unique and fixed). After this positioning action is completed, the terminal 7 is clamped and fixed by the semi-conical pressure blocks 508, preparing for subsequent angle adjustment and crimping.

[0106] To meet the requirement that the orientation of the terminals at both ends of the high-voltage wiring harness in new energy vehicles must be precisely set according to the overall vehicle layout, the terminal press-fit assembly 5 has an active orientation adjustment function:

[0107] After the terminal 7 is clamped by the semi-conical pressure block 508, the second directional motor 516 is started, and its output shaft drives the drive gear 517 to rotate. The drive gear 517 meshes with the external gear 507 on the outer side of the rear end of the rotating cylinder 505, thereby driving the rotating cylinder 505 to rotate around its own axis inside the support shaft seat 504. At the same time, since the two semi-conical pressure blocks 508 are slidably connected to the C-shaped guide bar 506 through the C-shaped guide groove 510, and the pressure block has clamped the terminal 7 at this time, the rotating cylinder 505 drives the semi-conical pressure block 508 and the clamped terminal 7 to rotate synchronously.

[0108] The control system precisely controls the rotation of the second directional motor 516 according to the target angle set by the project (e.g., 90° deflection relative to the initial angle), so that the terminal 7 rotates to the preset circumferential posture. After this stage is completed, the circumferential direction of the terminal 7 is completely matched with the vehicle installation requirements.

[0109] After the terminal 7 is adjusted to the correct position, the two sets of servo terminal crimping machines 502 operate simultaneously, driving the hexagonal crimping die 503 to apply precisely controlled pressure and movement to the terminal 7 sleeved at the end of the wire harness 6;

[0110] During the crimping process, the servo system monitors the pressure-displacement curve in real time to ensure that the crimping tensile strength meets the standard requirements (usually ≥200N), so that the terminal 7 and the aluminum conductor undergo plastic deformation under pressure to form an airtight cold weld connection. The hexagonal crimping die 503 presses the terminal 7 into a standard hexagonal profile to ensure that key indicators such as crimping resistance and pull-out force meet the technical requirements of high-voltage wire harnesses.

[0111] It should be noted that the servo-type terminal crimping machine 502 and the hexagonal crimping die 503 are both existing mature crimping technologies, and their specific internal control principles will not be elaborated here.

[0112] After the crimping action is completed, the second directional motor 516 and the second cylinder 515 are reset in sequence, and the terminal crimping assembly 5 releases the crimped terminal 7 so that the wire harness 6 can be removed. Subsequently, the gantry-type three-axis robotic arm assembly 3 pulls the wire harness 6 with the crimped terminal 7 out of the terminal crimping assembly 5 and transfers it back to the conveyor belt 2.

[0113] Please refer to this carefully. Figures 1 to 2 The maximum spacing between the two sets of transverse moving seats 302 is greater than the longest processing length of the wire harness 6;

[0114] Terminal socket assembly 4 and terminal press assembly 5 are located on the inner side of the movable area of ​​gantry three-axis robotic arm assembly 3;

[0115] The front area of ​​the terminal socket assembly 4 and the terminal press assembly 5 is provided with a platform to support the tail of the wire harness 6 bent into a "U" shape.

[0116] In this embodiment: the maximum distance between the two sets of transverse moving seats 302 is greater than the longest processing length of the wire harness 6, ensuring that the entire wire harness can be clamped in a straight state;

[0117] Terminal socket assembly 4 and terminal pressing assembly 5 are both located inside the movable area of ​​gantry three-axis robotic arm assembly 3, which can ensure that the moving stroke of gantry three-axis robotic arm assembly 3 can meet the moving requirements of wire harness 6 in terminal socket assembly 4 and terminal pressing assembly 5.

[0118] When the wire harness 6 is transferred in a U-shape, the tail end of the wire harness 6 will droop under its own weight. The platform set in the front area of ​​the terminal sleeve assembly 4 and the terminal pressing assembly 5 can support the tail end of the wire harness 6 that is bent into a U-shape, so as to facilitate the movement of the wire harness 6 and prevent the wire harness 6 from bending too much.

[0119] Please refer to this carefully. Figure 11 , Figure 12 The inner diameter of the T-shaped annular groove 511 matches the outer diameter of the mating round seat 512, and the outer diameter of the mating round seat 512 is greater than the maximum distance between the two semi-conical pressure blocks 508.

[0120] In this embodiment, the structural design ensures that the two semi-conical pressure blocks 508 can reliably separate when pulled backward, without detaching from the docking seat 512.

[0121] Please refer to this carefully. Figure 2 , Figure 4 In the two worm gear transmission 307, the spirals on the two worms are in opposite directions.

[0122] In this embodiment: by setting the spiral directions of the two worm gears in opposite directions, when the first directional motor 310 drives the horizontal gear shaft 308 to rotate, the two worm gears obtain the same speed but opposite directions of rotation, thereby driving the two vertical gear shafts 311 to rotate synchronously in opposite directions, and finally driving the two two-finger parallel pneumatic grippers 306 to achieve symmetrical and opposite rotational actions, and the auxiliary wire harness 6 is bent into a U shape more stably.

[0123] The above description is merely a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. An automatic crimping and shearing device for copper-aluminum composite terminals of high-voltage wiring harnesses for new energy vehicles, comprising an automatic wire stripping machine (1), a conveyor belt (2), a terminal socket assembly (4), and a terminal crimping assembly (5), characterized in that, The conveyor belt (2) and the new energy automatic wire stripping machine (1) are laid in a straight line, and the terminal socket assembly (4) and the terminal pressing assembly (5) are laid in a straight line and are arranged in parallel with the conveyor belt (2); A gantry-type three-axis robotic arm assembly (3) is provided in the area where the conveyor belt (2), terminal socket assembly (4), and terminal pressing assembly (5) are located. The gantry-type three-axis robotic arm assembly (3) is used to clamp and transfer the terminal pressing assembly (5) on the conveyor belt (2), so as to realize the displacement of the terminal pressing assembly (5) in the three work positions of the conveyor belt (2), terminal socket assembly (4), and terminal pressing assembly (5). The conveyor belt (2) protrudes from both ends into the working area of ​​the gantry-type three-axis robotic arm assembly (3) to receive wire harnesses (6) from the new energy automatic wire stripper (1) and to transport wire harnesses (6) with pressed terminals (7) to the next process.

2. The automatic pressing and shearing equipment for copper-aluminum composite terminals of a high-voltage wiring harness of a new energy vehicle according to claim 1, characterized in that, The gantry-type three-axis robotic arm assembly (3) includes a gantry-type three-axis slide (301), a connecting seat (304), a rotating seat (305), a two-finger parallel gripper (306), a worm gear transmission (307), a horizontal gear shaft (308), a side plate (309), a first directional motor (310), and a vertical gear shaft (311). Two sets of transverse moving seats (302) are symmetrically installed on the transverse arm of the gantry-type three-axis slide table (301). The connecting seat (304) is installed at the bottom of the vertical lifting toothed arm (303) on the transverse moving seat (302). The two-finger parallel pneumatic gripper (306) is rotatably installed on the connecting seat (304) through the rotating seat (305). The worm gearbox (307) is installed at the front end of the frame of the transverse moving seat (302). The horizontal gear shaft (308) passes horizontally through the worm in the two worm gearboxes (307) and is slidably connected to the worm. The side plates (309) are symmetrically fixed at both ends of the cross arm of the gantry three-axis slide table (301). The two ends of the horizontal gear shaft (308) are rotatably connected to the two side plates (309) respectively. The first directional motor (310) is mounted on the end face of a side plate (309) and the output end of the first directional motor (310) is connected to the horizontal gear shaft (308); The vertical gear shaft (311) vertically penetrates the worm gear in the worm gearbox (307) and is rotatably connected to the worm gear. The bottom of the vertical gear shaft (311) is connected to the top of the housing of the two-finger parallel pneumatic gripper (306).

3. The automatic pressing and shearing equipment for copper-aluminum composite terminals of a high-voltage wiring harness of a new energy vehicle according to claim 1, characterized in that, The terminal socket assembly (4) includes a first workstation (401), a vertical guide frame (402), a first cylinder (403), a horizontal plate (404), and a pusher head (405). The vertical guide rack (402) is provided in two sets. The two sets of vertical guide racks (402) are symmetrically installed on the top of the first workstation (401). The terminals (7) are arranged vertically and placed inside the vertical guide rack (402). The inner space of the vertical guide rack (402) matches the shape of the terminals (7). The bottom front end of the vertical guide rack (402) has a notch for the terminals (7) to be moved out. The first cylinder (403) is installed on the top of the first workstation (401) and distributed in the middle of the two sets of vertical guide frames (402). The output end of the first cylinder (403) extends backward and connects to the horizontal plate (404). The horizontal plate (404) is distributed at the rear end of two sets of vertical guide frames (402), and the push head (405) is symmetrically fixed at the front end of the horizontal plate (404), and the two push heads (405) are respectively aligned with the notches of the vertical guide frames (402).

4. The automatic pressing and shearing equipment for copper-aluminum composite terminals of a high-voltage wiring harness of a new energy vehicle according to claim 1, characterized in that, The terminal pressing assembly (5) includes a second workbench (501), a servo-type terminal pressing machine (502), a hexagonal pressing mold (503), a support shaft seat (504), a rotating cylinder (505), a C-shaped guide bar (506), a semi-conical pressing block (508), a positioning pressing groove (509), and a C-shaped guide groove (510). The servo terminal crimping machine (502) is provided in two sets, and the two sets of servo terminal crimping machines (502) are symmetrically installed on the top of the second workbench (501). The hexagonal crimping mold (503) is installed on the output end of the servo terminal crimping machine (502). The support shaft seat (504) is installed inside the frame of the servo terminal crimping machine (502) and distributed behind the hexagonal crimping mold (503). The rotating cylinder (505) is rotatably installed inside the support shaft seat (504) and extends towards the front end close to the servo terminal crimping machine (502). The inner cavity of the rotating cylinder (505) has a conical structure, and the inner diameter decreases from back to front. The C-shaped guide bar (506) is symmetrically fixed to the conical inner wall side of the rotating cylinder (505). Two semi-conical pressure blocks (508) are symmetrically arranged. The positioning pressure groove (509) is formed on the side of the two semi-conical pressure blocks (508) that are close to each other. The C-shaped guide groove (510) is opened on the outer side of the semi-conical pressure blocks (508) that are far apart from each other. The two semi-conical pressure blocks (508) are slidably installed on the inner side of the rotating cylinder (505) through the C-shaped guide groove (510) and the C-shaped guide strip (506). When the terminal (7) passes through the hexagonal crimping mold (503), the end of the terminal (7) is inserted into the inner side of the rotating cylinder (505). The two semi-conical pressing blocks (508) move forward along the inner wall of the rotating cylinder (505) and approach each other, and are pressed against the outer side of the end of the terminal (7) by the positioning pressing groove (509) to achieve the directional positioning of the terminal (7).

5. The automatic pressing and shearing equipment for copper-aluminum composite terminals of a high-voltage wiring harness of a new energy vehicle according to claim 4, characterized in that, The terminal press-fit assembly (5) also includes a T-shaped annular groove (511), a mating round seat (512), a connecting rod (513), a connecting plate (514), and a second cylinder (515); The T-shaped annular groove (511) is opened on one side of the two semi-conical pressure blocks (508) that are close to each other and passes through the rear end of the semi-conical pressure block (508). The T-shaped annular groove (511) is distributed at the rear end of the positioning pressure groove (509). The docking round seat (512) and the connecting rod (513) are connected and fixed in sequence along the axial direction. The two semi-conical pressure blocks (508) are sleeved on the outside of the docking round seat (512) through the T-shaped annular groove (511). The connecting rod (513) extends backward to the rear end of the servo terminal crimping machine (502), and the rear ends of the two connecting rods (513) are connected and fixed to the connecting plate (514). The second cylinder (515) is mounted on the bottom of the second workbench (501) by a bracket and is located between two sets of servo terminal crimping machines (502). The output axis of the second cylinder (515) extends rearward and is connected and fixed to the connecting plate (514).

6. The automatic pressing and shearing equipment for copper-aluminum composite terminals of a high-voltage wiring harness of a new energy vehicle according to claim 4, characterized in that, The terminal press assembly (5) also includes a second directional motor (516) and a drive gear (517). An external gear (507) is formed on the outer side of the portion of the rotating cylinder (505) that protrudes from the rear end of the support shaft seat (504). The second directional motor (516) is mounted behind the support shaft seat (504), and the drive gear (517) is connected to the output shaft of the second directional motor (516), and the drive gear (517) meshes with the external gear (507); The second directional motor (516) drives the rotating cylinder (505) and the semi-conical pressure block (508) to rotate as a whole, thereby driving the terminal (7) to rotate, thus realizing the orientation adjustment of the terminal (7).

7. The automatic pressing and shearing equipment for copper-aluminum composite terminals of a high-voltage wiring harness of a new energy vehicle according to claim 2, characterized in that, The maximum spacing between the two sets of transverse moving seats (302) is greater than the longest processing length of the wire harness (6); The terminal socket assembly (4) and the terminal press assembly (5) are located on the inner side of the movable area of ​​the gantry three-axis robotic arm assembly (3); The front area of ​​the terminal socket assembly (4) and the terminal press assembly (5) is provided with a platform to support the tail of the wire harness (6) bent into a "U" shape.

8. The automatic crimping and shearing equipment for copper-aluminum composite terminals of high-voltage wiring harnesses for new energy vehicles according to claim 5, characterized in that, The inner diameter of the T-shaped annular groove (511) matches the outer diameter of the mating round seat (512), and the outer diameter of the mating round seat (512) is greater than the maximum distance between the two semi-conical pressure blocks (508).

9. An automatic crimping and shearing device for copper-aluminum composite terminals of high-voltage wiring harnesses for new energy vehicles according to claim 2, characterized in that, The helical directions on the two worms in the two worm gearboxes (307) are opposite.

Images