A power copper-aluminum wiring terminal punching device

Abstract

The present application relates to the technical field of power hardware precision manufacturing, in particular to a power copper-aluminum wiring terminal punching device, which comprises a control console, the top of the control console is fixedly connected with a vertical frame, the vertical frame is provided with a punching execution unit, a bidirectional clamping unit and a segmented wedge-shaped synchronous linkage force increasing unit for driving the bidirectional clamping unit to act; the punching execution unit comprises a lifting guide rail fixedly connected with the vertical frame and a driving sliding table slidingly connected with the lifting guide rail. Through the cooperation of the segmented wedge-shaped synchronous linkage force increasing structure and the disc spring energy storage structure, the present application realizes the real-time proportional synchronous increase of the clamping force and the punching force, the greater the punching force is, the higher the synchronous clamping protection force of the welding interface is, which can effectively offset the reverse impact bending moment and high-frequency vibration generated in the punching process, reduce the problems of micro-cracks and welding separation of the welding interface, and greatly improve the product network detection pass rate.

Description

Technical Field

[0001] This invention relates to the field of precision manufacturing technology for power fittings, specifically a punching device for copper and aluminum terminals in power systems. Background Technology

[0002] DTL series copper-aluminum terminals are core safety components in power transmission and distribution networks. Their base is based on an advanced non-ferrous metal material system, achieving a metallurgical bond between the aluminum terminal block and the copper conductive flat head through flash welding and friction welding processes. The electrical contact area of ​​high-end grid-connected products utilizes new precious metal materials for electrical contact manufacturing to create a functional plating layer, enhancing long-term conductivity and corrosion resistance. The copper conductive flat head requires punching for bolted connection to electrical equipment. With the State Grid Corporation of China continuously raising its requirements for the quality of power fittings for grid connection, the structural integrity of the copper-aluminum weld interface, punching precision, and non-destructive processing of the precious metal electrical contact layer are all veto items in grid connection testing, directly determining the operational safety and long-term service life of the power system.

[0003] The core structural characteristic of copper-aluminum terminals is the metallurgical bonding of dissimilar metals: copper and aluminum have significant differences in physical properties and crystal structure. The copper-aluminum interface after welding is a brittle intermetallic compound layer, which has extremely poor resistance to impact loads, high-frequency vibrations, and shear deformation. Even micro-cracks at the interface, which are at the micrometer level, will rapidly expand due to contact heating and electro-corrosion during long-term energized operation, eventually leading to interface detachment, breakage of the conductive circuit, and causing major electrical safety accidents such as power outages and fires. Therefore, the protection of the copper-aluminum welding interface during the punching process is a core quality control point in the entire terminal manufacturing process.

[0004] Currently, the mainstream industry practice for punching copper-aluminum terminals uses general-purpose hydraulic punching machines and busbar processing machines. During the punching process, the instantaneous impact load and high-frequency vibrations from shearing fracture are directly transmitted to the copper-aluminum welding interface through the entire copper substrate, which is the core cause of both latent and overt damage to the welding interface. Existing solutions to address this issue often involve adding clamping structures for the copper-aluminum welding interface to pre-position and pre-clamp the terminals before punching, reducing terminal displacement and improving punching positioning accuracy. However, the clamping force in these solutions is usually a fixed value preset before punching, which cannot be synchronized with the real-time dynamic increase in punching force during the punching process. This fails to offset the peak impact load at the moment of punching fracture and cannot fundamentally suppress the impact damage to the brittle welding interface caused by punching, making it difficult to meet the comprehensive quality control requirements of high-end grid-connected power fittings. Summary of the Invention

[0005] The purpose of this invention is to provide a punching device for copper and aluminum electrical terminals to solve the problems mentioned in the background art.

[0006] The objective of this invention can be achieved through the following technical solutions: A punching device for copper and aluminum terminals for power supply, preferably, includes a control console, a vertical frame fixedly connected to the top of the control console, and a punching execution unit, a bidirectional clamping unit, and a segmented wedge-shaped synchronous linkage force amplification unit for driving the bidirectional clamping unit. The punching execution unit includes a lifting guide rail fixedly connected to the vertical frame, a drive slide table slidably connected to the lifting guide rail, a hydraulic rod fixedly connected to the top of the vertical frame, a punching punch fixedly connected to the bottom of the drive slide table, and a lower die table fixedly connected to the vertical frame and corresponding to the punching punch. The output end of the hydraulic rod is fixedly connected to the drive slide table, and a waste discharge hole adapted to the punching punch is provided on the lower die table. The bidirectional clamping unit includes an upper clamping plate and a lower clamping plate arranged opposite each other for clamping the welding interface of copper-aluminum terminals. The segmented wedge-shaped synchronous linkage force-increasing unit includes active wedges symmetrically fixed on both sides of the drive slide. The active wedges move down synchronously with the drive slide and drive the upper clamping plate and the lower clamping plate to move closer to each other to clamp the welding interface of the copper-aluminum terminal block through a mechanical linkage structure. The clamping force increases proportionally with the downward punching depth of the punching punch to suppress the damage of the punching impact to the welding interface of the copper-aluminum terminal block.

[0007] Preferably, the active wedge is provided with a large-angle closed stroke section and a small-angle force-increasing stroke section in sequence along the downward direction of the drive slide.

[0008] Preferably, the segmented wedge-shaped synchronous linkage force-enhancing unit further includes a U-shaped mounting bracket fixed on the vertical frame. The U-shaped mounting bracket is arranged at the bottom of the drive slide table along the downward direction of the drive slide table. Guide slide rods are symmetrically fixedly connected to both the upper and lower ends of the U-shaped mounting bracket. Follower brackets are slidably connected to the guide slide rods. The follower brackets and the active wedge are driven and cooperated through a transmission component. A return spring is fitted around the outer periphery of the guide slide rod, and the return spring is installed between the follower frame and the end of the guide slide rod.

[0009] Preferably, a transmission frame is fixedly connected to the top of the follower frame, and the transmission component includes a second transmission wheel rotatably connected to the top of the transmission frame. The second transmission wheel rolls against the inclined surface of the active wedge, and the active wedge pushes the follower frame to move away from the U-shaped mounting frame along the guide slide bar.

[0010] Preferably, the follower frame is symmetrically fixedly connected to a transmission guide rail on each opposite side, the U-shaped mounting frame is symmetrically fixedly connected to a clamping guide rail, a clamping slider is symmetrically slidably connected to the clamping guide rail, and a first transmission wheel embedded inside the transmission guide rail is rotatably connected to the top of the clamping slider.

[0011] Preferably, the transmission guide rail is provided with a clamping inclined section and a stable horizontal section that are connected to each other. When the follower frame drives the transmission guide rail to move, it guides the first transmission wheel to drive the clamping slider to move synchronously in opposite directions along the clamping guide rail perpendicular to the stamping direction.

[0012] Preferably, T-shaped support slide rods are symmetrically fixedly connected to the opposite sides of the upper clamping plate and the lower clamping plate. The T-shaped support slide rods pass through the clamping sliders on the corresponding sides and slide with them. A first disc spring is sleeved on the outer periphery of the T-shaped support slide rods. The first disc spring is installed between the clamping sliders and the upper or lower clamping plates on the corresponding sides.

[0013] Preferably, the punching execution unit further includes a pre-compression sleeve coaxially sleeved around the outer periphery of the punching head, a pre-compression slide is slidably connected to one side of the drive slide, the pre-compression sleeve is fixedly connected to the bottom of the pre-compression slide, a pre-compression support slide is fixedly connected to the top of the pre-compression slide, the top end of the pre-compression support slide passes through the drive slide and slides with it, a second disc spring is sleeved around the outer periphery of the pre-compression support slide, and the second disc spring is installed between the pre-compression slide and the drive slide.

[0014] Preferably, the top of the control panel is also fixedly connected to a feeding slide, and a feeding table is slidably connected inside the feeding slide. The top of the feeding table is provided with a positioning groove that is compatible with the copper-aluminum terminal block, and the bottom of the feeding table is fixedly connected to a transmission rack.

[0015] Preferably, a waste discharge guide rail is provided below the lower mold platform, a waste collection box corresponding to the output end of the waste discharge guide rail is fixedly connected to the top of the control console, a waste discharge push rod is slidably connected inside the waste discharge guide rail, a transmission rack is fixedly connected to the bottom of the waste discharge push rod, and a transmission gear is rotatably connected to the control console. The transmission gear meshes with both transmission rack one and transmission rack two for transmission.

[0016] The beneficial effects of this invention are: 1. This invention achieves real-time proportional synchronous growth of clamping force and punching force through the combination of segmented wedge synchronous linkage force-increasing structure and disc spring energy storage structure. The greater the punching force, the greater the clamping and protection force on the welding interface, which can effectively offset the reverse impact bending moment and high-frequency vibration generated during punching, reduce the problems of micro-cracks and weld failure at the welding interface, and significantly improve the product's pass rate for network access inspection.

[0017] 2. This invention adopts a pure mechanical rigid synchronous transmission design with a single power source. Relying on the same stroke of the drive slide, it simultaneously realizes the time-series linkage of the entire process of punching, clamping, feeding and waste discharge. It does not require additional configuration of independent drive components, sensors and electronic control systems, and completely solves the problems of action delay, poor synchronization and high failure rate of independent drive in the prior art.

[0018] 3. The present invention achieves a synergistic balance between welding interface protection and punching quality control through the partitioned protection design of the bidirectional clamping unit and the coaxial pre-compression unit. The two have separate operating areas and completely synchronized action sequence, without interfering with each other and working together. This not only eliminates the dual risks of excessive clamping crushing the welding interface and insufficient clamping impact failure from a structural point of view, but also solves the contradiction that the existing solution cannot simultaneously achieve welding surface protection and punching quality improvement. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, for those skilled in the art, other drawings can be obtained based on these drawings without creative effort. Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a schematic diagram showing the installation positions of the vertical frame and the feeding slide in this invention; Figure 3 This is a top view of the vertical frame in this invention; Figure 4 yes Figure 3 A cross-sectional view along the AA direction; Figure 5 This is a schematic diagram of the overall structure of the vertical frame in this invention; Figure 6 This is an exploded view of the internal structure of the lifting guide rail in this invention; Figure 7 This is a schematic diagram of the overall structure of the follower frame in this invention; Figure 8 This is a schematic diagram of the overall structure of the U-shaped mounting bracket in this invention; Figure 9 This is an exploded view of the internal structure of the waste discharge guide rail in this invention; Figure 10 This is an exploded view of the internal structure of the feeding slide in this invention.

[0020] The reference numerals in the attached diagram are as follows: 1. Control console; 2. Vertical frame; 3. Drive slide; 4. Punching punch; 5. Lower die table; 6. Upper clamping plate; 7. Lower clamping plate; 8. Active wedge; 9. U-shaped mounting bracket; 10. Guide slide rod; 11. Follower frame; 12. Return spring; 13. Transmission frame; 14. Second transmission wheel; 15. Transmission guide rail; 16. Clamping guide rail; 17. Clamping slider; 18. ... 19. Transmission wheel; 20. T-shaped support slide bar; 21. First disc spring; 22. Preload sleeve; 23. Preload slide frame; 24. Preload support slide bar; 25. Second disc spring; 26. Feeding slide block; 27. Feeding slide table; 28. Transmission rack two; 29. ​​Waste discharge guide rail; 30. Waste discharge push rod; 31. Transmission rack one; 32. Transmission gear; 33. Lifting guide rail; 34. Hydraulic rod; 35. Waste collection box. Detailed Implementation

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

[0022] A punching device for copper-aluminum terminals for power systems belongs to the category of high-end precision machining equipment for power fittings under the intelligent manufacturing equipment industry. It is mainly used in the field of precision manufacturing of high-end grid-connected power fittings. The core supporting DTL series copper-aluminum terminals in this field are based on an advanced non-ferrous metal material system for their base structure. The electrical contact functional layer of high-end grid-connected products is formed by a new electrical contact precious metal material manufacturing technology. It is adapted to the core requirement of high-precision and non-destructive precision machining for these high-end fittings under the large-scale and standardized mass production mode of the power industry. This invention solves the core technical problems of traditional punching equipment by using a single power source with pure mechanical rigid synchronous transmission design, a linkage segmented wedge synchronous force amplification mechanism, a bidirectional clamping mechanism for the welding interface, a coaxial floating pre-pressure structure, and an integrated feeding and waste discharge linkage unit. These problems include misalignment of the driving sequence of multiple power sources, asynchronous clamping force and punching force, cracking of the brittle copper-aluminum welding interface caused by punching impact, damage to the workpiece due to improper clamping, scratching of the precious metal electrical contact functional layer due to punching deformation, and poor consistency in batch production. Through a pure mechanical rigid linkage throughout the entire process combined with adaptive compensation for incoming material tolerances, it achieves strong synchronization between punching and clamping actions, no impact damage to the copper-aluminum welding interface throughout the process, no scratching of the precious metal electrical contact functional layer, and stable and controllable batch production accuracy. This meets the core usage requirements of the high-end electrical connection field of smart grids and the intelligent manufacturing equipment industry for high-reliability production, precise control of finished product quality, optimized processing energy efficiency, and large-scale continuous production of power fittings processing equipment.

[0023] like Figures 1-10 As shown, it includes a control console 1, a vertical frame 2 fixedly connected to the top of the control console 1, and a punching execution unit, a bidirectional clamping unit, and a segmented wedge-shaped synchronous linkage force amplification unit for driving the bidirectional clamping unit. The punching execution unit includes a lifting guide rail 32 fixedly connected to the vertical frame 2, a drive slide 3 slidably connected to the lifting guide rail 32, a hydraulic rod 33 fixedly connected to the top of the vertical frame 2, a punching punch 4 fixedly connected to the bottom of the drive slide 3, and a lower die 5 fixedly connected to the vertical frame 2 and corresponding to the punching punch 4. The output end of the hydraulic rod 33 is fixedly connected to the drive slide 3, and the lower die 5 is provided with a waste discharge hole adapted to the punching punch 4. The bidirectional clamping unit includes an upper clamping plate 6 and a lower clamping plate 7, which are arranged opposite to each other and used to clamp the welding interface of copper-aluminum terminals. The segmented wedge-shaped synchronous linkage force-increasing unit includes active wedges 8 symmetrically fixed on both sides of the drive slide 3. The active wedges 8 move down synchronously with the drive slide 3 and drive the upper clamping plate 6 and the lower clamping plate 7 to move closer to each other to clamp the welding interface of the copper-aluminum terminal block through a mechanical linkage structure. The clamping force increases proportionally with the downward punching depth of the punching punch 4 to suppress the damage of the punching impact to the welding interface of the copper-aluminum terminal block. Among them, the active wedge 8 is provided with a large angle closed stroke section and a small angle force-increasing stroke section in sequence along the downward direction of the drive slide 3; Furthermore, the segmented wedge-shaped synchronous linkage force-enhancing unit also includes a U-shaped mounting bracket 9 fixed on the vertical frame 2. The U-shaped mounting bracket 9 is arranged at the bottom of the drive slide 3 along the downward direction of the drive slide 3. Guide slide rods 10 are symmetrically fixedly connected to both the upper and lower ends of the U-shaped mounting bracket 9. Follower frame 11 is slidably connected to the guide slide rod 10. Follower frame 11 and active wedge 8 are driven and cooperated through transmission components. A return spring 12 is sleeved on the outer periphery of the guide slide rod 10, and the return spring 12 is installed between the follower frame 11 and the end of the guide slide rod 10; Furthermore, a transmission frame 13 is fixedly connected to the top of the follower frame 11. The transmission component includes a second transmission wheel 14 rotatably connected to the top of the transmission frame 13. The second transmission wheel 14 rolls against the inclined surface of the active wedge 8. The active wedge 8 pushes the follower frame 11 to move away from the U-shaped mounting frame 9 along the guide slide rod 10. Furthermore, transmission guide rails 15 are symmetrically fixedly connected to opposite sides of the follower frame 11, clamping guide rails 16 are symmetrically fixedly connected inside the U-shaped mounting frame 9, clamping sliders 17 are symmetrically slidably connected on the clamping guide rails 16, and the top of the clamping sliders 17 is rotatably connected to the first transmission wheel 18 embedded inside the transmission guide rails 15. Furthermore, the transmission guide rail 15 is provided with a clamping inclined section and a stable horizontal section that are connected to each other. When the follower frame 11 drives the transmission guide rail 15 to move, it guides the first transmission wheel 18 to drive the clamping slider 17 to move synchronously in opposite directions along the clamping guide rail 16 perpendicular to the stamping direction. Furthermore, T-shaped support slide rods 19 are symmetrically fixedly connected to the opposite sides of the upper clamping plate 6 and the lower clamping plate 7. The T-shaped support slide rods 19 pass through the corresponding clamping sliders 17 and slide with them. A first disc spring 20 is sleeved on the outer periphery of the T-shaped support slide rods 19. The first disc spring 20 is installed between the clamping sliders 17 and the corresponding upper clamping plate 6 or lower clamping plate 7. Furthermore, the punching execution unit also includes a pre-compression sleeve 21 coaxially sleeved around the outer periphery of the punching punch 4, a pre-compression slide 22 slidably connected to one side of the drive slide 3, the pre-compression sleeve 21 fixedly connected to the bottom of the pre-compression slide 22, a pre-compression support slide 23 fixedly connected to the top of the pre-compression slide 22, the top end of the pre-compression support slide 23 passing through the drive slide 3 and slidingly engaging with it, a second disc spring 24 sleeved around the outer periphery of the pre-compression support slide 23, and the second disc spring 24 installed between the pre-compression slide 22 and the drive slide 3; Furthermore, a feeding slide 25 is fixedly connected to the top of the control panel 1, and a feeding slide 26 is slidably connected inside the feeding slide 25. The top of the feeding slide 26 is provided with a positioning groove that is compatible with the copper-aluminum terminal block, and a transmission rack 27 is fixedly connected to the bottom of the feeding slide 26. Furthermore, a waste discharge guide rail 28 is provided below the lower mold table 5, and a waste collection box 34 corresponding to the output end of the waste discharge guide rail 28 is fixedly connected to the top of the control console 1. A waste discharge push rod 29 is slidably connected inside the waste discharge guide rail 28, and a transmission rack 30 is fixedly connected to the bottom of the waste discharge push rod 29. A transmission gear 31 is rotatably connected to the control console 1, and the transmission gear 31 meshes with both the transmission rack 30 and the transmission rack 27.

[0024] In use, firstly, the DTL series power copper-aluminum terminals to be processed are manually inserted into the positioning groove on the top of the feeding slide 26, so that the aluminum terminal tube and the copper conductive flat head of the terminal are completely in line with the contour of the groove, thus completing the pre-positioning of the terminal. Then, manually push the loading slide 26 along the guide direction of the loading slide 25 to move towards the lower mold table 5 inside the vertical frame 2 until the copper flat head of the terminal to be punched completely covers the waste discharge hole of the lower mold table 5, and the copper-aluminum welding interface is aligned with the clamping area between the upper clamping plate 6 and the lower clamping plate 7 to complete the loading positioning. After the material is positioned, the hydraulic rod 33 is activated. The output end of the hydraulic rod 33 pushes the drive slide 3 to descend vertically along the guide direction of the lifting guide rail 32, and simultaneously drives the punching punch 4 and the active wedges 8 on both sides to move downward. At the same time, the inclined surface of the active wedge 8 first forms a rolling contact with the second transmission wheel 14 at the top of the transmission frame 13. As the active wedge 8 moves downward, the second transmission wheel 14 pushes the transmission frame 13 and the follower frame 11 to move horizontally away from the U-shaped mounting frame 9 along the guide slide rod 10, and simultaneously squeezes the return spring 12 on the outer periphery of the guide slide rod 10 to produce a contraction deformation. As the follower frame 11 moves horizontally, it drives the inner transmission guide rail 15 to move synchronously, causing the first transmission wheel 18 at the top of the clamping slider 17 to roll along the clamping inclined section inside the transmission guide rail 15. This, in turn, drives the upper and lower sets of clamping sliders 17 to move synchronously in opposite directions perpendicular to the stamping direction along the clamping guide rail 16. Through the T-shaped support slide rod 19, the upper clamping plate 6 and the lower clamping plate 7 are pushed to close synchronously towards the middle, completely fitting the upper and lower surfaces of the copper-aluminum terminal welding interface, thus completing the gapless pre-locking of the welding interface. At this time, the lower end face of the punch 4 is in contact with the upper surface of the copper flat head to be punched. The pre-press sleeve 21, which is sleeved on the outer periphery of the punch 4, has contacted the copper flat head before the punch, and completely flattens the warped copper flat head and fits it against the upper surface of the lower die table 5. Subsequently, the hydraulic rod 33 continues to push the drive slide 3 downward, and the punching punch 4 cuts into the copper flat head to perform the punching operation. The punching force continues to increase with the increase of the punching depth. During this process, the small-angle force-increasing stroke section of the active wedge 8 continues to roll and resist the second transmission wheel 14, pushing the follower frame 11 to move further horizontally along the guide slide 10, driving the transmission guide rail 15 to move synchronously, so that the first transmission wheel 18 continues to roll along the clamping inclined section, driving the clamping slider 17 to continue to move towards the welding interface. At this time, the upper clamping clamp Since plate 6 and lower clamping plate 7 are completely stuck to the welding interface and cannot move further, the clamping slider 17 slides along the T-shaped support slide rod 19, further compressing the first disc spring 20 sleeved on the outer periphery of the T-shaped support slide rod 19. This causes the compression of the first disc spring 20 to increase synchronously with the downward depth of the punching punch 4. Through the elastic force of the first disc spring 20, the clamping force of the upper clamping plate 6 and lower clamping plate 7 and the punching force of the punching punch 4 can increase synchronously and proportionally in real time, thereby reducing the bending moment damage to the welding interface caused by the punching impact from the root. After the punch 4 completely penetrates the copper flat head, the copper shavings generated by punching fall into the waste discharge guide rail 28 below through the waste discharge hole of the lower die table 5. At this time, the hydraulic rod 33 is activated in reverse, which drives the drive slide table 3 and the punch 4 to move vertically upward to reset. The active wedge 8 moves upward synchronously, and the reset spring 12 releases its elastic potential energy, pushing the follower frame 11 to move in the opposite direction along the guide slide 10 to reset. Through the transmission guide rail 15, the clamping slider 17 moves in the opposite direction, so that the upper clamping plate 6 and the lower clamping plate 7 open synchronously, releasing the clamping of the welding interface. At the same time, the second disc spring 24 releases its elastic potential energy, pushing the pre-pressure sleeve 21 to continue to press against the copper flat head until the punch 4 completely disengages from the copper flat head. After the punching head is fully reset, the manual puller pulls the feeding slide 26 back to the initial feeding position along the feeding slide 25. At the same time as the feeding slide 26 retracts, the transmission rack 27 at the bottom drives the transmission gear 31 to rotate. Through the synchronous meshing of the transmission gear 31 and the transmission rack 30, the waste discharge push rod 29 moves along the waste discharge guide rail 28, pushing the punching waste that falls into the guide rail to the output end and into the waste collection box 34 to complete the automatic waste discharge. Finally, the manual removes the processed copper and aluminum terminals from the positioning groove to complete a single complete punching processing cycle.

[0025] The working principle of the punching device for copper-aluminum terminals in power systems provided by this invention is as follows: First, the copper-aluminum terminals are manually inserted into the positioning groove on the top of the feeding slide 26. Utilizing the self-centering characteristics of the V-shaped contour groove, the aluminum terminal, copper-aluminum welding interface, and copper conductive flat head of the terminal are made to fit the groove contour completely, so that the entire section can be positioned in a single feeding, avoiding the problems of hole misalignment and welding interface clamping misalignment caused by manual placement. After the hydraulic rod 33 is started, its output end directly drives the drive slide 3 to move vertically downward along the lifting guide rail 32. The bottom center of the drive slide 3 is coaxially fixed with the punching punch 4 and the active wedge 8 is symmetrically fixed on the left and right sides. Relying on the rigid synchronous transmission principle of a single power source and dual action, the drive slide 3 moves downward. The punching punch 4 and the active wedge 8 move downward synchronously. The strokes of the punching action and the clamping action are completely rigidly bound together. During the downward movement of the active wedge 8, the two inclined surfaces of its working surface with different inclination angles achieve two independent functional actions based on the segmented wedge inclined surface stroke-force decoupling transmission principle: In the early stage of downward movement, the large inclined angle closed stroke segment of the active wedge 8 first contacts the second transmission wheel 14, pushing the follower frame 11 to move horizontally, quickly converting the vertical downward motion into a large stroke horizontal motion, driving the clamping plate to quickly complete the closing pre-locking; in the later stage of downward movement, the small inclined angle force-increasing stroke segment of the active wedge 8 contacts the second transmission wheel 14, converting the vertical displacement into a linearly increasing large clamping force; When the follower frame 11 moves horizontally, it drives the inner transmission guide rail 15 to move synchronously. The first transmission wheel 18 rolls along the groove inside the transmission guide rail 15. Relying on the dual-stage action decoupling principle of the transmission guide rail, the clamping action and the force-increasing action are precisely separated: When the first transmission wheel 18 rolls in the clamping inclined section, it converts the horizontal movement of the follower frame 11 into the vertical opposite movement of the clamping slider 17. Through the T-shaped support slide rod 19, it pushes the upper clamping plate 6 and the lower clamping plate 7 to close synchronously until they are completely close to the copper-aluminum welding interface, completing the gapless pre-locking. After the first transmission wheel 18 enters the stable horizontal section, the follower frame 11 continues to move horizontally. The first transmission wheel 18 only rolls in the horizontal section and will not drive the clamping slider 17 to produce vertical displacement. Structurally, the vertical position of the upper clamping plate 6 and the lower clamping plate 7 completely avoids the risk of the upper clamping plate 6 and the lower clamping plate 7 continuing to move and crushing the brittle welding interface. After the clamping plates are pre-locked, the drive slide 3 continues to descend to perform the punching operation. At this time, relying on the principle of synchronous force amplification through the elastic energy storage of the disc springs, the clamping force and the punching force increase proportionally in real time. The upper clamping plates 6 and the lower clamping plates 7 are completely stuck to the copper-aluminum welding interface and cannot continue to generate vertical displacement. The clamping slider 17 can only slide along the T-shaped support slide 19 as the transmission guide rail 15 continues to move, further compressing the first disc spring 20 sleeved on the outer periphery of the T-shaped support slide 19. The first disc spring 20 adopts a mating combination structure. Its compression and output elastic force are in the linear flat section of the load-deformation curve. The compression and clamping force increase synchronously. The compression of the first disc spring 20 is completely determined by the descending depth of the active wedge 8, which is completely synchronized with the punching depth of the punching punch 4. It offsets the reverse impact bending moment generated during the punching process in real time, and fundamentally suppresses the industry problem of micro-cracks and weld failure in the brittle copper-aluminum welding interface.

[0026] During the punching operation, when the drive slide 3 moves downward, the pre-pressure sleeve 21 contacts the upper surface of the copper flat head before the punching punch 4, completely flattening the warped copper flat head and making it tightly fit the upper surface of the lower die table 5. As the drive slide 3 continues to move downward, the pre-pressure sleeve 21 and the pre-pressure slide 22 are fixed in position, and the drive slide 3 slides along the pre-pressure support slide 23, compressing the second disc spring 24. The elastic force of the second disc spring 24 continues to act on the pre-pressure sleeve 21, ensuring that the copper flat head is always stably pressed throughout the punching process, preventing workpiece bounce, hole misalignment, and burrs at the hole opening. After punching is completed, the drive slide 3 moves upward, and the second disc spring 24 releases its elastic potential energy, pushing the pre-pressure sleeve 21 to continue pressing against the copper flat head until the punching punch 4 is completely detached from the copper flat head, avoiding workpiece deformation and hole wall damage caused by the punch carrying material. In the feeding and waste removal process, when the feeding slide 26 moves towards the punching area, the transmission rack 27 at its bottom drives the transmission gear 31 to rotate clockwise. The transmission gear 31 simultaneously drives the transmission rack 30 to move to the right, causing the waste removal push rod 29 to retract to the lower right side of the waste removal hole, completely clearing the waste removal channel. The waste generated by punching can fall smoothly into the waste removal guide rail 28. After punching is completed, when the feeding slide 26 retracts to the initial position, the transmission rack 27 drives the transmission gear 31 to rotate counterclockwise, simultaneously driving the transmission rack 30 to move to the left. The waste removal push rod 29 moves to the left along the waste removal guide rail 28, directly pushing the waste that falls into the guide rail to the output end, where it falls into the waste collection box 34 to complete the automatic waste removal. During the downward movement of the drive slide 3, when the follower frame 11 moves horizontally along the guide slide rod 10, it synchronously compresses the return spring 12 to accumulate elastic potential energy. During the return stroke, the active wedge 8 moves upward, and the return spring 12 releases its elastic potential energy, continuously pushing the follower frame 11 to move in the opposite direction, so that the second transmission wheel 14 is always in close contact with the inclined surface of the active wedge 8. At the same time, when the follower frame 11 moves in the opposite direction, it drives the clamping slider 17 to move in the opposite direction through the transmission guide rail 15, so that the upper clamping plate 6 and the lower clamping plate 7 open synchronously, automatically releasing the welding interface, and all components return to the initial position, preparing for the next processing cycle.

[0027] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claimed invention.

Claims

1. A punching device for copper-aluminum terminals in power systems, characterized in that: Includes a control console (1), with a vertical frame (2) fixedly connected to the top of the control console (1), and a punching execution unit, a bidirectional clamping unit and a segmented wedge synchronous linkage force amplification unit installed on the vertical frame (2); The punching execution unit includes a lifting guide rail (32) fixedly connected to the vertical frame (2), a drive slide (3) slidably connected to the lifting guide rail (32), a hydraulic rod (33) fixedly connected to the top of the vertical frame (2), a punching punch (4) fixedly connected to the bottom of the drive slide (3), and a lower die table (5) fixedly connected to the vertical frame (2) and corresponding to the punching punch (4). The output end of the hydraulic rod (33) is fixedly connected to the drive slide (3), and the lower die table (5) is provided with a waste discharge hole adapted to the punching punch (4). The bidirectional clamping unit includes an upper clamping plate (6) and a lower clamping plate (7) arranged opposite to each other for clamping the welding interface of copper-aluminum terminals. The segmented wedge synchronous linkage force-enhancing unit includes active wedges (8) symmetrically fixed on both sides of the drive slide (3). The active wedges (8) move down synchronously with the drive slide (3) and drive the upper clamping plate (6) and the lower clamping plate (7) to approach each other and clamp the welding interface of the copper-aluminum terminals through the mechanical linkage structure.

2. The punching device for copper-aluminum terminals for power applications according to claim 1, characterized in that: The active wedge (8) is provided with a large angle closed stroke section and a small angle force-increasing stroke section in sequence along the downward direction of the drive slide (3).

3. The punching device for copper-aluminum terminals for power applications according to claim 2, characterized in that: The segmented wedge-shaped synchronous linkage force-enhancing unit also includes a U-shaped mounting bracket (9) fixed on the vertical frame (2). The U-shaped mounting bracket (9) is arranged at the bottom of the drive slide (3) along the downward direction of the drive slide (3). The upper and lower ends of the U-shaped mounting bracket (9) are symmetrically fixedly connected with guide slide rods (10). A follower frame (11) is slidably connected on the guide slide rod (10). The follower frame (11) and the active wedge (8) are driven and cooperated through the transmission component. A return spring (12) is sleeved on the outer periphery of the guide slide (10), and the return spring (12) is installed between the follower frame (11) and the end of the guide slide (10).

4. The punching device for copper-aluminum terminals for power transmission according to claim 3, characterized in that: The top of the follower frame (11) is fixedly connected to the transmission frame (13). The transmission component includes a second transmission wheel (14) rotatably connected to the top of the transmission frame (13). The second transmission wheel (14) rolls against the inclined surface of the active wedge (8). The active wedge (8) pushes the follower frame (11) to move away from the U-shaped mounting frame (9) along the guide slide (10) by moving downward.

5. The punching device for copper-aluminum terminals for power transmission according to claim 4, characterized in that: The follower frame (11) is symmetrically fixedly connected to a transmission guide rail (15) on one side. The U-shaped mounting frame (9) is symmetrically fixedly connected to a clamping guide rail (16). A clamping slider (17) is symmetrically slidably connected on the clamping guide rail (16). The top of the clamping slider (17) is rotatably connected to a first transmission wheel (18) embedded inside the transmission guide rail (15).

6. The punching device for copper-aluminum terminals for power applications according to claim 5, characterized in that: The transmission guide rail (15) is provided with a clamping inclined section and a stable horizontal section that are connected to each other. When the follower frame (11) drives the transmission guide rail (15) to move, it guides the first transmission wheel (18) to drive the clamping slider (17) to move synchronously in opposite directions along the clamping guide rail (16) perpendicular to the stamping direction.

7. The punching device for copper-aluminum terminals for power applications according to claim 6, characterized in that: The upper clamping plate (6) and the lower clamping plate (7) are symmetrically fixed with T-shaped support slide rods (19) on opposite sides. The T-shaped support slide rods (19) pass through the clamping sliders (17) on the corresponding side and slide with them. The outer periphery of the T-shaped support slide rods (19) is fitted with a first disc spring (20). The first disc spring (20) is installed between the clamping sliders (17) and the upper clamping plate (6) or the lower clamping plate (7) on the corresponding side.

8. The punching device for copper-aluminum terminals for power applications according to claim 1, characterized in that: The punching execution unit also includes a pre-pressure sleeve (21) coaxially sleeved on the outer periphery of the punching punch (4), a pre-pressure slide (22) slidably connected to one side of the drive slide (3), the pre-pressure sleeve (21) is fixedly connected to the bottom of the pre-pressure slide (22), a pre-pressure support slide (23) is fixedly connected to the top of the pre-pressure slide (22), the top end of the pre-pressure support slide (23) passes through the drive slide (3) and slides with it, a second disc spring (24) is sleeved on the outer periphery of the pre-pressure support slide (23), and the second disc spring (24) is installed between the pre-pressure slide (22) and the drive slide (3).

9. The punching device for copper-aluminum terminals for power applications according to claim 1, characterized in that: The top of the control panel (1) is also fixedly connected to a feeding slide (25), and a feeding slide (26) is slidably connected inside the feeding slide (25). The top of the feeding slide (26) is provided with a positioning groove that is compatible with copper and aluminum terminals, and the bottom of the feeding slide (26) is fixedly connected to a transmission rack (27).

10. The punching device for copper-aluminum terminals for power applications according to claim 9, characterized in that: The lower mold platform (5) is provided with a waste discharge guide rail (28). The top of the control console (1) is fixedly connected to a waste collection box (34) corresponding to the output end of the waste discharge guide rail (28). The waste discharge guide rail (28) is slidably connected to a waste discharge push rod (29). The bottom of the waste discharge push rod (29) is fixedly connected to a transmission rack (30). The control console (1) is rotatably connected to a transmission gear (31). The transmission gear (31) meshes with both the transmission rack (30) and the transmission rack (27).

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