A new energy cell pole multi-station cold heading fixed-length cutting material forming system and method

Abstract

The present application relates to the technical field of metal stamping, and provides a new energy cell pole post multi-station cold heading fixed-length cutting forming system, which comprises a feeding and cutting mechanism, a clamping and transferring mechanism, a multi-station cold heading forming mechanism, a station die assembly and a surplus feedback control unit. The feeding and cutting mechanism is used for feeding, straightening, fixed-length feeding and cutting of a conductive metal wire rod to form a material section. The clamping and transferring mechanism sequentially transfers the material section according to a preset station spacing. The multi-station cold heading forming mechanism is used for gradually completing preforming and storing of the material section, storage compression forming, main body constraint forming and negative tolerance edge sealing shaping, and cutting off the pole post workpiece and separating waste at a cutting and separating waste station. The surplus feedback control unit collects edge sealing load and / or cutting load, identifies the matching state of the volume of the material section, the storage surplus, the main body forming surplus, the edge sealing surplus and the cutting surplus, and corrects the cutting length of the subsequent material section.

Description

Technical Field

[0001] This invention relates to the field of metal stamping technology, and in particular to a multi-station cold heading fixed-length cutting forming system and method for new energy battery cell terminals. Background Technology

[0002] In the mass production of new energy battery cell terminals, copper terminals, aluminum terminals, and copper-aluminum composite terminals need to balance conductivity, dimensional consistency, surface quality, and production efficiency. For battery cell terminals with a center rod structure, especially racetrack-shaped center rod terminals, the cross-section is not a regular body of revolution. The metal flow resistance during cold heading differs in the arc end area, straight edge area, and transition angle area. If ordinary fixed-length cutting, multi-station cold heading, or single-cavity extrusion methods are still used for processing, problems such as insufficient filling in the arc end area, bulging flash in the straight edge area, folding lines in the transition angle area, burrs on the parting surface, uneven loading of the punch, and cracking of the die are likely to occur, affecting the dimensional stability of the terminal and the reliability of subsequent battery cell assembly.

[0003] For example, Chinese patent CN115301879A discloses a cold heading forming mold for new energy vehicle battery terminals. It utilizes a moving frame, mold block, ejector pin, and material placement plate to achieve cold heading, demolding, and material handling of multiple terminals, thus improving terminal processing efficiency. However, this solution primarily focuses on the material handling and demolding structure of the cold heading mold, without addressing the differentiated flow resistance structures for the arc-shaped terminal terminals' arc-shaped end areas, straight-edge areas, and transition angle areas. Another example is Chinese patent CN115608976B, which discloses an automotive battery electrode terminal forming device. This device includes a forming component, a demolding component, a receiving component, a dividing component, and a grinding device, designed to improve the low efficiency of electrode terminal forming, dividing, and finishing. While this solution can mechanize and integrate the forming, receiving, dividing, and polishing processes, it primarily focuses on the removal, dividing, and trimming after forming. It doesn't address the coordinated matching of material volume, angular orientation, zoned metal flow resistance, and mold cavity prestress during multi-station cold heading. This makes it difficult to solve problems such as underfilling of the end area, straight edge flash, corner folds, and mold overload that occur during the forming of the racetrack-shaped center rod pole. Furthermore, Chinese patent CN210956834U discloses a novel composite pole for lithium battery top covers. It reveals that the extreme ends and the base are formed by the engagement of rivet-oriented posts and rivet holes to create the composite pole, and explains that the joining process can include stamping or cold heading. The pole shape can be circular, polygonal, or irregular. This solution mainly addresses the connection strength and conductivity of the composite pole, but doesn't specifically disclose measures such as zoned flow guidance, end area replenishment, negative tolerance interference scraping, and scraping load feedback adjustment of the cutting length during the cold heading process of the racetrack-shaped center rod pole.

[0004] In addition, the following defects still exist in the existing technology: most pole cold heading solutions mainly focus on cold heading efficiency, demolding and material handling, or process integration, without establishing a zoned flow resistance matching structure that combines end area material replenishment, straight edge flow restriction, and corner damping for racetrack-shaped poles; existing fixed-length cutting is mostly aimed at fixed tangent length or material utilization rate, without being related to end area material replenishment reserves, negative tolerance scraping allowance, and scraping load feedback; existing clamping and transfer mechanisms are usually only used for equidistant handling, making it difficult to maintain the angular reference of the racetrack-shaped non-rotation section; existing prestressed combined dies are mostly used to improve crack resistance strength, without further participating in the flow resistance adjustment of the arc end area, straight edge area, and transition corner area; existing negative tolerance scraping, synchronous oil mist lubrication, and wear-resistant coatings are mostly used as separate measures for removing excess material, reducing friction, or extending service life, making it difficult to simultaneously suppress burrs, fold lines, sticking to the die, and tearing during plastic flow.

[0005] This invention addresses common problems in the field, such as uneven filling of the racetrack-shaped pole post, disconnect between fixed-length cutting and forming allowance, lack of angular transfer reference, bulging and flashing in the straight edge area, insufficient material replenishment in the arc end area, folding in the transition corner area, difficulty in participating in flow resistance adjustment of the prestressed mold, lack of feedback correction for scraping and sealing, and instability of the lubricating film in the high-pressure forming area. Summary of the Invention

[0006] The purpose of this invention is to address the shortcomings of current methods by proposing a multi-station cold heading fixed-length cutting and forming system and method for new energy battery cell terminals.

[0007] To overcome the shortcomings of existing technologies, the present invention adopts the following technical solution: a multi-station cold heading and fixed-length cutting forming system for new energy battery cell terminals, comprising a feeding and cutting mechanism, a clamping and conveying mechanism, a multi-station cold heading forming mechanism, station mold assemblies, and a margin feedback control unit; the feeding and cutting mechanism is used to feed, straighten, feed and cut conductive metal wires to form material segments to be cold-headed, and the feeding and cutting mechanism determines the cutting length of subsequent material segments according to the target terminal volume, a preset forming margin, and the cutting correction amount output by the margin feedback control unit; the clamping and conveying mechanism is used to clamp the material segments and sequentially convey the material segments to each station in the multi-station cold heading forming mechanism according to a preset spacing between adjacent stations; the multi-station cold heading forming mechanism includes multiple cold heading forming stations arranged sequentially along the material segment conveying direction and a cutting and scrap separation station located after the multiple cold heading forming stations, the multiple cold heading forming stations being used to make the material segments... During the secondary transfer process, pre-forming storage, material replenishment and compression, main body constraint forming, and negative tolerance edge sealing shaping are gradually completed. The cutting and scrap separation station is used to cut off the pole post workpiece after it has been gradually compressed and formed by multiple cold heading forming stations, and to separate the pole post workpiece from the scrap. The station mold assembly includes multiple station molds corresponding to the multiple cold heading forming stations. The multiple station molds have at least a material storage and forming structure, a material storage and compression structure, a main body constraint structure, and a negative tolerance edge sealing structure. The allowance feedback control unit is connected to the negative tolerance edge sealing structure, the cutting and scrap separation station, and the material feeding and cutting mechanism for control. It is used to collect the edge sealing load during the negative tolerance edge sealing shaping process and / or the cutting load during the cutting and scrap separation process, and to identify the matching state between the material segment volume, the available metal allowance of the pre-forming storage section, the main body forming allowance, the negative tolerance edge sealing allowance, and the cutting allowance based on the edge sealing load and / or the cutting load, thereby correcting the cutting length of the subsequent material segment.

[0008] The beneficial effects achieved by this invention are:

[0009] 1. Through the cooperation of the main constraint structure and the negative tolerance edge sealing structure, after the material segment completes the main contour constraint, it can use the negative tolerance scraping edge to perform interference scraping, extrusion, flattening or sealing of the excess material on the outer periphery, ensuring that the whole system has the advantage of directly sealing the flash generation channel during the forming process.

[0010] 2. Through the cooperation of the material storage forming structure and the material storage compression structure, the metal of the material segment itself can first form a pre-formed material storage part in a predetermined area, and then the pre-formed material storage part is transformed into a usable metal distribution of the main body constraint forming through subsequent material storage compression forming, ensuring that the whole system has the advantages of staged adjustment of metal flow and improvement of local filling.

[0011] 3. Through the cooperation of the clamping and transfer mechanism and the station mold assembly, the material segment can sequentially pass through the pre-forming storage, storage compression forming, main body constraint forming, negative tolerance edge sealing and shaping and cutting and waste separation processes according to the preset spacing between adjacent stations, ensuring that the whole system has the advantages of multi-station step-by-step forming, clear process connection and continuous evolution of blank state.

[0012] 4. Through the cooperation of the negative tolerance edge sealing structure, the cutting and scrap separation station and the allowance feedback control unit, the edge sealing load and the cutting load can jointly reflect the matching state between the material segment volume, the available metal allowance of the pre-formed storage section, the main body forming allowance, the negative tolerance edge sealing allowance and the cutting allowance, ensuring that the whole system has the closed-loop control advantage of the back end load reverse correction of the front end cutting length.

[0013] 5. Through the overall coordination of the material feeding and cutting mechanism, clamping and conveying mechanism, multi-station cold heading forming mechanism, station mold assembly and allowance feedback control unit, the material segment can be continuously formed according to the path of fixed length cutting - stable conveying - zoned material storage - material storage compression - main body constraint - negative tolerance edge sealing - cutting and waste separation - load feedback correction, ensuring that the whole system has the closed-loop manufacturing advantage from front-end material segment volume control to back-end forming quality feedback. Attached Figure Description

[0014] The invention will be further understood from the following description taken in conjunction with the accompanying drawings. The components in the drawings are not necessarily drawn to scale, but rather the emphasis is on illustrating the principles of the embodiments. In different views, the same reference numerals designate the same parts.

[0015] Figure 1 This is a schematic diagram of the internal structure of the housing, feeding and cutting mechanism, clamping and transferring mechanism, multi-station cold heading forming mechanism, station mold assembly and allowance feedback control unit of the present invention.

[0016] Figure 2 for Figure 1 Enlarged schematic diagram of part A in the middle.

[0017] Figure 3 This is a schematic diagram showing a partial detail of the cutting opening of the feeding and cutting mechanism of the present invention.

[0018] Figure 4 This is a schematic diagram of the internal structure of the five processes of the multi-station cold heading forming mechanism of the present invention.

[0019] Figure 5 This is a partial schematic diagram of the feeding and cutting mechanism, clamping and transferring mechanism, multi-station cold heading forming mechanism, and station mold assembly of the present invention.

[0020] Figure 6 This is a schematic diagram of the pole state of the six processes in the cold heading forming station of the present invention.

[0021] Explanation of reference numerals in the attached drawings: 1. Frame; 2. Metal wire; 3. Straightening wheel; 4. Pressing wheel; 5. Feeding drive motor; 6. Infeed die; 7. Lubrication controller; 8. Upright pole; 9. Telescopic pole; 10. Sliding groove; 11. Cutting die; 12. Clamping component; 13. Nozzle; 14. Branch pipe; 15. Support plate; 16. Storage die shell; 17. Storage punch; 18. Storage main die shell; 19. Storage main die core; 20. Storage ejector pin; 21. Storage die drive mechanism; 22. Storage main die drive mechanism; 23. Storage compression die shell; 24. Storage compression die drive mechanism; 25. Storage compression punch; 26. Storage compression main die core; 27. Storage compression main die shell; 28. Storage compression ejector pin; 29. ​​Storage compression main die drive mechanism 30. Main body constrained punch die shell; 31. Main body constrained punch die drive mechanism; 32. Main body constrained punch; 33. Main body constrained main die core; 34. Main body constrained main die shell; 35. Main body constrained ejector pin; 36. Main body constrained main die drive mechanism; 37. Edge sealing punch die shell; 38. Edge sealing punch die drive mechanism; 39. Edge sealing punch; 40. Edge sealing main die core; 41. Edge sealing main die shell; 42. Edge sealing ejector pin; 43. Edge sealing main die drive mechanism; 44. Cutting punch die shell; 45. Cutting punch die drive mechanism; 46. Cutting main die shell; 47. Cutting die cavity; 48. Cutting ejector pin; 49. Cutting main die drive mechanism; 50. Support plate; 51. Material segment temporary storage groove; 52. Transfer beam; 53. Stand; 54. Cutting punch; 55. Material segment. Detailed Implementation

[0022] The following specific embodiments illustrate the implementation of the present invention. Those skilled in the art can understand the advantages and effects of the present invention from the content disclosed in this specification. The present invention can be implemented or applied through other different specific embodiments, and various details in this specification can also be modified and changed based on different viewpoints and applications without departing from the spirit of the present invention. Furthermore, the accompanying drawings of the present invention are for simple illustrative purposes only and are not depictions of actual dimensions; this is stated beforehand. The following embodiments will further describe the relevant technical content of the present invention in detail, but the disclosed content is not intended to limit the scope of protection of the present invention.

[0023] according to Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5 ,as well as Figure 6As shown, this embodiment provides a multi-station cold heading and fixed-length cutting forming system for new energy battery cell terminals, including a feeding and cutting mechanism, a clamping and transferring mechanism, a multi-station cold heading forming mechanism, station mold assemblies, and a margin feedback control unit. The feeding and cutting mechanism is used to feed, straighten, feed, and cut conductive metal wire 2 to form a material segment to be cold-headed. The feeding and cutting mechanism determines the cutting length of the subsequent material segment based on the target terminal volume, the preset forming margin, and the cutting correction amount output by the margin feedback control unit. The clamping and transferring mechanism is used to clamp the material segment and sequentially transfer the material segment to each station in the multi-station cold heading forming mechanism according to the preset spacing between adjacent stations. The multi-station cold heading forming mechanism includes multiple cold heading forming stations arranged sequentially along the material transfer direction, and a cutting and scrap separation station located after the multiple cold heading forming stations. The multiple cold heading forming stations are used to enable the material segment to gradually complete pre-forming storage, material replenishment compression, main body constraint forming, and negative tolerance edge sealing shaping during the sequential transfer process. The cutting and scrap separation station is used to cut off the pole post workpiece after it has been gradually compressed and formed by the multiple cold heading forming stations, and to separate the pole post workpiece from the scrap. The station mold assembly includes multiple station molds correspondingly arranged in the multiple cold heading forming stations. The multiple station molds have at least a material storage and forming structure, a material storage and compression structure, a main body constraint structure, and a negative tolerance edge sealing structure.

[0024] The margin feedback control unit is connected to the negative tolerance edge sealing structure, the cutting and scrap separation station, and the material feeding and cutting mechanism, respectively. It is used to collect the edge sealing load during the negative tolerance edge sealing forming process and / or the cutting load during the cutting and scrap separation process. Based on the edge sealing load and / or cutting load, it identifies the matching status between the material segment volume, the available metal margin in the pre-forming storage section, the main body forming margin, the negative tolerance edge sealing margin, and the cutting margin, thereby correcting the cutting length of subsequent material segments. The available metal margin in the pre-forming storage section refers to the metal formed by the material segment itself during the pre-forming storage process and the storage compression forming process.

[0025] In this embodiment, the multi-station cold heading and fixed-length cutting system for new energy battery cells further includes a central processing unit, a power supply device, and a housing. The central processing unit is implemented using a PLC controller, industrial controller, microcontroller, or embedded controller. It is connected to the feeding and cutting mechanism, the clamping and conveying mechanism, the multi-station cold heading mechanism, the cutting and scrap separation station, and the allowance feedback control unit. It receives signals such as edge sealing load, cutting load, feeding length, station cycle time, and clamping and conveying position, and outputs cutting length correction commands, feeding control commands, clamping and conveying control commands, and station action synchronization control commands based on these signals. The feeding and cutting mechanism, clamping and conveying mechanism, multi-station cold heading mechanism, station mold assembly, and allowance feedback control unit are all mounted on the frame 1.

[0026] The margin feedback control unit includes at least a load signal acquisition terminal, a load comparison and processing terminal, and a cutting correction output terminal; the load signal acquisition terminal is used to receive the edge sealing load during the negative tolerance edge sealing and shaping process and / or the cutting load during the cutting and waste separation process; the load comparison and processing terminal is used to compare the acquired edge sealing load and / or cutting load with a preset load range; and the cutting correction output terminal is used to output a cutting length correction amount to the feeding and cutting mechanism.

[0027] The power supply device converts external mains power into the voltage required for the normal operation of the central processing unit, material cutting mechanism, clamping and conveying mechanism, multi-station cold heading forming mechanism, load detection device, arrival detection device, feeding drive device, conveying drive device, and related electrical components in the cutting and waste separation station, thereby maintaining the normal operation of the aforementioned components. The specific power conversion method of the power supply device can be implemented using power supply technologies well-known to those skilled in the art, and will not be elaborated upon here. Furthermore, the power supply device can be adapted and selected according to the actual operating voltage, current load, control method, and installation environment of each electrical component in the system. It should be noted that the specific model, power, output voltage level, wiring method, and protection configuration of the power supply device can be conventionally selected and adapted by those skilled in the art based on the equipment scale, number of stations, drive component type, controller power supply requirements, and on-site power conditions, and is not the focus of this application's improvement; the specific power conversion circuit and conventional protection circuit inside the power supply device will not be further limited or elaborated upon in this embodiment.

[0028] In this embodiment, multiple cold heading stations (such as...) Figure 6The cold heading stations (as shown in a, b, c, d, e, and f) are arranged sequentially at intervals along the same straight line or at intervals along the circumference of the transfer turntable; the center distance between two adjacent cold heading stations is a preset station spacing. The clamping and transferring mechanism transfers materials at equal intervals according to the preset station spacing, so that each material segment can pass through each cold heading station sequentially, and in each cold heading station, pre-forming storage, material replenishment and compression, main body constraint forming, negative tolerance edge sealing and shaping, and cutting and waste separation are gradually completed. Specifically, after the feeding and cutting mechanism straightens and cuts the conductive metal wire 2 to form a material segment, the material segment is first pushed to the feeding position of the first cold heading station. After the first cold heading forming station completes the pre-pressing and shaping, the ejector at the corresponding station ejects the material segment from the station mold to a clamping position. Subsequently, the clamping member 12 of the clamping and transfer mechanism clamps the material segment and, driven by the transfer drive, moves along the station arrangement direction by a preset station spacing, transferring the material segment to the feeding position of the second cold heading forming station. After the second cold heading forming station completes the corresponding forming action, the ejector ejects the material segment again, and the clamping and transfer mechanism continues to clamp and transfer it to the next station. This process continues, with the material segment passing through multiple cold heading forming stations in sequence, finally entering the cutting and scrap separation station.

[0029] In this embodiment, the clamping and transfer mechanism adopts a clamping beam transfer structure, a turntable clamping and transfer structure, or a multi-claw synchronous transfer structure. Preferably, a clamping beam transfer structure is adopted. Taking the clamping beam transfer structure as an example, the clamping and transfer mechanism includes a transfer beam 52, a plurality of clamping members 12 spaced apart along the transfer beam 52, a transfer drive member for driving the transfer beam 52 to reciprocate, and a positioning detection member for detecting the positioning status of the clamping members 12. The spacing between the plurality of clamping members 12 is consistent with the preset station spacing between adjacent cold heading forming stations, so that each clamping member 12 can simultaneously perform material picking and feeding for multiple stations. In each transfer cycle, the clamping members 12 sequentially perform clamping, retraction, translation, feeding, and releasing actions, thereby transferring the material segment formed at the previous station to the next station. Figure 5As shown, the clamping and transferring mechanism further includes a support plate 50, a sliding mechanism, a sliding seat, a sliding rail disposed on the transfer beam 52, a stand 53, and a clamping drive mechanism. One end of the support plate 50 is connected to the sliding seat, and the other end of the support plate 50 extends upward toward the station's running trajectory. The sliding seat is slidably connected to the sliding rail, and the layout direction of the sliding rail is parallel to the direction of the cold heading forming station. The stand 53 is connected to the frame 1 and supports the transfer beam 52. The clamping drive mechanism is disposed at the end of the support plate 50 that extends into the cold heading forming station and is drivenly connected to the clamping member 12 to form a clamping part. In this embodiment, the cold heading forming station and the cutting and waste separation station are respectively provided with corresponding clamping members 12, and the formed material segment of each station is transferred to the next station. During the clamping and transfer process, each clamping member 12 clamps and moves synchronously. In this embodiment, the new energy battery cell terminal is a circular or irregularly shaped center rod terminal, and is transferred between various stations by the clamping and transferring mechanism. To ensure that the station conversion process and the cold heading compression action do not interfere with each other, a station cycle interlock relationship is set between the clamping and transferring mechanism and the multi-station cold heading forming mechanism. Specifically, the clamping member 12 only performs the clamping action when the punch of the corresponding cold heading forming station completes its return stroke, the ejector pushes the material segment to the clamping position, and the arrival detection member confirms that the clamping member 12 is in the material picking position; the next cold heading forming station is only allowed to perform the compression forming action after the clamping member 12 sends the material segment into the next cold heading forming station and the arrival detection member confirms that the material segment is in place. This avoids compression before the material segment has fully entered the station mold, ensuring a clear conversion path and stable cycle between stations.

[0030] For irregularly shaped center rod poles, the clamping and transfer mechanism is also provided with an angular limiting surface or an anti-rotation clamping groove, so that the material segment maintains a preset angular reference when transferred between adjacent workstations, and avoids misalignment between the pre-formed storage part and the material replenishment and introduction area in the mold of the subsequent workstation; for round center rod poles, the clamping member 12 is mainly used to ensure that the axial position of the material segment is aligned with the center of the workstation. In a complete forming cycle, the material segment conversion path is as follows: After the conductive metal wire 2 is cut into segments by the feeding and cutting mechanism, it enters the first cold heading forming station; after pre-pressing and shaping at the first cold heading forming station, it is transferred to the second cold heading forming station by the clamping and transferring mechanism; after forming a pre-shaped storage section at the second cold heading forming station, it is transferred to the third cold heading forming station; after completing the replenishment and compression at the third cold heading forming station, it is transferred to the fourth cold heading forming station; after completing the main body constraint forming at the fourth cold heading forming station, it is transferred to the fifth cold heading forming station; after completing the negative tolerance edge sealing and shaping at the fifth cold heading forming station, it is transferred to the sixth cutting and scrap separation station; finally, the sixth cutting and scrap separation station cuts off the pole workpiece and separates it from the scrap. Simultaneously, the margin feedback control unit collects the edge-sealing load at the fifth cold heading station and / or the cutting load at the sixth cutting and scrap separation station, and feeds the collection results back to the feeding and cutting mechanism to correct the cutting length of subsequent material segments. It should be noted that the cutting length correction mainly applies to material segments entering the feeding and cutting mechanism subsequently, while material segments already in the transfer path between multiple cold heading stations continue to be formed according to the current station's cycle time to ensure the stability of the continuous production process.

[0031] Optionally, the material storage and forming structure is used to form a pre-formed material storage section in a predetermined area of ​​the material segment, corresponding to the amount of metal replenishment required for subsequent main body forming; such as Figure 5 As shown, after the material segment is cut by the feeding and cutting mechanism, it forms the cut material segment in the first process. It then enters the pre-forming storage stage of the second process. The storage forming structure is correspondingly set in this pre-forming storage stage to pre-compress or upset the local metal of the cut material segment, forming a pre-forming storage section for subsequent material replenishment compression and main body forming. The pre-forming storage section is formed in the end area of ​​the material segment, the middle rod forming area, the shoulder transition area, or the outer peripheral material replenishment area. It is not an independent structure of the final product, but rather an intermediate storage reserve in the subsequent forming process. For example... Figure 5As shown, the material segment undergoes six processes from left to right: cut material segment, pre-formed storage, storage compression forming, main body constraint forming, negative tolerance edge sealing and shaping, and cutting and scrap separation. Storage compression forming corresponds to the third process in the diagram. It refers to the continued compression, shaping, or introduction of the pre-formed storage section formed in the second process, so that the metal in the pre-formed storage section participates in the forming of the pole rod region, the pole body region, or the transition region between the two in the subsequent main body constraint forming. Its essence is the redistribution of the volume of the material segment's own metal between different work stations. The material storage compression structure is used to compress, widen, reduce the diameter, or axially extend the pre-formed material storage section, transforming the metal of the material segment in the pre-formed material storage section from a localized storage state to a metal distribution usable in subsequent main body constraint forming. The main body constraint structure is used to limit the excessive outward expansion of the material segment metal towards the outer periphery of the pole body during the gradual compression forming process of the material segment. The main body constraint structure is correspondingly set in the main body constraint forming stage of the fourth process, used to constrain the contour of the material segment after pre-formed storage and material storage compression forming, so that the material segment metal forms the shape of the pole body under the constraint of the forming cavity, constraint working zone, or limiting forming surface, thereby reducing peripheral bulging, dimensional deviations, and flash precursors. The negative tolerance sealing structure is used to perform interference scraping and sealing of the excess material on the outer periphery of the material segment when the material segment enters the corresponding station mold and undergoes plastic flow, and to close the flash generation channel at the forming gap.

[0032] The negative tolerance edge sealing structure is set in the negative tolerance edge sealing and shaping stage of the fifth process. It is used to perform interference scraping, flattening or sealing of the excess material on the outer periphery, the mold parting edge allowance or the forming edge allowance after the material section has completed the main constraint forming. This prevents the excess material from continuing to enter the forming gap or mold parting gap, thereby completing the outer periphery edge sealing and shaping before the sixth process of cutting and separating waste.

[0033] like Figure 4 and 5 As shown, the sixth process is the cutting and waste separation process, which is used to cut off the pole piece after it has been progressively compressed and formed by the first five forming processes, and to separate the pole piece from the waste. The sixth process does not belong to the material storage forming structure, the main body constraint structure, or the negative tolerance edge sealing structure itself, but its cutting load and the edge sealing load of the fifth process together serve as the feedback basis for the allowance feedback control unit. This is used to determine whether the material segment volume, the metal allowance of the pre-formed storage part, the main body forming allowance, the negative tolerance edge sealing allowance, and the cutting allowance are matched, and to further correct the cutting length of the subsequent material segments.

[0034] like Figure 4 and 5As shown, the material segment sequentially presents the following states along the transfer direction of the workstation: cut material segment, pre-formed storage blank, storage compression forming blank, main body constraint forming blank, negative tolerance edge sealing and shaping blank, and the pole post workpiece after cutting and scrap separation. Optionally, the multiple cold heading forming stations include a first pre-compression forming station, a second storage pre-forming station, a third replenishment compression station, a fourth main body constraint forming station, and a fifth negative tolerance edge sealing and shaping station, arranged sequentially along the material segment transfer direction; the cutting and scrap separation station is the sixth station, as shown below. Figure 5 As shown. In this embodiment, as Figure 5 As shown, the material segment, from left to right along the transfer direction of the workstation, sequentially presents the following states: cut material segment, pre-formed storage blank, storage compression forming blank, main body constraint forming blank, negative tolerance edge sealing and shaping blank, and the pole post workpiece after cutting and scrap separation. To achieve the morphological transformation of each stage, multiple workstation molds in the workstation mold assembly sequentially form the storage forming structure, storage compression structure, main body constraint structure, and negative tolerance edge sealing structure according to the process sequence; the cutting and scrap separation workstation is set after the negative tolerance edge sealing structure to complete the final cutting and scrap separation.

[0035] The first process is the state of the cut material segment. The cut material segment is formed by the feeding and cutting mechanism, which straightens, feeds and cuts the conductive metal wire 2 to form a material segment 55 of a predetermined length. The material segment serves as the initial blank for subsequent cold heading, and its cutting length is corrected by the allowance feedback control unit based on the subsequent edge sealing load and / or cutting load. In this embodiment, a transfer interlock relationship is set between the clamping and transfer mechanism and the ejector pins in each process. Specifically, after each process completes cold heading, the corresponding punch drive mechanism first drives the corresponding punch to return, and then the corresponding main die drive mechanism drives the corresponding ejector pin to eject the intermediate blank formed in the current process to the preset clamping position; when the ejection position detection device confirms that the intermediate blank has reached the preset clamping position, the central processing unit controls the clamping and transfer mechanism to clamp the intermediate blank; when the clamping position detection device confirms that the clamping device has completed clamping, the corresponding ejector pin retracts, and the clamping and transfer mechanism then performs a translational transfer action. Therefore, the intermediate blanks formed in each process can enter the next process in the order of punch return → ejector pin ejection → clamping → ejector pin retraction → clamping and transfer, avoiding problems such as the intermediate blanks falling, shifting or being inaccurately clamped between demolding and transfer.

[0036] The second process is the pre-forming material storage process, which corresponds to the material storage forming structure. The material storage forming structure includes a material storage die component and a material storage main die component arranged opposite to each other. The material storage die component includes a material storage die shell 16, a material storage die drive mechanism 21, and a material storage punch 17. The material storage punch 17 is installed inside the material storage die shell 16, and the material storage die drive mechanism 21 is connected to the material storage punch 17 for driving the material storage punch 17 to reciprocate towards the material storage main die component. The end of the material storage punch 17 is configured as a flat end compression surface, a stepped compression surface, a reduced diameter compression surface, or a compression surface with rounded corner transition. The material storage main die component includes a material storage main die shell 18, a material storage main die core 19, a material storage ejector pin 20, and a material storage main die drive mechanism 22. The main mold core 19 for material storage is installed inside the main mold shell 18 for material storage. A pre-forming cavity for material storage is formed inside the main mold core 19 for material storage. The pre-forming cavity for material storage includes a material segment positioning section and a material storage forming section. The material segment positioning section is used to limit the axial position and radial offset of the material segment, and the material storage forming section is used to limit the forming space of the pre-formed material storage part. During the pre-forming material storage process, the clamping and transfer mechanism sends the cut material segment formed in the first process into the entrance of the main mold core 19 for material storage. The main mold driving mechanism 22 for material storage or the ejector pin 20 for material storage provides limiting support for one end of the material segment. Subsequently, the die driving mechanism 21 for material storage pushes the punch 17 for material storage to move forward, so that the material segment undergoes local upsetting, diameter reduction, step compression or variable cross-section pre-forming under the joint constraint of the punch 17 for material storage and the pre-forming cavity for material storage. Under axial pressure, the metal of the material segment flows into the material forming section, forming an annular thickened portion, a local protrusion, a stepped allowance portion, a shoulder transition material storage portion, or an irregularly shaped material storage portion, thereby obtaining a pre-formed material storage blank. After the pre-forming material storage is completed, the material storage die drive mechanism 21 drives the material storage punch 17 to return, causing the material storage punch 17 to exit the entrance area of ​​the material storage main die core 19; subsequently, the material storage main die drive mechanism 22 drives the material storage ejector pin 20 to move towards the exit direction of the material storage main die core 19, ejecting the pre-formed material storage blank from the material storage pre-forming cavity to the preset clamping position. The preset clamping position is located on the clamping path of the clamping and transfer mechanism, so that the clamping members of the clamping and transfer mechanism can clamp the pre-formed material storage blank from both radial sides or the preset clamping surface. After the ejector pin 20 ejects the preformed blank to the preset clamping position, the ejection or clamping detection component outputs a positioning signal to the central processing unit. The central processing unit, after confirming that the storage punch 17 has returned, the ejector pin 20 has been ejected to the correct position, and the clamping and transfer mechanism is in the material-picking position, controls the clamping and transfer mechanism to perform a clamping action. After the clamping component clamps the preformed blank, the main mold drive mechanism 22 then drives the ejector pin 20 to retract, to avoid interference between the ejector pin 20 and the translational path of the clamping and transfer mechanism. Subsequently, the clamping and transfer mechanism transfers the preformed blank to the entrance of the main mold core 26 of the storage compression mold in the third process, according to the preset spacing between adjacent stations.

[0037] The third process is the material storage compression forming process, which corresponds to the material storage compression structure. The material storage compression structure includes a material storage compression die component and a material storage compression main die component arranged opposite to each other. The material storage compression die component includes a material storage compression die shell 23, a material storage compression die drive mechanism 24, and a material storage compression punch 25. The material storage compression punch 25 is installed inside the material storage compression die shell 23. The material storage compression die drive mechanism 24 is connected to the material storage compression punch 25 for driving the material storage compression punch 25 towards the material storage compression main die component. The end of the material storage compression punch 25 is configured as a flattened end face, a reduced diameter inlet end face, a widened compression end face, or a stepped transition compression end face. The material storage compression main die component includes a material storage compression main die shell 27, a material storage compression main die core 26, a material storage compression ejector pin 28, and a material storage compression main die drive mechanism 29. A storage compression forming cavity is formed within the storage compression main mold core 26. This cavity includes a storage inlet section, a compression shaping section, and a transition outlet section. The storage inlet section receives the pre-formed storage blank formed in the second process. The compression shaping section compresses, widens, reduces the diameter, or axially extends the pre-formed storage portion. The transition outlet section allows the compressed metal allowance to transition to the position required for subsequent main body shaping. During the storage compression forming process, the clamping and transfer mechanism feeds the pre-formed storage blank into the storage compression main mold core 26. The storage compression main mold drive mechanism 29 or the storage compression ejector pin 28 provides limiting support for the pre-formed storage blank. Subsequently, the storage compression punch drive mechanism 24 pushes the storage compression punch 25 forward, further compressing and guiding the pre-formed storage portion between the storage compression punch 25 and the storage compression forming cavity. At this time, the metal in the pre-formed storage portion changes from a localized storage state to a metal distribution state more suitable for subsequent main body shaping, thus obtaining the storage compression formed blank. The purpose of this process is not external material replenishment, but rather to redistribute the remaining metal in the material segment formed in the second process. After the material compression forming is completed, the material compression die drive mechanism 24 drives the material compression punch 25 to return, causing the material compression punch 25 to leave the entrance area of ​​the material compression main die core 26; subsequently, the material compression main die drive mechanism 29 drives the material compression ejector pin 28 to push outward, pushing the material compression formed blank from the material compression forming cavity to a preset clamping position that the clamping and transfer mechanism can grasp. During the ejection process, the material compression ejector pin 28 is not only used for demolding, but also for axial support and position holding of the material compression formed blank before the clamping parts close, preventing the material compression formed blank from shifting, falling, or changing its posture due to the release of demolding resistance. After the clamping and transferring mechanism clamps the stored material compression forming blank, the central processing unit controls the stored material compression ejector pin 28 to retract, and the clamping and transferring mechanism then transfers the stored material compression forming blank to the entrance of the main body constraint mold core 33 of the fourth process according to the preset station spacing. Thus, the demolding, clamping and transferring processes of the stored material compression forming blank are continuously connected.

[0038] The fourth process is the main body constraint forming process, which corresponds to the main body constraint structure. The main body constraint structure includes a main body constraint die component and a main body constraint master die component arranged opposite to each other. The main body constraint die component includes a main body constraint die shell 30, a main body constraint die drive mechanism 31, and a main body constraint punch 32. The main body constraint punch 32 is installed inside the main body constraint die shell 30, and the main body constraint die drive mechanism 31 is used to push the main body constraint punch 32 toward the main body constraint master die component. The end of the main body constraint punch 32 is set as a flat end compression surface, a stepped compression surface, a reduced diameter compression surface, or a compression surface with rounded corners according to the contour of the pole body. The main body constraint master die component includes a main body constraint master die shell 34, a main body constraint master die core 33, a main body constraint ejector pin 35, and a main body constraint master die drive mechanism 36. A main constraint forming cavity is formed within the main constraint mold core 33. This cavity includes an inlet section, a main body contour forming section, a constraint working band, and a discharge transition section. The inlet section guides the stored material compression forming blank into the main constraint forming cavity; the main body contour forming section defines the shape of the pole body; the constraint working band limits excessive outward expansion of the metal segment towards the outer periphery of the body; and the discharge transition section reduces tearing during demolding. During the main constraint forming process, the clamping and transfer mechanism feeds the stored material compression forming blank into the entrance of the main constraint mold core 33. The main constraint mold drive mechanism 36 or the main constraint ejector pin 35 provides limiting support to the tail end of the blank. Subsequently, the main constraint punch drive mechanism 31 pushes the main constraint punch 32 forward, pressing the stored material compression forming blank into the main constraint forming cavity. The metal allowance in the blank participates in the plastic forming of the pole rod region, the pole body region, or the transition region between the two under axial pressure. Simultaneously, it is radially restricted by the main body contour forming section and the constraint working zone, preventing disorderly bulging outwards, thus obtaining the main body constraint formed blank. After the main body constraint forming is completed, the main body constraint die drive mechanism 31 drives the main body constraint punch 32 to return, releasing the axial pressure of the main body constraint punch 32 on the main body constraint formed blank. Subsequently, the main body constraint main die drive mechanism 36 drives the main body constraint ejector pin 35 to move towards the exit direction of the main body constraint main die core 33, ejecting the main body constraint formed blank from the main body constraint forming cavity. Since the main body constraint formed blank has formed a relatively clear main body outer contour, its outer peripheral dimensions and angular references affect the subsequent negative tolerance edge sealing and shaping. Therefore, when the main body constraint ejector pin 35 ejects the main body constraint formed blank, it stops it at a position corresponding to the clamping center of the clamping and transfer mechanism. After the main constrained forming blank is ejected into place, the clamping member of the clamping and transfer mechanism clamps the main constrained forming blank, and after the main constrained ejector pin 35 retracts, it sends the main constrained forming blank into the entrance of the edge sealing main mold core 40 of the fifth process. For irregularly shaped center rod poles, the clamping member also maintains the angular reference of the main constrained forming blank through the angular limiting clamping member during the transfer process, so as to prevent it from circumferentially deflecting before entering the negative tolerance edge sealing structure.

[0039] The fifth process is the negative tolerance edge banding shaping process, which corresponds to the negative tolerance edge banding structure. The negative tolerance edge banding structure includes an edge banding die component and an edge banding main die component arranged opposite to each other. The edge banding die component includes an edge banding die shell 37, an edge banding die driving mechanism 38, and an edge banding punch 39. The edge banding punch 39 is installed inside the edge banding die shell 37, and the edge banding die driving mechanism 38 is used to push the edge banding punch 39 toward the edge banding main die component. The end of the edge banding punch 39 is configured as an edge banding pressing end face, a flat pressing end face, a stepped edge banding end face, or an edge banding end face with a rounded corner transition. The edge-sealing main mold component includes an edge-sealing main mold shell 41, an edge-sealing main mold core 40, an edge-sealing ejector pin 42, and an edge-sealing main mold drive mechanism 43. An edge-sealing forming cavity is formed within the edge-sealing main mold core 40. Negative tolerance scraping edges are provided at the entrance side, forming edge, or parting edge of the edge-sealing forming cavity. A preset interference fit is formed between the negative tolerance scraping edge and the theoretical entry dimension of the outer periphery of the main constrained forming blank. The edge-sealing main mold core 40 is also provided with a waste discharge groove, a micro-waste discharge channel, or a waste collection cavity to discharge micro-edge material or debris generated by interference scraping. During the negative tolerance edge-sealing forming process, the clamping and transfer mechanism sends the main constrained forming blank into the entrance of the edge-sealing main mold core 40. The edge-sealing main mold drive mechanism 43 or the edge-sealing ejector pin 42 provides limiting support for the main constrained forming blank. Subsequently, the edge-sealing punch drive mechanism 38 pushes the edge-sealing punch 39 forward, causing the main constrained forming blank to enter the edge-sealing forming cavity. Because the negative tolerance scraping edge has a preset interference relative to the theoretical entry dimension of the outer periphery of the main constrained forming blank, when the main constrained forming blank enters the edge sealing and shaping cavity, its excess material on the outer periphery first contacts the negative tolerance scraping edge and is scraped, squeezed, flattened or sealed, so that the excess material cannot continue to enter the forming gap or parting gap, thus obtaining the negative tolerance edge sealing and shaping blank. After the negative tolerance edge sealing and shaping is completed, the edge sealing die drive mechanism 38 drives the edge sealing punch 39 to return, so that the edge sealing punch 39 exits the entrance area of ​​the edge sealing and shaping cavity; then, the edge sealing main die drive mechanism 43 drives the edge sealing ejector pin 42 to push outward, pushing the negative tolerance edge sealing and shaping blank from the edge sealing main die core 40 to the material picking position of the clamping and transfer mechanism. When ejecting the negative tolerance edge-sealing forming blank, the ejector pin 42 overcomes the demolding resistance caused by interference scraping between the negative tolerance scraping edge and the outer periphery of the blank, and holds the negative tolerance edge-sealing forming blank at a preset clamping height or on the clamping center line. After confirming that the edge-sealing punch 39 has returned and the ejector pin 42 has been ejected to the correct position, the clamping and transfer mechanism controls the clamping parts to clamp the negative tolerance edge-sealing forming blank. After the clamping parts are clamped, the ejector pin 42 retracts, and the clamping and transfer mechanism transfers the negative tolerance edge-sealing forming blank to the predetermined cutting position of the cutting die 47 in the sixth process. This avoids the negative tolerance edge-sealing forming blank from shifting after demolding due to the edge-sealing allowance or micro-chip resistance, ensuring accurate cutting and scrap separation positions in the subsequent process. The negative tolerance edge-sealing forming blank has already undergone edge-sealing treatment before entering the cutting and scrap separation station, which can reduce subsequent flash, burrs, and cutting resistance fluctuations.The system utilizes the cooperation between the main constraint structure and the negative tolerance edge sealing structure to allow the material segment to be interference-scraped, extruded, flattened, or sealed off on the outer periphery after the main contour constraint is completed. This ensures that the entire system has the advantage of directly sealing the flash generation channel during the forming process, thereby solving the problems of flash in the straight edge area, burrs at the parting edge, and low efficiency and surface damage caused by deburring after forming in the existing technology.

[0040] The sixth process is the waste separation process, which corresponds to the waste separation station. The waste separation station includes the waste separation die component, the waste separation main die component, and the waste discharge component. The waste separation die component includes the waste separation die shell 44, the waste separation die drive mechanism 45, and the waste separation punch 54; the waste separation main die component includes the waste separation main die shell 46, the waste separation die 47, the waste separation ejector pin 48, and the waste separation main die drive mechanism 49; the waste discharge component includes a waste separation channel, a waste guide groove, or a waste collection cavity. During the cutting and waste separation process, the clamping and transfer mechanism feeds the negative tolerance edge-sealing shaping blank into the predetermined cutting position of the cutting die 47. The cutting main die drive mechanism 49 or the cutting ejector pin 48 supports and positions the blank. Subsequently, the cutting punch drive mechanism 45 pushes the cutting punch 54 forward, so that the cutting punch 54 cooperates with the cutting die 47 to cut off the connecting material, edge material, or waste material to be separated from the negative tolerance edge-sealing shaping blank. The cut-off pole post workpiece is ejected by the ejector pin and clamped by the clamping and transfer mechanism (the two cooperate with each other to ensure that the clamping and transfer mechanism can accurately clamp), and the waste material is discharged through the waste separation channel, waste guide groove, or waste collection cavity, forming the pole post workpiece state after cutting and waste separation. After the cutting punch 54 and the cutting die 47 complete the cutting, the cutting die drive mechanism 45 drives the cutting punch 54 to return. Subsequently, the cutting main die drive mechanism 49 drives the cutting ejector pin 48 to push outward, ejecting the cut-off pole piece to the finished product clamping position. The finished product clamping position corresponds to the clamping center of the clamping and transfer mechanism or the discharge clamping mechanism, so that the clamping components can stably clamp the cut-off pole piece. In this process, the cutting ejector pin 48 first provides axial support and ejection positioning for the pole piece, and then the clamping and transfer mechanism clamps the pole piece. After the clamping components are clamped, the cutting ejector pin 48 retracts, and the clamping and transfer mechanism transfers the pole piece to the finished product discharge area. Thus, the ejector pin 48 and the clamping and transfer mechanism form a coordinated action of ejection positioning → clamping confirmation → ejector pin retraction → transfer and discharge, which prevents the pole piece after ejection from falling, flipping or deviating from the clamping center at the moment of demolding.

[0041] Optionally, the feeding and cutting mechanism includes a material rack, a pressure roller 4, a straightening roller, a feeding drive, and a cutting die 11. The pressure roller 4 and the straightening roller are used to straighten the conductive metal wire 2. The feeding drive is used to adjust the feeding length entering the cutting die 11 according to the cutting length correction amount output by the margin feedback control unit. The straightening roller is used to bend and guide the conductive metal wire 2 released from the material rack. The pressure roller 4 is symmetrically arranged on both sides of the wire and feeds the straightened wire into the cutting die 11. The two rollers are arranged opposite each other on both sides of the conductive metal wire 2 to clamp the straightened conductive metal wire 2 and, under the drive of the feeding drive, press the conductive metal wire 2 into the cutting die 11 along the conveying direction. Figure 5 As shown, the rack (not shown in the figure) is used to store the wound metal wire 2, that is, the conductive metal wire 2 supplied in bundles or rolls. During production, after the conductive metal wire 2 is released from the rack, it first enters the area of ​​the straightening roller 3 along the conveying direction shown in the figure; the straightening roller 3 is set along the conveying path of the conductive metal wire 2 and rolls in contact with the conductive metal wire 2 to eliminate the bending deformation formed by the wound metal wire 2 during the unloading process, so that the conductive metal wire 2 gradually forms a straight state suitable for subsequent fixed-length feeding and cutting.

[0042] The pressure rollers 4 are symmetrically arranged on both sides of the wire and feed the straightened wire into the cutting die 11. Specifically, the pressure rollers 4 are located downstream of the straightening rollers 3 and upstream of the cutting die 11; the symmetrically arranged pressure rollers 4 form a feeding gap for the conductive metal wire 2 to pass through, and the two clamp the conductive metal wire 2 relative to each other, so that the conductive metal wire 2 maintains a stable axial feeding posture before entering the cutting die 11. The feeding drive motor 5 is arranged in one of the pressure rollers 4 and is coaxially arranged with the pressure roller 4, and coaxially drives the pressure roller 4 to rotate. When the feeding drive drives the pressure roller 4 to rotate, the conductive metal wire 2 moves along the feeding direction under the action of the clamping friction force, thereby entering the cutting die 11 according to the preset feeding length. The metal wire 2 includes conductive and ductile metal materials, such as copper, aluminum, silver or gold. The tangent die 11 is located downstream of the pressure rollers 4 and is used to perform a cutting action after the conductive metal wire 2 enters the predetermined cutting position, forming a cutting section 55 that subsequently enters the multi-station cold heading mechanism. Therefore, the wire path formed by the feeding and cutting mechanism is: material rack feeding—straightening roller 3—pressure roller 4—fixed-length cutting by the tangent die 11. Additionally, a wire feed die 6 is provided between the pressure rollers 4 and the tangent die 11 for the conductive metal wire 2 to pass through. The wire feed die 6 has a limiting hole for the metal wire 2 to pass through, allowing for initial positioning and guidance of the wire, ensuring no deviation in the wire feeding direction. The limiting hole is adapted to the diameter of the metal wire 2. Figure 3As shown, the feeding and cutting mechanism also includes a telescopic rod 9, a telescopic drive mechanism, and sliding grooves 10 provided on both sides of the tangent die 11. One end of the telescopic rod 9 is connected to the tangent die 11, and the other end of the telescopic rod 9 is driven to connect to the telescopic drive mechanism. The telescopic rod 9 is configured as a telescopic structure and performs telescopic movements under the drive of the telescopic drive mechanism. In addition, the feeding and cutting mechanism also includes a vertical rod 8, which is connected to the base of the telescopic drive mechanism, and the other end is connected to the top of the frame 1 to form a support suspended above the frame 1.

[0043] Optionally, the negative tolerance edge sealing structure includes a negative tolerance scraping edge. The negative tolerance scraping edge forms an interference scraping gap with the forming entrance, forming edge, or parting edge of the corresponding die. This interference scraping gap is used to scrape and seal excess material on the outer periphery of the material segment when it enters the die and undergoes plastic flow. The negative tolerance edge sealing structure is correspondingly set in the negative tolerance edge sealing and shaping stage of the fifth process. The negative tolerance scraping edge is located at the forming entrance, edge sealing and shaping cavity entrance, forming edge, or parting edge of the edge sealing main die core 40. To avoid interpreting the interference scraping gap as simply an internal die gap, the interference scraping gap specifically refers to the fact that the entrance contour dimension defined by the negative tolerance scraping edge is smaller than the theoretical entry dimension of the corresponding outer periphery of the main constrained forming blank, thereby forming a preset interference between the negative tolerance scraping edge and the outer periphery of the main constrained forming blank.

[0044] For circular center rod poles, the preset interference is that the diameter of the edge-sealing and shaping cavity inlet is smaller than the outer diameter of the main constrained forming blank. For racetrack-shaped, polygonal, or other irregularly shaped center rod poles, the preset interference is set such that the straight edge region, arc region, shoulder transition region, or local edge of the edge-sealing and shaping cavity inlet shrinks inward relative to the corresponding outer peripheral contour of the main constrained forming blank. The preset interference is set based on the pole material, material segment diameter, target pole shape dimensions, allowable edge-sealing allowance, and mold load-bearing capacity.

[0045] During the negative tolerance edge banding forming process, the clamping and transfer mechanism sends the main constrained forming blank formed in the fourth process into the entrance of the edge banding main mold core 40. The edge banding main mold drive mechanism 43 or the edge banding ejector pin 42 provides limiting support for the main constrained forming blank. Subsequently, the edge banding punch drive mechanism 38 pushes the edge banding punch 39 toward the edge banding main mold core 40, causing the main constrained forming blank to enter the edge banding forming cavity. Since the negative tolerance scraping edge has a preset interference relative to the theoretical entry dimension of the outer periphery of the main constrained forming blank, when the main constrained forming blank enters the edge banding forming cavity, its excess material on the outer periphery first contacts the negative tolerance scraping edge and is scraped, squeezed, flattened, or closed under the axial thrust of the edge banding punch 39 and the radial constraint of the edge banding forming cavity. As a result, the excess material cannot continue to enter the forming gap or parting gap, thus forming the negative tolerance edge banding forming blank in the fifth process. A waste chip discharge groove is provided below the edge sealing main mold core 40. The waste chip discharge groove is located on the outside of the negative tolerance scraping edge to discharge the trace amount of edge material or debris generated during the interference scraping process, so as to avoid the micro-chips from being trapped in the edge sealing forming cavity, forming entrance or parting edge, causing subsequent pressure damage, scratches or mold wear on the pole surface. The cemented carbide mold core is at least one of the following: material storage main mold core 19, material storage compression main mold core 26, main body constraint main mold core 33 and edge sealing main mold core 40. That is to say, the cemented carbide mold core is not limited to being set in only one cold heading forming station, but is selectively set in the preforming material storage station, material storage compression forming station, main body constraint forming station or negative tolerance edge sealing forming station according to the forming load, radial mold expansion force, wear degree and product shape accuracy requirements of different stations.

[0046] By cooperating with the material storage and forming structure and the material storage and compression structure, the metal of the material segment can first form a pre-formed material storage part in a predetermined area, and then the pre-formed material storage part is transformed into a usable metal distribution for the main body constraint forming through subsequent material storage and compression forming. This ensures that the entire system has the advantages of staged adjustment of metal flow and improvement of local filling, thereby solving the problems of insufficient metal allowance in the arc end area of ​​the rod pole column in the racetrack shape, uneven regional filling, and easy local underfilling in one forming.

[0047] In this embodiment, the cemented carbide mold core forms the forming cavity required for the corresponding process. When the cemented carbide mold core is placed in the material storage forming structure, a material storage pre-forming cavity is formed inside it to form a pre-formed material storage blank. When the cemented carbide mold core is placed in the material storage compression structure, a material storage compression forming cavity is formed inside it to form a material storage compression forming blank. When the cemented carbide mold core is placed in the main body constraint structure, a main body constraint forming cavity is formed inside it to form a main body constraint forming blank. When the cemented carbide mold core is placed in the negative tolerance edge sealing structure, an edge sealing and shaping cavity is formed inside it, and a negative tolerance scraping edge is provided on the entrance side of the edge sealing and shaping cavity to form a negative tolerance edge sealing and shaping blank. The prestressed sleeve is fitted around the outer periphery of the cemented carbide mold core and forms an interference fit with the cemented carbide mold core. After assembly, the prestressed sleeve applies a radially inward preload to the cemented carbide mold core, so that the cemented carbide mold core is already in a pre-compression state before the material segment enters the corresponding station and is subjected to cold heading compression. When the material segment is subjected to axial compression by the punch in the corresponding station and generates radial outward expansion force, the radial preload provided by the prestressed sleeve can offset at least part of the radial expansion force, thereby reducing the risk of the carbide die core cracking, splitting, cavity expansion or dimensional drift.

[0048] Preferably, the prestressed sleeve is a single-layer prestressed steel ring, or a multi-layer prestressed steel ring sequentially fitted radially from the inside to the outside along the carbide mold core. For the main body constraint forming station and the negative tolerance edge sealing forming station, due to the large radial constraint load and peripheral scraping load they bear, a structure in which the carbide mold core and the multi-layer prestressed sleeve are used is preferred; for the material storage forming station and the material storage compression forming station, a single-layer prestressed sleeve, a multi-layer prestressed sleeve, or a conventional mold shell support structure are selected according to the material of the material segment, the wire diameter, the station load, and the mold life requirements.

[0049] The cemented carbide mold core provides a high-hardness, high-wear-resistance, and dimensionally stable forming cavity, while the prestressed sleeve enhances the cemented carbide mold core's ability to resist radial expansion forces, ensuring the cavity dimensions remain stable during continuous compression, material storage forming, material storage compression, main body constraint, and negative tolerance edge sealing processes in multiple cold heading stations. This is particularly suitable for copper poles, aluminum poles, or irregularly shaped rod poles that are prone to radial expansion forces during cold heading due to high local metal flow resistance. When the allowance feedback control unit outputs a cutting length correction amount based on the edge sealing load during the subsequent negative tolerance edge sealing and / or the cutting load during the cutting and waste separation process, the feeding drive adjusts the rotation angle, feeding pulse number, or feeding stroke of the pressure roller 41 and / or pressure roller 4 according to this cutting length correction amount, thereby increasing or decreasing the length of the conductive metal wire 2 entering the cutting die 11, thus correcting the cutting length of the subsequent material segment.

[0050] By cooperating with the clamping and transfer mechanism and the station mold assembly, the material segment can sequentially pass through the pre-forming storage, storage compression forming, main body constraint forming, negative tolerance edge sealing and shaping, and cutting and waste separation processes according to the preset spacing between adjacent stations. This ensures that the entire system has the advantages of multi-station step-by-step forming, clear process connection, and continuous evolution of blank state, thereby solving the problems of unclear material segment transfer path and unclear station state connection in the multi-station cold heading process of the prior art.

[0051] Optionally, the margin feedback control unit includes a load detection element, a load comparison unit, and a cutting length correction unit. The load detection element is used to acquire the edge sealing load and / or cutting load. The load comparison unit is used to compare the edge sealing load and / or cutting load with a preset load range. The cutting length correction unit is used to correct the cutting length of subsequent material segments based on the comparison results. Optionally, when the edge sealing load and / or cutting load are continuously higher than the preset load range, the cutting length correction unit reduces the cutting length of subsequent material segments; when the edge sealing load and / or cutting load are continuously lower than the preset load range, the cutting length correction unit increases the cutting length of subsequent material segments. In this embodiment, the edge sealing load is acquired by an edge sealing load detection element disposed on the edge sealing die drive mechanism 38, the edge sealing punch 39, the edge sealing main die shell 41, the edge sealing main die drive mechanism 43, or the edge sealing drive mechanism; the cutting load is acquired by a cutting load detection element disposed on the cutting die drive mechanism 45, the cutting punch 54, the cutting die 47, the cutting main die drive mechanism 49, or the cutting drive mechanism. The edge sealing load is preferably the peak load or the median of the stable section load between the start of contact between the negative tolerance scraping edge and the end of the edge sealing punch 39; the cutting load is preferably the peak load or the median of the stable section load at the moment when the cutting punch 54 and the cutting die 47 cooperate to complete the cutting.

[0052] In this embodiment, through the cooperation of the material storage compression structure and the main body constraint structure, the material segment after pre-forming storage can form the main body outline of the pole column under the constraint of the main body constraint forming cavity and the constraint working belt. This ensures that the whole system has the advantages of controlling metal expansion, stabilizing the main body size and reducing forming off-center load, thereby solving the problems of easy extrusion and flash in the straight edge area of ​​the pole column in the racetrack shape and insufficient consistency of the outer perimeter size of the main body.

[0053] To avoid misjudgment caused by a single impact, vibration, or localized debris, the allowance feedback control unit performs median sampling of the load on several consecutive blanks. If the edge-sealing load of the k-th blank during the negative tolerance edge-sealing forming process is... The shear load during the waste separation process is The edge sealing load and shear load values ​​used for the judgment are as follows:

[0054] ;

[0055] ;

[0056] in, Let be the median edge sealing load corresponding to the k-th blank; Let be the median shear load corresponding to the k-th blank; The preferred number of continuous blanks to participate in the median sampling is any integer value between 3 and 7. If the preset reasonable range for the edge sealing load is... The preset reasonable range for the shear load is .in, This is the lower limit of the edge sealing load. This is the upper limit of the edge banding load; To cut off the lower limit of the load, This is the upper limit of the shear load. The aforementioned preset reasonable range is determined during the trial production stage based on the edge sealing load and shear load of qualified pole sample parts, and is stored in the register of the central processing unit or in the memory connected to the central processing unit.

[0057] Estimate the edge banding allowance deviation based on the edge banding load deviation:

[0058] ; This refers to the deviation volume of the edge sealing allowance calculated from the edge sealing load. This is the edge sealing load-to-allowance conversion factor, calibrated by varying the edge sealing load corresponding to different cutting lengths during trial production. This represents the volume of negative tolerance edge sealing allowance deviation when the negative tolerance edge sealing load deviates from the preset reasonable range by 1N. When the hardness, yield strength, or peripheral forming resistance of the pole material is high, the same edge sealing allowance deviation will cause a larger change in edge sealing load. The value is relatively small; when the pole material is soft, plastic flow is easy, or the edge sealing load is not sensitive to changes in the allowance. The values ​​are relatively large. For copper poles, the edge-sealing scraping load and peripheral extrusion resistance are usually large. A value of 0.0015–0.004 mm³ / N is preferred; for aluminum poles, due to the relatively soft material, The preferred value is 0.003 to 0.006 mm³ / N. In this embodiment, the preferred value is: .when When this occurs, it indicates that the negative tolerance edge sealing allowance is too large, or that the material section volume or outer perimeter allowance is too large; when When this occurs, it indicates that the negative tolerance edge sealing allowance is too small, or that the material section volume or available metal allowance is insufficient.

[0059] Estimate the shear margin deviation based on the shear load deviation:

[0060] ; This refers to the deviation volume of the shear margin calculated from the shear load. The shear load-to-margin conversion factor can be obtained by calibration through variations in shear load corresponding to different cutting lengths during trial production. Shear load-to-margin conversion factor This is used to represent the volume of the shear margin deviation when the shear load deviates from the preset reasonable range by 1N. As a positive value, in this embodiment, when the hardness, shear strength, or shear resistance of the pole material is large, the same shear allowance deviation will cause a larger change in the shear load. The value is relatively small; when the pole material is soft, the shear resistance is small, or the shear load is not sensitive to changes in the margin. The value is relatively large. For copper poles, due to their typically high material strength and shear resistance, A value of 0.003–0.006 mm³ / N is preferred; for aluminum poles, due to the relatively soft material, A value of 0.005–0.008 mm³ / N is preferred. This is suitable for applications with small cutting gaps, sharp cutting edges, and stable lubrication. A relatively stable intermediate value can be selected; when the cutter wear increases, the cutting gap changes, or the cutting load fluctuates significantly, trial production calibration should be performed again. In this embodiment, to balance the universal compatibility of copper and aluminum electrodes and to avoid overly sensitive cutting length correction, a more suitable value is preferred. This value indicates that when the shear load deviates by 1N from the preset reasonable range boundary, the margin feedback control unit converts it into a shear margin deviation volume of approximately 0.005mm³, and further combines this with the cross-sectional area of ​​the conductive metal wire. This is converted into a correction amount for the cutting length of subsequent material sections.

[0061] when When this occurs, it indicates that the cutting allowance is too large or the material segment volume is too large; when When this occurs, it indicates that the cutting allowance is too small or the material segment volume is insufficient.

[0062] The margin feedback control unit uses a geometric consistency judgment method based on the same direction deviation to determine the material section margin matching deviation:

[0063] ; The volume is used to match the material allowance deviation. When the two deviations are in opposite directions, it indicates that there may be local burrs, mold jamming, cutter wear, or single-station abnormalities. In this case, the cutting length is not directly corrected, but rather... Set to 0, and it can output a workstation abnormality prompt.

[0064] Let the cross-sectional area of ​​the conductive metal wire be... For round wire, ,in For wire diameter; for non-circular wire, Take the actual measured cross-sectional area of ​​the wire. If the correction amount for the cutting length of the subsequent material segment corresponding to the k-th blank is... ,but: ; This is the correction amount for the cutting length; To correct the scaling factor, the value is taken as follows: This is to avoid making too large a correction at once; in this embodiment, 0, meaning that when the margin feedback control unit calculates the material segment margin matching deviation volume based on the edge sealing load and / or shearing load. Afterwards, it will not be Instead of using all theoretical length deviations as the cutting length correction, only 30% of the deviation is corrected. This avoids excessive adjustment of the cutting length due to single load fluctuations, local changes in material hardness, mold temperature rise, or interference from trace amounts of debris. This is a correction value for the maximum allowable cutting length in a single operation; Indicates will Limited to to Within the range. Due to This indicates that the material segment volume or allowance is too large. Adding a negative sign before the formula reduces the subsequent cutting length of the material segment. Because... This indicates that the volume or margin of the material segment is insufficient, leading to an increase in the cutting length of subsequent material segments.

[0065] By coordinating the negative tolerance edge sealing structure, the cutting and scrap separation station, and the allowance feedback control unit, the edge sealing load and the cutting load can jointly reflect the matching state between the material segment volume, the available metal allowance of the pre-formed storage section, the main body forming allowance, the negative tolerance edge sealing allowance, and the cutting allowance. This ensures that the entire system has the closed-loop control advantage of the rear load correcting the front cutting length, thereby solving the problems of lack of feedback correction in existing scraping edge sealing and the inability to adjust the edge sealing allowance in a timely manner if it is too large or too small.

[0066] In this embodiment, considering that the load feedback generated by the fifth or sixth process acts on the subsequent uncut material segments, rather than on the blanks already in the cold heading forming stations, if the current basic cutting length is... The current corrected target cutting length is ,but: ; The target cutting length performed by the feeding and cutting mechanism before the k-th correction; The target cutting length to be executed by the feeding and cutting mechanism after the kth correction; The minimum cutting length allowed to ensure the minimum forming volume of the pole post; The maximum allowable cutting length to avoid excessive flash, excessive cutting resistance, or mold overload. and The target pole's theoretical volume, material cross-sectional area, preset process allowance, and mold allowable load are determined and pre-stored in the central processing unit or its connected memory.

[0067] In actual control process, only when The cutting length correction unit only outputs the corresponding cutting length correction amount when the same deviation direction is maintained in n consecutive blanks; wherein n is preferably 2 to 5. This avoids frequent adjustments to the feeding and cutting mechanism caused by occasional abnormal loads on a single blank.

[0068] By cooperating with the material feeding and cutting mechanism and the allowance feedback control unit, the material feeding and cutting mechanism no longer passively cuts materials according to a fixed cutting length. Instead, it can correct the cutting length of subsequent material segments based on the edge sealing load during the negative tolerance edge sealing and forming process and / or the cutting load during the cutting and waste separation process. This ensures that the entire system has the advantage of dynamic matching between the cutting volume and the subsequent forming allowance, thereby solving the problem of the disconnect between fixed-length cutting and forming allowance in the existing technology.

[0069] Optionally, the forming system also includes a synchronous lubrication unit, which includes an oil mist generator, compressed air pipeline, nozzle 13 assembly, and lubrication controller 7. The nozzle 13 assembly is positioned towards the forming inlet, negative tolerance sealing structure, and / or main constraint structure of the station mold assembly. The lubrication controller 7 is used to control the nozzle 13 assembly to spray oil mist before or at the moment the material enters the corresponding station mold, so as to form a pressure-bearing lubricating film before the material undergoes plastic flow. The synchronous lubrication unit is set as an auxiliary lubrication mechanism of the multi-station cold heading fixed-length cutting forming system for new energy battery cell terminals, and is coordinated with the cold heading cycle of the multi-station cold heading forming mechanism. It does not constitute a separate part of the station mold assembly, but is arranged near the feeding side, forming inlet side, or sealing and shaping area of ​​the corresponding station mold, and is used to lubricate the outer periphery of the material segment and / or the forming inlet of the mold with oil mist before the material segment enters the station mold.

[0070] In this embodiment, an oil mist generator is used to atomize lubricating oil into oil mist, and a compressed air pipeline is used to deliver the oil mist to the nozzle 13 assembly. The compressed air pipeline includes a compressed air source, a pressure reducing valve, a solenoid valve, a flow regulating valve, and branch pipelines 14, which are respectively connected to the nozzle 13 assemblies at the corresponding workstations. The lubrication controller 7 is connected to the solenoid valve, the flow regulating valve, and the central processing unit, and is used to control the nozzle 13 assembly to spray oil mist according to the material section arrival signal, the die return signal, or the transfer cycle of the clamping and transfer mechanism. The compressed air source is set on the support plate 50, and one side of the support plate 50 is connected to the side wall of the frame 1 to form a stable support.

[0071] The nozzle assembly 13 includes a first nozzle 13 facing the inlet of the material storage and forming structure, a second nozzle 13 facing the inlet of the material storage and compression structure, a third nozzle 13 facing the inlet of the main constraint structure, and a fourth nozzle 13 facing the inlet of the negative tolerance sealing structure or the negative tolerance scraping edge. Each nozzle 13 is located on the feeding side of the corresponding station mold, and the spraying direction forms an angle with the direction in which the material segment enters the station mold, so that the oil mist covers the outer periphery of the material segment, the forming inlet, the inlet of the constraint working zone, or the negative tolerance scraping edge area.

[0072] During operation, when the arrival detection component detects that the material segment is about to enter the corresponding station mold, or when the central processing unit determines that the clamping and transfer mechanism is about to send the material segment into the corresponding station based on the cold heading cycle, the lubrication controller 7 controls the corresponding nozzle 13 assembly to spray oil mist in advance. When the material segment enters the corresponding station mold and begins to undergo plastic flow, the oil mist forms a pressure-bearing lubricating film between the outer periphery of the material segment and the forming inlet of the station mold. The pressure-bearing lubricating film is used to reduce the frictional resistance between the outer periphery of the material segment and the mold cavity, reduce the outer periphery scratch during the main body constraint forming process, and reduce material adhesion, scratching, and scratching resistance fluctuations at the negative tolerance scraping edge during the negative tolerance edge sealing and shaping process.

[0073] Furthermore, the lubrication controller 7 sets the spraying duration, spraying pressure, and spraying frequency according to the forming load and friction state of different workstations. For example, the spraying amount at the material forming structure and the material compression structure is used to ensure smooth metal flow in the material section; the spraying amount at the main constraint structure is used to reduce friction at the constraint working zone; and the spraying amount at the negative tolerance sealing structure is used to reduce scraping resistance and micro-chip adhesion at the negative tolerance scraping edge.

[0074] The specific oil mist generation method, nozzle type 13, pipeline connection method, and lubricant type of the synchronous lubrication unit are conventionally selected by those skilled in the art based on the material of the material segment, wire diameter, number of cold heading stations, forming load, and equipment space. As long as a lubricating film can be formed before or at the moment the material segment enters the corresponding station mold, it is considered an implementation method of the synchronous lubrication unit in this embodiment. The purpose of setting up this synchronous lubrication unit is to synchronize with the multi-station cold heading forming cycle, reduce forming friction and edge-sealing scraping resistance, and does not change the core technical line of this application, which uses margin feedback control to correct the cutting length.

[0075] In this embodiment, the lubrication controller determines the oil injection quantity and injection duration of the nozzle assembly based on the equivalent contact pressure at each station. Let the first... Each lubrication station corresponds to any one of the following structures: material storage and forming structure, material storage and compression structure, main constraint structure, or negative tolerance edge sealing structure. This indicates the pre-forming material storage station. This indicates the material compression forming station. This indicates the main body constraint forming station. This indicates a negative tolerance edge sealing and shaping station.

[0076] No. The equivalent contact pressure of each lubrication station is: ; For the first The blank is in the first The equivalent contact pressure of each lubrication station, and ; For the first The median forming load corresponding to each lubrication station; For the first The equivalent contact area between the outer periphery of the material section and the mold inlet, forming cavity, constraint working zone, or negative tolerance scraping edge in each lubrication station. For the negative tolerance edge sealing and shaping station, Take the aforementioned median edge sealing load For the main constraint forming station, the main constraint forming load detected at the main constraint punch or the main constraint main mold drive mechanism is taken; for the preforming storage station and the storage compression forming station that do not have separate load detection components, the corresponding station reference forming load calibrated during the trial production stage is adopted.

[0077] The lubrication controller determines the target pressure-bearing lubrication film thickness based on the equivalent contact pressure.

[0078] ; For the first The target pressure-bearing lubricating film thickness for each lubrication station; For the first The reference lubrication film thickness for each lubrication station; For the first The reference equivalent contact pressure of each lubrication station; For material to enter the first stage The transfer or pressing speed of the mold at each workstation; The reference transfer or pressing speed; For the first Surface roughness at the forming entrance of the mold station, the constraint working zone, or the negative tolerance scraping edge; The reference surface roughness; , , These are the pressure correction index, speed correction index, and roughness correction index, respectively. and These represent the lower and upper limits of the target lubricating film thickness, respectively.

[0079] In this embodiment, The value range is 0.25 to 0.60, preferably 0.40; The value range is 0.10 to 0.40, preferably 0.20; The value range is 0.10 to 0.30, preferably 0.20. Target pressure-bearing lubricating film thickness. The preferred value range is 0.001mm to 0.008mm; wherein, the pre-forming material storage station and the material compression forming station are preferably 0.0015mm to 0.0035mm, the main body constraint forming station is preferably 0.002mm to 0.005mm, and the negative tolerance edge sealing and shaping station is preferably 0.003mm to 0.006mm. In this embodiment, the reference lubricating film thickness of the negative tolerance edge sealing and shaping station is... The preferred size is 0.003 mm.

[0080] No. The equivalent oil injection quantity required for each lubrication station is: ; For the first The lubrication station is at the first The equivalent amount of oil sprayed before the blank enters the workpiece; The coverage correction factor is used to compensate for uneven coverage of oil mist on the outer periphery of the material section and at the mold inlet. Its value ranges from 1.00 to 1.30, with 1.10 being preferred. This is the equivalent contact area; The target pressure-bearing lubricating film thickness; For the first The oil mist deposition efficiency of each nozzle ranges from 0.20 to 0.70, and is preferably 0.45.

[0081] No. The spray duration of each nozzle is: ; For the first The spray duration of each nozzle; For the first The equivalent oil deposition flow rate of each nozzle under the current compressed air pressure and oil mist generator setting represents the actual volume of lubricating oil deposited on the outer periphery of the material section or the mold inlet area per unit time, rather than the compressed air flow rate. Minimum spray duration; This is the maximum spray duration. Preferably, Take a time of 0.02s to 0.05s. The time is taken as 0.15s to 0.30s. In this embodiment, , .

[0082] To ensure that the oil spraying action is synchronized with the time when the material enters the mold at the station, the lubrication controller determines the spraying start time according to the following formula: ; For the first The injection start-up time of each nozzle; For the first The blank enters the first The estimated time of entry for forming the mold at each workstation; For the first The response delay time of the solenoid valve corresponding to each nozzle; For the first The spray distance between each nozzle outlet and the corresponding forming inlet or the target lubrication area on the outer periphery of the material segment; This represents the average velocity of the oil mist as it travels from the nozzle exit to the target lubrication area. The spraying end time is: ; For the first The spraying end time of each nozzle. The lubrication controller can complete the oil mist coverage before the material enters the corresponding die, ensuring a pressure-bearing lubricating film is formed before the material undergoes plastic flow. When the first... When the forming load at each station increases, the equivalent contact area increases, the material entry speed increases, or the surface roughness of the mold increases, the target pressure-bearing lubricating film thickness... Equivalent fuel injection quantity and spray duration The corresponding increase occurs when the oil mist deposition efficiency... Increase or nozzle equivalent deposited oil flow rate When the spraying time is increased, under the condition of achieving the same lubricating film thickness, the required spraying time is... The corresponding decrease.

[0083] By cooperating with the synchronous lubrication unit and the station mold assembly, a pressure-bearing lubricating film can be formed before the material segment enters the material storage and forming structure, the material storage and compression structure, the main constraint structure, or the negative tolerance edge sealing structure. This ensures that the entire system has the advantages of reducing frictional resistance in the high-pressure forming area, reducing material sticking and tearing, and stabilizing the edge sealing scraping load. This solves the problems of unstable lubricating film in the high-pressure forming area, fluctuations in negative tolerance scraping resistance, and easy generation of fold lines in the transition corner area.

[0084] In addition, the feeding and cutting mechanism also includes a material segment storage groove 51. The material segment storage groove 51 is located on the discharge side of the tangent die 11 and on the material picking path of the clamping and transferring mechanism, and is used to receive the material segment 55 cut by the tangent die 11. The tangent die 11 is located downstream of the pressure rollers 4 and is used to perform the cutting action after the conductive metal wire 2 enters the predetermined cutting position. The material segment formed after the conductive metal wire 2 is cut falls into the material segment storage groove 51. The material segment storage groove 51 is a groove structure extending along the axial direction of the material segment. It includes a receiving bottom surface and limiting sidewalls located on both sides of the receiving bottom surface. The receiving bottom surface is used to support the cut material segment, and the limiting sidewalls are used to limit the lateral rolling or displacement of the material segment during the temporary storage process. The material storage groove 51 is configured as an inclined guide groove. One end of the material storage groove 51 near the material outlet side of the tangent die 11 is higher than the end near the material pick-up side of the first cold heading forming station. This allows the cut material segment, after entering the material storage groove 51, to roll or slide along the groove direction of the material storage groove 51 towards the first cold heading forming station under its own gravity. Therefore, after being cut, the material segment can move to the pick-up position of the clamping and transferring mechanism without the need for an additional complex pushing mechanism. Preferably, the inclination angle of the material storage groove relative to the horizontal plane is 1° to 10°, more preferably 3° to 6°. When the inclination angle is too small, the material segment may not be able to roll smoothly to the pick-up position due to frictional resistance or cutting burrs; when the inclination angle is too large, the rolling speed of the material segment is too fast, impacting the groove end limiting structure and causing posture deviation. In this embodiment, the inclination angle of the material storage groove relative to the horizontal plane is preferably 4°. A stop or positioning block is provided at one end of the material segment temporary storage groove 51 near the first cold heading forming station. The stop is used to restrict the material segment from rolling forward out of the material segment temporary storage groove 51 and to keep the material segment at a preset picking position where the clamping and transfer mechanism can stably grip it. The stop is set as an end block, an elastic buffer block, or an arc-shaped limiting surface adapted to the outer circumference of the material segment to reduce impact and rebound when the material segment arrives at its destination. At the same time, the groove width of the material segment temporary storage groove is adapted to the outer diameter or maximum outer width of the cut material segment. For a circular material segment, let the outer diameter of the material segment be... The width of the material storage tank is ,but Set to greater than and less than Preferably, ~ In this embodiment, it is preferably set to For irregularly shaped material sections or intermediate blanks that have formed a directional outer perimeter after passing through previous workstations, the groove width... The maximum outer width of the material segment is determined to ensure smooth entry into the material segment storage groove while preventing significant lateral movement within the groove. The receiving bottom surface of the material segment storage groove 51 is configured as a V-shaped groove, an arc-shaped groove, or a flat-bottomed groove. Preferably, for circular material segments, the receiving bottom surface is a V-shaped groove or an arc-shaped groove to automatically maintain centering during rolling or sliding; for irregularly shaped material segments, the receiving bottom surface is configured as a contoured groove that matches the outer periphery of the material segment to maintain the stability of the material segment's posture before entering the clamping and transfer mechanism. One end of the groove of the material segment storage groove 51 is close to the discharge side of the tangent die 11, and the other end is close to the feed side of the first cold heading forming station; that is, the material segment storage groove 51 is located in the transition area between the tangent die 11 and the first cold heading forming station, so that the material segment storage groove 51 is simultaneously located between the material dropping position of the tangent die 11 and the material picking position of the clamping and transfer mechanism. The first cold heading forming station refers to the first forming station among multiple cold heading forming stations (the location of the first process mentioned above), that is, the station used to receive the cut material segments and perform subsequent pre-forming and storage.

[0085] During operation, after the tangent die 11 completes the cutting, the cut material segment enters the material segment storage tank 51 under the action of gravity, the action of the pusher, or the action of the cutter retraction, and is held in the preset picking position by the material segment storage tank 51. When the clamping and transfer mechanism feeds material to the first cold heading forming station, the clamping member 12 moves to the picking opening of the material segment storage tank 51 and clamps the material segment in the storage tank; then, the clamping member 12 takes the material segment out of the material segment storage tank 51 and sends it to the feeding position of the first cold heading forming station along the preset transfer path.

[0086] To facilitate the clamping member 12 in gripping the material segment, a material retrieval opening is provided above or to the side of the material segment storage groove 51. The material retrieval opening corresponds to the clamping movement path of the clamping member 12, enabling the clamping member 12 to grip the material segment from both radial sides or axial ends. A guide notch or clearance groove is also provided at the end of the material segment storage groove 51 near the first cold heading station to prevent interference between the clamping member 12 and the material segment storage groove 51 during material retrieval, lifting, or translation. A material segment arrival detection device is also provided at the material segment storage groove 51. This device uses a proximity switch, photoelectric detection device, or mechanical trigger detection device to detect whether the cut material segment has fallen into the preset retrieval position. The central processing unit (CPU) only allows the clamping component 12 to perform clamping action when the material segment arrival detection component confirms that the material segment is located in the material segment temporary storage slot 51 and the clamping and transfer mechanism is in the material picking position. When the material segment is not in place or the material segment posture is abnormal, the CPU controls the feeding drive, the tangent die 11, or the clamping and transfer mechanism to pause to avoid empty clamping, off-center clamping, or the material segment not being aligned with the first cold heading forming station. The complete feeding path formed by the feeding and cutting mechanism is as follows: material rack placement → straightening roller 3 straightening → pressing roller 41 and pressing roller 4 pressing → tangent die 11 cutting to a fixed length → material segment temporary storage slot 51 receiving the material segment → clamping and transfer mechanism picking up the material segment from the material segment temporary storage slot 51 → clamping component 12 sending the material segment into the first cold heading forming station → and then clamping and transferring it in each station through the clamping component 12. By setting up a material segment temporary storage groove 51, the cut material segment has a stable receiving position and material picking benchmark before entering the first cold heading forming station, thereby ensuring clear connection between the actions of cutting, temporary storage, clamping and feeding at the first station.

[0087] Through the cooperation of the material feeding and cutting mechanism, the material segment temporary storage groove 51 and the clamping and transfer mechanism, the material segment cut by the tangent die 11 can first fall into the material segment temporary storage groove 51, and then be picked up by the clamping and transfer mechanism from the preset picking position and sent to the first cold heading forming station. This ensures that the whole system has the advantages of continuous and stable cutting, temporary storage, picking and first station feeding actions, thereby avoiding the problems of posture deviation, inaccurate picking and unstable feeding at the first station when the cut material segment is directly transferred.

[0088] In addition, the present invention also provides a method for cold heading and fixed-length cutting of new energy battery cell terminals at multiple stations. The forming method includes the following steps: S1, feeding, straightening, fixed-length feeding and cutting of conductive metal wire 2 to form material segments to be cold-headed; after the conductive metal wire 2 is released from the material rack, it passes through the straightening wheel 3 for straightening, the pressing wheel 4 for pressing and feeding and the cutting die 11 for fixed-length cutting in sequence, and the cut material segments are placed into the material segment temporary storage groove 51; the material segment temporary storage groove 51 is used to receive the cut material segments and keep the material segments in a preset picking position that can be picked up by the clamping and transfer mechanism. S2. The material segment is sequentially transferred to multiple cold heading forming stations according to the preset spacing between adjacent stations by the clamping and transfer mechanism. The clamping and transfer mechanism first clamps the cut material segment from the material segment temporary storage groove 51 and transfers the material segment to the first cold heading forming station. After the first cold heading forming station completes the corresponding forming action and pushes the intermediate blank to the clamping position, the clamping and transfer mechanism transfers the intermediate blank to the next cold heading forming station according to the preset station spacing. S3. In multiple cold heading forming stations, the material segment sequentially completes pre-forming storage, storage compression forming, main body constraint forming, and negative tolerance edge sealing shaping. Among them, pre-forming storage is completed by the storage forming structure, which is used to press the cut material segment into a pre-forming storage blank; storage compression forming is completed by the storage compression structure, which is used to further compress, widen, reduce the diameter, or axially extend the pre-forming storage part in the pre-forming storage blank to form a storage compression forming blank; main body constraint forming is completed by the main body constraint structure, which is used to constrain the contour of the storage compression forming blank and form a main body constraint forming blank; negative tolerance edge sealing shaping is completed by the negative tolerance edge sealing structure, which is used to seal and shape the excess material on the outer periphery of the main body constraint forming blank to form a negative tolerance edge sealing shaping blank. S4. During the negative tolerance edge sealing process, the excess material on the outer periphery of the material section is interference-scraped and sealed by the negative tolerance edge sealing structure, and the flash generation channel at the forming gap is closed. The negative tolerance scraping edge in the negative tolerance edge sealing structure forms a preset interference with the theoretical outer periphery entry dimension of the main constrained forming blank. When the main constrained forming blank enters the edge sealing cavity, its excess material on the outer periphery is scraped, squeezed, flattened or sealed by the negative tolerance scraping edge, thereby reducing flash and burr generation. S5. In the cutting and scrap separation station, the pole post workpiece, which has been gradually compressed and formed by multiple cold heading forming stations, is cut off and the pole post workpiece is separated from the scrap. The clamping and transfer mechanism transfers the negative tolerance edge sealing forming blank to the cutting and scrap separation station. The cutting punch 54 and the cutting die 47 cooperate to cut off the connecting material, edge material or scrap to be separated, so that the pole post workpiece is separated from the scrap and forms the pole post workpiece state after cutting and scrap separation.S6. Collect the edge sealing load during the negative tolerance edge sealing and forming process and / or the cutting load during the cutting and waste separation process, and identify the matching status between the material segment volume, the available metal allowance of the pre-formed storage section, the main body forming allowance, the negative tolerance edge sealing allowance, and the cutting allowance based on the edge sealing load and / or cutting load. The edge sealing load is collected by the edge sealing load detection device set at the negative tolerance edge sealing structure, and the cutting load is collected by the cutting load detection device set at the cutting and waste separation station. The allowance feedback control unit compares the edge sealing load and / or cutting load with the corresponding preset load range. When both the edge sealing load and the cutting load are consistently high, it is determined that the material segment volume, the negative tolerance edge sealing allowance, or the cutting allowance is too large. When both the edge sealing load and the cutting load are consistently low, it is determined that the material segment volume or the available metal allowance of the pre-formed storage section is insufficient. When the deviation directions of the two are inconsistent, it is determined that there may be a single station abnormality, scraping chip retention, cutter wear, or local jamming. In this case, the cutting length is not directly corrected.

[0089] S7. Correct the cutting length of subsequent material segments according to the matching status. When the matching status shows that the material segment volume or forming allowance is too large, the allowance feedback control unit outputs a correction amount to reduce the cutting length to the feeding drive; when the matching status shows that the material segment volume or forming allowance is too small, the allowance feedback control unit outputs a correction amount to increase the cutting length to the feeding drive; the feeding drive adjusts the rotation angle, feeding pulse number, or feeding stroke of the pressure rollers 4 according to the cutting length correction amount, so that the length of the conductive metal wire 2 that subsequently enters the cutting die 11 changes accordingly. Among them, the cutting length correction in step S7 applies to the conductive metal wire 2 that has not yet been cut, but does not apply to the blanks that are already in the material segment temporary storage tank 51, the clamping and transfer mechanism, or multiple cold heading forming stations; the blanks that have entered the multi-station cold heading forming mechanism continue to complete the pre-forming storage, storage compression forming, main body constraint forming, negative tolerance edge sealing and shaping, and cutting and scrap separation in sequence according to the current station cycle. Therefore, it avoids disruption of the workstation cycle time due to real-time corrections during continuous production. The material segment is sequentially formed along the workstation transfer direction into the state of the cut material segment, pre-formed storage blank, storage compression forming blank, main body constraint forming blank, negative tolerance edge sealing and shaping blank, and the pole column workpiece after cutting and scrapping. Furthermore, the rear edge sealing load and / or cutting load can reverse the front fixed length cutting process, so that the cutting volume matches the subsequent multi-station forming allowance.

[0090] Through the overall coordination of the material feeding and cutting mechanism, clamping and conveying mechanism, multi-station cold heading forming mechanism, station mold assembly and allowance feedback control unit, the material segment can be continuously formed according to the path of fixed length cutting, stable conveying, zoned material storage, material storage compression, main body constraint, negative tolerance edge sealing, cutting and waste separation, and load feedback correction. This ensures that the entire system has the closed-loop manufacturing advantages from front-end material segment volume control to back-end forming quality feedback, thereby systematically solving problems such as uneven filling of the rod pole in the racetrack shape, mismatch of cutting allowance, lack of angular reference, flash burrs and unstable cutting and waste separation.

[0091] The content disclosed above is only a preferred and feasible embodiment of the present invention, and is not intended to limit the scope of protection of the present invention. Therefore, all equivalent technical changes made based on the content of the present invention specification and drawings are included within the scope of protection of the present invention. Furthermore, the elements therein can be updated as technology develops.

Claims

1. A multi-station cold heading and fixed-length cutting forming system for new energy battery cell terminals, characterized in that, The system includes a feeding and cutting mechanism, a clamping and transferring mechanism, a multi-station cold heading forming mechanism, station mold assemblies, and a margin feedback control unit. The feeding and cutting mechanism is used to feed, straighten, deliver, and cut conductive metal wires to form segments for cold heading. The feeding and cutting mechanism determines the cutting length of subsequent segments based on the target electrode volume, a preset forming margin, and the cutting correction amount output by the margin feedback control unit. The clamping and transferring mechanism is used to clamp the segments and sequentially transfer them according to a preset spacing between adjacent stations. The material is fed to each station in the multi-station cold heading forming mechanism. The multi-station cold heading forming mechanism includes multiple cold heading forming stations arranged sequentially along the material transfer direction and a cutting and scrap separation station located after the multiple cold heading forming stations. The multiple cold heading forming stations are used to enable the material to gradually complete pre-forming storage, replenishment compression, main body constraint forming and negative tolerance edge sealing shaping during the sequential transfer process. The cutting and scrap separation station is used to cut off the pole post workpiece after it has been gradually compressed and formed by the multiple cold heading forming stations and separate the pole post workpiece from the scrap. The station mold assembly includes multiple station molds correspondingly arranged in the multiple cold heading stations. The multiple station molds have at least a material storage and forming structure, a material storage and compression structure, a main body constraint structure, and a negative tolerance edge sealing structure. The margin feedback control unit is connected to the negative tolerance edge sealing structure, the cutting and waste separation station, and the material feeding and cutting mechanism, respectively. It is used to collect the edge sealing load during the negative tolerance edge sealing and forming process and / or the cutting load during the cutting and waste separation process. Based on the edge sealing load and / or cutting load, it identifies the matching status between the material segment volume, the available metal margin in the pre-formed storage section, the main body forming margin, the negative tolerance edge sealing margin, and the cutting margin, and then corrects the cutting length of the subsequent material segment.

2. The multi-station cold heading and fixed-length cutting forming system for new energy battery cell terminals according to claim 1, characterized in that, The material storage and forming structure is used to form a pre-formed material storage section in a predetermined area of ​​the material segment, corresponding to the amount of metal replenishment required for subsequent main body forming; the material storage and compression structure is used to compress, widen, reduce the diameter or extend the axially of the pre-formed material storage section, so that the metal of the material segment itself in the pre-formed material storage section is transformed from a local storage state to a metal distribution that can be used for subsequent main body constraint forming; the main body constraint structure is used to limit the excessive outward expansion of the material segment metal to the outer periphery of the pole column body during the gradual compression forming process of the material segment; the negative tolerance sealing structure is used to perform interference scraping and sealing of the excess material on the outer periphery of the material segment when the material segment enters the corresponding station mold and undergoes plastic flow, and to close the flash generation channel at the forming gap.

3. The multi-station cold heading and fixed-length cutting system for new energy battery cell terminals according to claim 2, characterized in that, The multiple cold heading forming stations include a first pre-compression forming station, a second material storage pre-forming station, a third material replenishment and compression station, a fourth main body constraint forming station, and a fifth negative tolerance edge sealing forming station arranged sequentially along the material transfer direction; the cutting and waste separation station is the sixth station.

4. The multi-station cold heading and fixed-length cutting forming system for new energy battery cell terminals according to claim 3, characterized in that, The feeding and cutting mechanism includes a material rack, a pressure roller, a straightening roller, a feeding drive, and a cutting die. The pressure roller and the straightening roller are used to straighten the conductive metal wire, and the feeding drive is used to adjust the feeding length entering the cutting die according to the cutting length correction amount output by the margin feedback control unit.

5. The multi-station cold heading and fixed-length cutting system for new energy battery cell terminals according to claim 4, characterized in that, The margin feedback control unit includes a load detection component, a load comparison unit, and a cutting length correction unit. The load detection component is used to acquire the edge sealing load and / or the cutting load. The load comparison unit is used to compare the edge sealing load and / or the cutting load with a preset load range. The cutting length correction unit is used to correct the cutting length of the subsequent material segment based on the comparison result.

6. The multi-station cold heading and fixed-length cutting system for new energy battery cell terminals according to claim 5, characterized in that, When the edge sealing load and / or the cutting load are continuously higher than the preset load range, the cutting length correction unit reduces the cutting length of the subsequent material segment; when the edge sealing load and / or the cutting load are continuously lower than the preset load range, the cutting length correction unit increases the cutting length of the subsequent material segment.

7. The multi-station cold heading and fixed-length cutting system for new energy battery cell terminals according to claim 5 or 6, characterized in that, The negative tolerance edge sealing structure includes a negative tolerance scraping edge. An interference scraping gap is formed between the negative tolerance scraping edge and the forming entrance, forming edge or parting edge of the corresponding station mold. The interference scraping gap is used to scrape and seal the excess material on the outer periphery of the material segment when the material segment enters the corresponding station mold and undergoes plastic flow.

8. The multi-station cold heading and fixed-length cutting system for new energy battery cell terminals according to claim 7, characterized in that, The forming system also includes a synchronous lubrication unit, which includes an oil mist generator, a compressed air pipeline, a nozzle assembly, and a lubrication controller. The nozzle assembly is positioned toward the forming inlet, negative tolerance sealing structure, and / or main constraint structure of the station mold assembly. The lubrication controller is used to control the nozzle assembly to spray oil mist before or at the moment the material enters the corresponding station mold, so as to form a pressure-bearing lubricating film before the material undergoes plastic flow.

9. The multi-station cold heading and fixed-length cutting system for new energy battery cell terminals according to claim 8, characterized in that, The feeding and cutting mechanism also includes a material segment storage tank, which is disposed on the discharge side of the tangent die and located on the material picking path of the clamping and transferring mechanism, and is used to receive the material segments cut by the tangent die.

10. A method for multi-station cold heading and fixed-length cutting of new energy battery cell terminals, applied to the multi-station cold heading and fixed-length cutting system for new energy battery cell terminals according to claim 9, characterized in that, The forming method includes the following steps: S1. Feed, straighten, feed to a fixed length and cut the conductive metal wire to form a section for cold heading; S2. The material segment is sequentially transferred to multiple cold heading forming stations according to the preset spacing between adjacent stations by a clamping and transfer mechanism; S3. In the multiple cold heading forming stations, the material segment is sequentially pre-formed and stored, stored material is compressed and formed, main body is constrained and formed, and negative tolerance edge sealing and shaping is performed. S4. During the negative tolerance edge sealing process, the excess material on the outer periphery of the material section is subjected to interference scraping and edge sealing through the negative tolerance edge sealing structure, and the flash generation channel at the forming gap is closed. S5. In the cutting and waste separation station, the pole piece that has been gradually compressed and formed by multiple cold heading stations is cut off, and the pole piece is separated from the waste. S6. Collect the edge sealing load during the negative tolerance edge sealing and shaping process and / or the cutting load during the cutting and waste separation process, and identify the matching status between the material segment volume, the available metal allowance of the pre-formed storage section, the main body forming allowance, the negative tolerance edge sealing allowance and the cutting allowance based on the edge sealing load and / or cutting load. S7. Adjust the cutting length of the subsequent material section according to the matching state.

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