A method and system for controlling a punch forming process of a battery pole assembly

Abstract

The application provides a stamping forming process control method and system of a battery pole assembly. It belongs to the technical field of metal plastic working and battery manufacturing. The method comprises the following steps: performing signal denoising and feature extraction on collected element spectrum signals to generate an element composition original data set; performing element proportion statistics and distribution marking processing on the element composition original data set to generate a material micro-characteristics feature set; and through linkage adjustment of the material micro-characteristics and stamping parameters, the work hardening rate of different batches of aluminum coils is adapted, and the flatness compliance rate of the welding reference surface of the pole assembly is improved, and the fluctuation range of the springback amount of the stamping part is reduced.

Description

Technical Field

[0001] This invention proposes a method and system for controlling the stamping process of battery terminal assembly, belonging to the field of metal plastic processing and battery manufacturing technology. Background Technology

[0002] In the mass production of power battery terminal modules, the stamping process of the positive and negative terminals and connecting pieces directly determines the assembly accuracy of the battery module and the reliability of subsequent laser welding. Currently, this process generally adopts a progressive die stamping mode with fixed parameters. For soft aluminum materials, such as 1060 aluminum in the O state, batch fluctuations in the chemical composition directly change the work hardening rate. However, existing processes cannot adjust the stamping speed and blank holder force synchronously with batch differences in materials, resulting in the springback of stamped parts remaining unstable for a long time, making it difficult to meet the assembly requirement of weld gaps not exceeding 0.05mm.

[0003] In the field of stamping forming and precision control, the industry has made some technological explorations. Regarding springback control in aluminum alloy stamping, Shenzhen Xielida Precision Technology Co., Ltd.'s patent application for "High-Precision Aluminum Alloy Stamping Process and Die Design Method" (publication number CN120297047A) predicts material flow, springback, and stress distribution data based on experimental data of the aluminum alloy to be processed, simulates and compensates for springback in the die profile to manufacture the stamping die, and performs springback calibration on the stamped aluminum alloy. However, the core of this method lies in the die profile pre-compensation and offline springback calibration based on experimental data. It fails to solve the problem of dynamic drift in springback caused by batch fluctuations in material during actual stamping, and it also cannot correct the micron-level elastic flexural deformation generated by large progressive dies under high-tonnage stamping conditions in real time. Regarding the automatic stamping and forming of battery terminals, Ningbo Zhenyu Automation Technology Co., Ltd.'s patent application for "An Automatic Stamping and Forming Equipment for Terminals" (publication number CN119346731A) achieves automatic forming and stamping of terminal blanks through the coordinated operation of a first forming device, a conveying device, a transfer and screening device, a diversion and feeding device, and a second forming device. However, this solution focuses on the automated material flow and forming efficiency improvement among multiple devices. Its stamping and forming parameters are still based on preset values, lacking a compensation mechanism for dynamic deformation of the mold, and failing to establish real-time linkage between force, displacement, and other sensor signals and process parameters during the stamping process. In terms of online detection of stamping defects, related technical solutions propose an automatic detection device and method for stamped aluminum plates based on machine vision, achieving defect detection through a conveyor belt, light source, camera, industrial control computer, and server. However, such solutions are mostly offline sampling inspection modes after welding or stamping, with a long detection response cycle, which cannot match the online real-time response requirements of millisecond-level stamping cycles. Defects such as sticking to the die and micro-cracks generated during the stamping process of soft aluminum materials are difficult to be identified and intervened in a timely manner during the stamping process, which can easily lead to batch scrapping problems.

[0004] Meanwhile, under high-tonnage stamping conditions, large progressive dies will experience micron-level elastic flexural deformation. Traditional stamping equipment only locks the mechanical bottom dead center of the slide block, without incorporating the correction of dynamic die deformation. The thickness tolerance fluctuation of stamped parts exceeds the control threshold, directly affecting the uniformity control of subsequent electroplating layers. When stamping dissimilar aluminum composite materials, the yield strength and hardening index of the two materials do not match, and the deformation process is uncoordinated, easily leaving internal stress, directly reducing the peel strength compliance rate of subsequent laser welding. The existing stamping control system has not yet established a linkage between material microstructure, equipment dynamic response, and process parameter adjustment. The industry urgently needs a closed-loop stamping control scheme adapted for dissimilar aluminum composite pole components. Therefore, a method is urgently needed to simultaneously solve deep-seated problems such as real-time compensation of die elastic deformation, online identification of stamping defects, and coordinated control of dissimilar material deformation, while achieving adaptive adjustment of stamping speed and blank holder force, thus establishing a closed-loop control across the entire chain of materials, equipment, and processes. Summary of the Invention

[0005] This invention provides a method and system for controlling the stamping process of battery terminal assembly, in order to solve the problems mentioned in the background art above: This invention proposes a method for controlling the stamping process of a battery terminal assembly, the method comprising: S1. Online spectral acquisition and processing are performed on the 1060 aluminum O-state and 6061-T6 aluminum composite coils conveyed at the incoming material station. The acquired elemental spectral signals are denoised and feature extracted to generate a raw elemental composition dataset. The raw elemental composition dataset is then processed with elemental proportion statistics and distribution labeling. The impurity element proportion range, grain size distribution range, and material yield strength corresponding features are extracted from the data to generate a material microstructure feature set. S2. Perform work hardening rate matching processing on the material micro-property feature set, obtain the basic processing attributes of the corresponding batch of materials through the preset material property mapping rules, map the basic processing attributes to the preset process parameter initial matching system, and generate the initial process parameter set; perform historical production data association processing on the initial process parameter set of the same batch, supplement the parameter adaptation range under different stamping strokes, and generate the extended process parameter set. S3. Perform stamping instruction conversion processing on the extended process parameter set, converting the process requirements in the form of parameter adaptation range into continuous adjustment instructions that the press can execute, and generating a press operation instruction set; perform execution unit matching processing on the press operation instruction set, selecting the adjustment unit combination corresponding to the instruction set from the preset execution module library, and generating execution unit matching data; S4. Perform boundary delineation processing on the matching data of the execution unit, and limit the operating range of each adjustment unit by combining the material batch attributes, stamping stroke segment and pressure output range, and generate the operating boundary data of each adjustment unit; arrange the action timing of the operating boundary data of each adjustment unit to generate the unit action execution sequence data. S5. Perform dynamic compensation calculation on the unit action execution sequence data, combine historical mold deformation data and real-time pressure feedback signal to obtain the deformation correction value of the corresponding stamping station, and generate mold dynamic compensation data; perform bottom dead center position linkage adjustment on the mold dynamic compensation data to generate press slide real-time running trajectory data. S6. Perform multi-dimensional status acquisition and processing on the real-time running trajectory data of the press slide, and simultaneously acquire vibration signals, strip position signals and die closing pressure signals during the stamping process to generate a full status dataset of the stamping process; perform abnormal feature comparison processing on the full status dataset of the stamping process, and output the running status mark data of the corresponding station.

[0006] This invention proposes a stamping process control system for battery terminal assembly, the system comprising: One or more processors; Memory, used to store one or more programs; Wherein, when the one or more programs are executed by the one or more processors, the one or more processors are made to implement the method described in any one of the above.

[0007] The beneficial effects of this invention are as follows: By linking the microscopic properties of the material with the stamping parameters, the work hardening rate of different batches of aluminum coils is adapted, improving the flatness compliance rate of the welding reference surface of the pole assembly and reducing the fluctuation range of springback in the stamped parts. Real-time compensation of dynamic mold deformation corrects cavity position deviations under high-tonnage stamping, enhancing the stability of the thickness tolerance of the stamped parts and reducing unevenness in the thickness of subsequent electroplating layers. Synchronous monitoring of multiple signals throughout the stamping process promptly captures early characteristics of die sticking and micro-cracks, preventing defective parts from flowing into subsequent processes and avoiding batch scrap. Through the synergistic control of composite stamping of dissimilar materials, the deformation rhythm of the two types of aluminum materials is balanced, controlling the forming accuracy of the pole assembly and improving the peel strength of subsequent laser welding, thereby increasing the overall production yield of the stamping process. Attached Figure Description

[0008] Figure 1 This is a diagram illustrating the steps of the method described in this invention; Figure 2 This is a detailed flowchart of step S4 in this invention. Detailed Implementation

[0009] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0010] Example 1 One embodiment of the present invention, such as Figure 1 As shown, a method for controlling the stamping process of a battery terminal assembly is provided, the method comprising: S1. Online spectral acquisition and processing are performed on the 1060 aluminum O-state and 6061-T6 aluminum composite coils conveyed at the incoming material station. The acquired elemental spectral signals are denoised and feature extracted to generate a raw elemental composition dataset. The raw elemental composition dataset is then processed with elemental proportion statistics and distribution labeling. The impurity element proportion range, grain size distribution range, and material yield strength corresponding features are extracted from the data to generate a material microstructure feature set. S2. Perform work hardening rate matching processing on the material micro-property feature set, obtain the basic processing attributes of the corresponding batch of materials through the preset material property mapping rules, map the basic processing attributes to the preset process parameter initial matching system, and generate the initial process parameter set; perform historical production data association processing on the initial process parameter set of the same batch, supplement the parameter adaptation range under different stamping strokes, and generate the extended process parameter set. S3. Perform stamping instruction conversion processing on the extended process parameter set, converting the process requirements in the form of parameter adaptation range into continuous adjustment instructions that the press can execute, and generating a press operation instruction set; perform execution unit matching processing on the press operation instruction set, selecting the adjustment unit combination corresponding to the instruction set from the preset execution module library, and generating execution unit matching data; S4. Perform boundary delineation processing on the matching data of the execution unit, and limit the operating range of each adjustment unit by combining the material batch attributes, stamping stroke segment and pressure output range, and generate the operating boundary data of each adjustment unit; arrange the action timing of the operating boundary data of each adjustment unit to generate the unit action execution sequence data. S5. Perform dynamic compensation calculation on the unit action execution sequence data, combine historical mold deformation data and real-time pressure feedback signal to obtain the deformation correction value of the corresponding stamping station, and generate mold dynamic compensation data; perform bottom dead center position linkage adjustment on the mold dynamic compensation data to generate press slide real-time running trajectory data. S6. Perform multi-dimensional status acquisition and processing on the real-time running trajectory data of the press slide, and simultaneously acquire vibration signals, strip position signals and die closing pressure signals during the stamping process to generate a full status dataset of the stamping process; perform abnormal feature comparison processing on the full status dataset of the stamping process, and output the running status mark data of the corresponding station.

[0011] The working principle and effects of the above technical solution are as follows: By accurately detecting and analyzing the material of the composite aluminum material, the stamping processing characteristics of different batches of raw materials can be precisely adapted, effectively improving the dimensional accuracy and finished product consistency of the battery terminal assembly stamping. Through layered iterative optimization of stamping process parameters, the range of process parameter adaptation is broadened, adapting to the production and processing needs of multi-specification composite aluminum materials and improving the universal adaptability of the entire stamping process. By limiting the range and arranging the timing of the press adjustment unit, the operating status of the stamping equipment throughout the entire process is standardized, significantly reducing equipment operating deviations during stamping. Through dynamic compensation for die deformation and real-time adjustment of the slide trajectory, forming defects caused by die wear and material deformation are effectively reduced, avoiding the problem of decreased product qualification rate due to long-term accumulated errors. Through full-process operating condition monitoring and anomaly comparison marking, various operational anomalies in stamping production are captured in a timely manner, enhancing the stability and production fault tolerance of the entire stamping production process.

[0012] In one embodiment of the present invention, S1 includes: S11. Multiple sets of synchronous spectral acquisition probes are deployed along the transverse and longitudinal directions of the material roll. They follow the conveying speed of the material belt at a uniform speed to complete the continuous spectral scanning of the entire roll of composite aluminum material, retain complete spectral waveform records at different conveying rates, and summarize them to form the original spectral sampling total data. S12. A multi-level adaptive filtering algorithm is used to remove ambient light noise and electromagnetic interference from the transmission motor from the total sampled data, and to remove blank spectral segments without effective element information, leaving pure element response spectral sequences. S13. Perform three-dimensional feature decomposition on the pure element response spectral sequence: peak amplitude, peak offset, and spectral line half-width. Record all the decomposed numerical indicators into a structured storage unit to generate the original dataset of elemental composition. S14. Traverse all sampling point values ​​in the original dataset of elemental composition, and statistically analyze the percentage of aluminum matrix elements, trace alloy elements, and non-metallic impurity elements at each point. Mark the fluctuation range of each element according to the length of the roll. S15. Associate the spectral characteristics of each sampling point with the metallographic detection benchmark curve of the material, deduce the average grain size and grain size fluctuation range of the corresponding points, match the material yield strength range corresponding to the spectral values, and integrate all the derived indicators to generate a set of material microstructure characteristics.

[0013] The working principle and effects of the above technical solution are as follows: Through multi-dimensional continuous spectral scanning, comprehensive detection of the entire coil of composite aluminum material is achieved, eliminating the problem of missing material information caused by partial sampling and improving the completeness of raw material data acquisition. Multi-level adaptive filtering removes interference data generated by the external environment and equipment operation, reducing the impact of invalid and distorted spectral signals on material detection results and significantly improving the purity and reliability of spectral data. Multi-dimensional spectral feature decomposition and structured data organization standardize the statistical form of raw material element data, improving the regularity and accuracy of material composition data organization. Through segmented elemental proportion statistics and micro-parameter derivation, material differences at different locations on the coil are accurately captured. This allows for a comprehensive understanding of the aluminum material's compositional distribution and precise acquisition of core micro-characteristics such as grain size and strength, providing accurate data support for subsequent stamping process parameter adaptation and reducing forming defects caused by differences in incoming material.

[0014] In one embodiment of the present invention, S2 includes: S21. Extract three core indicators from the material's micro-characteristic set: grain size range, impurity ratio range, and yield strength range. Substitute these into the hardening rate calculation model to complete the full-domain calculation of the processing hardening rate of a single batch of composite aluminum materials and output a continuous hardening rate variation curve. S22. Compare the global hardening rate change curve with the built-in multilayer material property comparison table segment by segment to match and obtain the three basic processing properties of the material roll: ductility, resilience, and ultimate deformation threshold. S23. Fill the three types of basic processing attributes into the initial process parameter matching system consisting of the stamping pressure reference range, the strip feeding speed reference range, and the mold opening and closing buffer time reference range, respectively. After filling in the complete reference values, generate the initial process parameter set. S24. Retrieve complete past production storage records matching the material batch code, and extract parameter fluctuation records of composite material rolls of the same material and thickness in each stamping stroke segment of shallow stretching, deep forming, trimming, and shaping. S25. Overlay the historical parameter fluctuation range of each stroke segment onto the corresponding parameter entry in the initial process parameter set, expand the floating value range of each process parameter, and integrate all expanded entries to generate an extended process parameter set.

[0015] The working principle and effects of the above technical solution are as follows: By calculating the hardening rate across the entire microscopic core indicators of aluminum, the actual processing performance of a single batch of material is accurately matched, reducing processing deviations caused by adapting fixed process parameters to different material batches. By matching the hardening rate curve with the basic processing properties of the material, the initial configuration of process parameters is aligned with the deformation characteristics of the material itself, improving the degree of alignment and accuracy of the initial process parameters. By filling the process benchmark parameters according to the material processing properties, standardized initial process matching is completed, avoiding subjective errors and parameter omissions caused by manual parameter matching. By superimposing historical production parameter data for each stamping stroke, the range of process parameter adaptation is broadened, which can not only adapt to the processing requirements of different forming processes, but also improve the compatibility of process parameters with production conditions, effectively reducing stamping defects caused by batch material fluctuations, and improving the overall process adaptability and finished product stability of battery terminal stamping production.

[0016] In one embodiment of the present invention, step S3 includes: S31. Split all interval-type parameter entries in the extended process parameter set. The split entries include the stamping main pressure interval, feeding interval, slide descending speed interval, and buffer pressure relief duration interval. After splitting, they are converted into a segmented step-like numerical sequence. S32. Convert the segmented step-type numerical sequence into pulse level signals that can be recognized by the servo drive unit, hydraulic pressure regulating unit, and servo feeding unit, and connect all level signals in series according to the stamping process sequence to form a continuous adjustment command stream. S33. Divide the continuous adjustment instruction stream into independent instruction units according to the stamping process, bind the process execution timing mark and archive and store them uniformly, and summarize all archived instruction units to generate the press operation instruction set. S34. Analyze the drive adjustment type corresponding to each instruction in the press operation instruction set, distinguish the four major instruction categories of pressure adjustment, speed adjustment, position adjustment and duration adjustment, and extract the hardware adjustment function requirements required for each type of instruction. S35. Traverse all voltage regulation modules, speed regulation modules, positioning modules, and delay buffer modules in the locally stored execution module library, filter the module types that perfectly match the functional requirements, arrange the module combinations according to the process execution order, and record the module model and arrangement order to generate execution unit matching data.

[0017] The working principle and effects of the above technical solution are as follows: By segmenting and converting range-type process parameters into numerical values, broad process standards are transformed into refined numerical sequences, making stamping process control more precise and uniform, and reducing equipment operation fluctuations caused by excessively large parameter ranges. By converting process values ​​into equipment-recognizable level command signals, the execution barriers between process parameters and stamping equipment are broken down, improving the smoothness and accuracy of process parameter execution. By systematically archiving various adjustment commands according to processes, equipment operation commands are made more systematic and standardized, reducing the probability of command errors during multi-process alternating operations. By classifying and analyzing command adjustment types and matching corresponding functional modules, the hardware configuration is made to perfectly match actual production needs, avoiding processing errors caused by equipment module mismatches, improving the operational coordination accuracy of the entire stamping equipment, effectively enhancing the stability of process execution, and improving the overall yield level of battery terminal component stamping.

[0018] One embodiment of the present invention, such as Figure 2 As shown, S4 includes: S41. Retrieve all selected adjustment unit models in the execution unit matching data, retrieve the upper limit and lower limit of the rated output of the corresponding model hardware, and form the inherent numerical boundary benchmark of the hardware. S42. Retrieve the limit deformation threshold and crack resistance critical pressure value within the current composite material roll batch attributes, and combine the deformation difference of each stamping stroke segment in the entire process from shallow stretching to shaping to compress the invalid value segment within the inherent hardware boundary. S43. The stable output pressure range of the press hydraulic system is superimposed, and the maximum and minimum values ​​of the allowable output of each regulating unit are corrected again. A special safe operating range is defined for each type of regulating unit, and all range limits are summarized to generate the operating boundary data of each regulating unit. S44. Analyze the sequence of the complete stamping process and divide it into five continuous process nodes: material strip feeding, mold closing and pre-pressing, slide descent and forming, pressure relief and buffering, and mold opening and reset. S45. Bind the operating boundary data of each adjustment unit to the corresponding process node, mark the unit start time, continuous running time and stop exit time in each node, and string all the bound records together in chronological order to generate unit action execution sequence data.

[0019] The working principle and effects of the above technical solution are as follows: By progressively tightening the operating value range of each adjustment unit, redundant ranges in equipment hardware and ranges incompatible with operating conditions are eliminated, effectively reducing pressure and speed fluctuations during the stamping process. By combining material deformation characteristics with the hydraulic system's operating status to correct operating limits, the equipment's control range perfectly matches the aluminum forming requirements, reducing the probability of defects such as material cracking and forming deviation. By dividing standardized process nodes, the rhythm of the entire stamping operation is regulated, improving the chaotic connection between multiple processes. By deeply binding the operating boundaries of each unit with the process sequence, the start-up, shutdown, and running time of each equipment unit are precisely controlled. This ensures the control accuracy of each stamping process and makes the coordinated operation of the entire set of equipment more stable and orderly, significantly improving the consistency of stamping and forming, and effectively avoiding process deviations and product quality fluctuations caused by equipment exceeding limits.

[0020] In one embodiment of the present invention, S43 includes: S431. Collect the full-condition operating parameters of the hydraulic system of the press, record the pressure output values ​​of each working condition such as no-load standby, low-pressure pre-pressing, high-pressure forming, and pressure relief, organize the pressure fluctuation data under continuous working conditions, and generate a full-domain pressure operation dataset of the hydraulic system. S432. Filter stable pressure value segments within the entire pressure operation data with fluctuation amplitude below a preset threshold, eliminate abnormal data caused by instantaneous pressure shocks and oil circuit pressure fluctuations, and lock the pressure range in which the hydraulic system can output continuously and stably. S433. The hydraulic stable pressure range is superimposed and compared with the compressed hardware value range of each regulating unit. The maximum and minimum output values ​​of each regulating unit are corrected twice to eliminate the value range with insufficient adaptability to the working condition. S434. Combining the pressure bearing characteristics of composite aluminum stamping, and matching the pressure tolerance conditions of different forming processes, independent and dedicated safe operating ranges are defined for various adjustment units such as pressure adjustment, speed adjustment, and position adjustment. S435. Summarize the safe operating range values ​​of all adjustment units after correction, standardize them into a unified range record, and integrate all records to generate the operating boundary data of each adjustment unit.

[0021] The working principle and effects of the above technical solution are as follows: By collecting pressure data from the hydraulic system under all operating conditions, it comprehensively covers the operating status of each stage of stamping, compensating for the insufficient coverage caused by partial data collection and improving the comprehensiveness of pressure data statistics. By screening stable pressure values ​​and eliminating abnormal data, it reduces data interference caused by oil circuit vibration and instantaneous pressure shocks, making the pressure benchmark more closely match the actual stable operating state of the equipment. By superimposing hydraulic stability intervals to perform secondary correction on the values ​​of the adjustment units, it gradually eliminates operating sections with poor adaptability, significantly reducing the mismatch between equipment adjustment parameters and actual operating conditions. By combining the pressure-bearing characteristics of aluminum materials to divide exclusive operating intervals for different adjustment units, it adapts to the forming requirements of each stamping process, which not only eliminates forming defects caused by equipment exceeding limits, but also improves the precision of equipment adjustment, making stamping pressure control more stable and uniform, effectively reducing product dimensional deviations in mass production, and improving the overall quality stability of stamping forming.

[0022] In one embodiment of the present invention, S433 includes: Retrieve the hardware value ranges after the initial compression of each adjustment unit, collect the upper and lower limit parameters of the values ​​of various adjustment units, and generate the initial compression interval dataset of the units. The initial compression interval dataset of the unit is compared with the pressure interval of the hydraulic system's continuous and stable output by superimposing data dimension by dimension to complete the full interval numerical overlap verification and generate interval overlap comparison data. The unit value segments that exceed the hydraulic stable output range in the overlapping comparison data of the interval are investigated, and invalid value ranges that cannot be adapted to the stamping conditions are screened out to generate the initial screening data of the unit adaptation interval. Numerical accuracy calibration is performed on the initial screening data of the unit adaptation interval, the critical values ​​of the upper and lower limits of the output of each adjustment unit are fine-tuned, the secondary correction of the operating values ​​of all adjustment units is completed, and the unit-corrected interval data is generated.

[0023] The working principle and effects of the above technical solution are as follows: By aggregating the numerical ranges after the initial compression of each adjustment unit, the operating parameters of the equipment are uniformly summarized, improving the overall accuracy of parameter verification. Through multi-dimensional data overlay comparison and overlap verification, the differences in the compatibility between equipment parameters and the hydraulic system operating state are accurately identified, reducing parameter matching deviation problems. By screening out invalid numerical segments that do not meet the conditions for stable hydraulic output, all parameter ranges that are not suitable for actual stamping conditions are eliminated, reducing the probability of pressure fluctuations during equipment operation. Through refined calibration of critical values ​​in the calibration range, high-precision correction of the adjustment parameters is achieved, ensuring that the operating ranges of various adjustment units conform to the stable operating state of the equipment and adapt to the actual forming requirements of aluminum stamping, effectively improving the accuracy of equipment control, reducing stamping defects caused by parameter range deviations, and ensuring the dimensional uniformity and production stability of battery terminal products during mass production.

[0024] In one embodiment of the present invention, S45 includes: Collect the operational boundary data of each control unit, organize the pressure, velocity, and position numerical constraints corresponding to different control units, and generate a unit boundary collection dataset; The matching unit boundary aggregation dataset is matched with five preset process nodes, and the numerical constraints of various adjustment units are correspondingly embedded into each process operation link to generate process unit binding data. Collect the standard running time and node switching interval of each process node, record the start and stop time nodes of each adjustment unit in the corresponding process, and generate unit timing labeling data. Perform process node continuity verification on the unit time sequence annotation data, correct overlapping periods and idle periods of cross-process unit operation, and generate time sequence verification completion data; Based on the time progression of the stamping process, the timing annotations of all completed verifications are sequentially linked and integrated to generate unit action execution sequence data.

[0025] The working principle and effects of the above technical solution are as follows: By collecting and organizing the numerical constraints of various adjustment units, the operating parameters of the equipment are unified and standardized, improving the overall regularity of process parameter matching. By precisely binding boundary parameters to each stamping process, the control standards of different equipment units are made to match the operational needs of the corresponding production links, reducing processing deviations caused by parameter and process mismatches. By accurately recording the start-up and shutdown sequence of each unit and conducting continuity verification, the overlapping and idle problems in process connections are eliminated, avoiding stamping instability caused by equipment timing errors. By orderly integrating standardized timing content to form a complete execution sequence, the smoothness of the connection between each stamping process is ensured, and the overall operating rhythm of the equipment is unified, effectively enhancing the collaborative operation capability of the entire stamping equipment, reducing forming fluctuations in batch production, and continuously improving the consistency and production stability of battery terminal component stamping.

[0026] In one embodiment of the present invention, step S5 includes: S51. Disassemble the complete timing record of the molding process within the unit action execution sequence data, lock the complete running segment when the slider arrives at the mold forming area, and extract the reference output values ​​of the pressure adjustment unit and the position adjustment unit during this segment. S52. Retrieve the deformation offset archive record corresponding to the cumulative forming number of battery terminal stamping dies of the same specification, and distinguish between two types of long-term deformation values: punch wear offset and die springback deformation. S53. Collect the instantaneous pressure fluctuation values ​​of the forming stage transmitted back in real time by the hydraulic sensor of the press, and substitute the long-term deformation value and the instantaneous pressure fluctuation value into the compensation calculation model to solve the forming dimension deformation correction value for each station. S54. Match all deformation correction values ​​corresponding to punches and dies at each stamping station to the corresponding process timing nodes, mark the duration of the correction value's effect, and integrate all station correction records to generate dynamic mold compensation data. S55. Convert the internal dimension correction value of the mold dynamic compensation data into the longitudinal displacement increase or decrease value of the slider, and synchronously adjust the displacement values ​​of the slider downward acceleration section, uniform speed forming section, and buffer deceleration section. Connect the displacement change values ​​throughout the entire process to generate real-time running trajectory data of the press slider.

[0027] The working principle and effects of the above technical solution are as follows: By accurately extracting the equipment's baseline operating values ​​for the molding process, deformation compensation calculations are ensured to be based on the actual process operating conditions, reducing compensation errors caused by baseline parameter deviations. By distinguishing between long-term mold wear and springback deformation data, the performance changes caused by long-term mold use can be accurately captured, compensating for the shortcomings of fixed parameter compensation in adapting to mold wear. By combining real-time pressure fluctuations and historical deformation data to collaboratively calculate correction values, the compensation results are made to fit the actual working conditions of each stamping, improving the accuracy of deformation correction. By accurately matching the correction values ​​to the corresponding process time periods, the dynamic compensation is implemented in a timely and precise manner, avoiding molding anomalies caused by misaligned compensation timing. By converting the correction values ​​to optimize the slider's entire running trajectory, it can both offset dimensional deviations caused by mold wear and adapt to real-time stamping condition changes, effectively reducing dimensional consistency deviations in batch production, improving the stamping accuracy of battery terminals, and extending the effective service life of the mold.

[0028] In one embodiment of the present invention, S53 includes: Continuously collect high-frequency sampling signals from hydraulic sensors during the molding process, continuously record instantaneous pressure change values ​​throughout the molding process, and compile and organize the original dataset of pressure fluctuations during the molding stage. Data cleaning processing is performed on the original dataset of pressure fluctuations during the molding stage to remove abnormal values ​​caused by instantaneous interference from sensors and retain effective pressure fluctuation data that conforms to the actual operating state of the press. The punch wear offset and die springback deformation data obtained by S52 are collected and fused with the effective pressure fluctuation data to generate a comprehensive set of stamping forming deformation parameters. Import the stamping deformation comprehensive parameter set into the preset mold deformation compensation calculation model, complete the single-station deformation deviation quantification calculation, and generate single deformation calculation data for each stamping station. The deformation calculation data of each station is adapted and calibrated to match the station, and the deformation correction standard of multiple stations is unified. The forming dimension deformation correction values ​​of all stamping stations are output in batches.

[0029] The working principle and effects of the above technical solution are as follows: By acquiring pressure data throughout the entire forming process at high frequency, subtle pressure fluctuations in the stamping operation can be completely captured, improving the completeness of the working condition data acquisition. By cleaning and screening the raw pressure data, abnormal data caused by external interference is filtered out, ensuring that the pressure data used in the calculation closely matches the actual operating state of the equipment, reducing the interference of invalid data on compensation calculations. By integrating mold deformation data and real-time pressure data for comprehensive calculation, taking into account both long-term mold wear and differences in single stamping conditions, deformation determination is more closely aligned with actual production conditions. By quantifying deformation deviations at different workstations and unifying the correction standards across multiple workstations, compensation differences between different workstations are eliminated. This ensures the targeted nature of deformation corrections at each workstation while maintaining the overall parameter uniformity of production, effectively reducing product dimensional deviations caused by mold wear and pressure fluctuations, and steadily improving the dimensional accuracy and batch production consistency of battery terminal assembly stamping.

[0030] In one embodiment of the present invention, step S6 includes: S61. Vibration acquisition sensors, position grating sensors, and hydraulic pressure sensors are respectively installed along the press slide transmission mechanism, mold assembly base, and material belt conveyor rail, and the synchronous sampling program of all sensors is started simultaneously. S62. Divide the sampling time window according to each running segment in the real-time running trajectory data of the slider, and synchronously record three types of sampling information in each time window: vibration amplitude waveform, material strip grating displacement pulse, and instantaneous value of mold closing pressure. S63. Bind the three types of sampling information under different time windows to the corresponding stamping station code and process node code, and unify and standardize them into structured sampling records. All standardized records are merged to generate a full state dataset of the stamping process. S64. Retrieve the reference feature library for normal stamping conditions in the storage unit. The reference feature library contains three types of standard feature curves: standard vibration amplitude range, allowable strip offset range, and stable die closing pressure range. S65. For each workstation, the sampled information in the full state dataset of the stamping process is compared with the curve in the benchmark feature library segment by segment. Abnormal waveforms and abnormal values ​​that exceed the standard range are identified. Each workstation is marked with three categories: normal, slight deviation, and severe abnormality. The corresponding workstation's operating status label data is output.

[0031] The working principle and effects of the above technical solution are as follows: By simultaneously deploying three types of sensors at multiple locations and uniformly initiating the sampling process, vibration, displacement, and pressure information are collected simultaneously, compensating for the information gaps caused by single-dimensional monitoring and improving the completeness of stamping condition data collection. By dividing the sampling window according to the slide block running period, the collected data is precisely correlated with the stamping process, reducing identification errors caused by data mixing from different processes. By binding the workstation and process codes to organize all sampling records, a clear time-series full-process status dataset is formed, reducing the difficulty of finding the source of anomalies. By retrieving standardized operating condition characteristic curves for segmented comparison, various subtle numerical deviations are accurately captured, which can distinguish the severity of faults and identify potential equipment operation hazards in advance, preventing the continuous accumulation of minor operating condition anomalies from causing batch product defects. This simultaneously improves the speed of fault identification and quality control in the stamping production line, and reduces missed detections caused by manual inspections.

[0032] According to one embodiment of the present invention, a stamping process control system for a battery terminal assembly includes: One or more processors; Memory, used to store one or more programs; Wherein, when the one or more programs are executed by the one or more processors, the one or more processors are made to implement the method described in any one of the above.

[0033] Example 2 This embodiment further identifies the sources of anomalies and determines the compensation amount for the bottom dead center of the slider, the duration of compensation, and the conditions for exiting compensation for different sources of anomalies.

[0034] The method for controlling the stamping process of a battery terminal assembly described in this embodiment includes steps S1 to S7.

[0035] S1. Following the method described in Example 1, perform online spectral acquisition, signal denoising, feature extraction, and material microstructure identification on the composite material roll to generate a material microstructure feature set.

[0036] S2. Following the method described in Example 1, the work hardening rate and basic processing attributes are matched based on the material microstructure feature set, and historical production data of the same batch are associated to generate an extended process parameter set.

[0037] S3. Following the method described in Example 1, the extended process parameter set is converted into a press operation instruction set, and the corresponding adjustment unit is selected from the execution module library to generate execution unit matching data.

[0038] S4. Following the method described in Example 1, based on material properties, the rated output range of the adjustment unit, and the stable output range of the press hydraulic system, define the operating boundaries of each adjustment unit and form unit action execution sequence data.

[0039] S5. Following the method described in Example 1, combine the punch wear offset, die springback deformation, and instantaneous pressure fluctuation values ​​during the forming stage to generate dynamic compensation data for the mold and real-time running trajectory data of the press slide.

[0040] S6. Following the method described in Example 1, synchronously collect vibration amplitude waveform, strip grating displacement pulse and instantaneous value of die closing pressure to generate a full state dataset of the stamping process, and output the running status mark data of the corresponding stamping station.

[0041] S7. Based on the data obtained in steps S5 and S6, perform joint processing on the real-time pressure signal, slider position deviation, mold vibration signal, strip position offset, mold historical usage data, and stamping part size detection results after each compensation to identify the current source of the anomaly; determine whether the slider bottom dead point adjustment is allowed based on the source of the anomaly, and generate the slider bottom dead point compensation amount, compensation duration, and compensation exit conditions.

[0042] Step S7 includes steps S71 to S73.

[0043] S71. Determine the results of the structural anomaly characterization of the mold. The basic analysis cycle is based on a complete stamping stroke, and the corresponding sampling time windows are divided according to the process nodes in step S4: material feeding, mold closing pre-pressing, slide descent forming, pressure relief buffering, and mold opening reset.

[0044] Extract the instantaneous values ​​of the die-closing pressure at each stamping station within multiple consecutive stamping cycles, and compare them with the stable die-closing pressure range of the current composite roll and the corresponding stamping process. When the instantaneous value of the die-closing pressure exceeds the stable die-closing pressure range, record the start time, end time, direction of the pressure deviation, and the number of consecutive abnormal stamping cycles.

[0045] The persistence of pressure deviation is determined by its duration, proportion, and number of consecutive abnormal cycles within the slide's downward forming time window. A low persistence of pressure deviation occurs only at a single sampling point or within a single stamping cycle; a high persistence of pressure deviation occurs when it persists continuously across multiple stamping cycles and maintains a consistent direction.

[0046] Extract the vibration amplitude waveform within the same stamping cycle, determine the main vibration peak times during the mold closing pre-press, slide downward forming, and pressure relief buffering stages, and align the main vibration peak times with the downward acceleration segment, uniform forming segment, buffer deceleration segment, and bottom dead point dwell time in the real-time running trajectory data of the press slide.

[0047] When the main vibration peak appears in the same slider movement stage in multiple consecutive stamping cycles and the time offset relative to that movement stage remains stable, the phase consistency between the vibration signal and the slider movement stage is considered to be high; when the main vibration peak appears randomly in different movement stages, the phase consistency is considered to be low.

[0048] Retrieve the cumulative number of punches for the corresponding stamping station punch and compare it with the preset maintenance number of punches to determine the cumulative punching degree of the punch; retrieve the springback deformation record of the corresponding die in the historical production batches, and determine the historical springback trend of the die based on whether the springback deformation changes continuously in the same direction.

[0049] Further analysis of the operational status data of each stamping station determines whether the anomaly is permanently fixed at the same stamping station. When the anomaly occurs continuously at the same stamping station and does not migrate to subsequent stamping stations along the material feed direction, the degree of station-fixed anomaly is relatively high; when the anomaly appears sequentially at different stamping stations along the material feed, the degree of station-fixed anomaly is relatively low.

[0050] The duration of pressure deviation, the phase consistency between vibration signal and slider movement stage, the cumulative punching degree of punch, the historical springback trend of die and the duration of abnormal fixed position are standardized and fused according to the preset influence degree to obtain the structural anomaly characterization results of the mold.

[0051] Among them, the longer the pressure deviation lasts, the more stable the correspondence between the vibration peak and the slide movement stage, the closer the cumulative punching number of the punch is to the preset maintenance punching number, the more obvious the long-term change trend of the die springback deformation, and the longer the abnormality is fixed in the same punching station, the higher the mold structural abnormality characterization result.

[0052] When the structural anomaly characterization results of the mold meet the preset judgment conditions, and the cumulative stamping degree of the punch, the historical springback trend of the die, and the persistence of the abnormal fixed position are all high, the source of the anomaly is initially identified as long-term wear of the mold.

[0053] When the structural anomaly characterization results of the mold meet the preset judgment conditions, but the cumulative stamping degree of the punch and the historical springback trend of the die are low, and the slider position deviation and vibration amplitude increase with the pressure increase in the high-pressure forming stage and decrease after pressure relief, the source of the anomaly is initially identified as the elastic deflection of the mold.

[0054] S72. Determine the characterization results of non-structural disturbances. Continue to call the pressure deviation duration and the phase consistency between the vibration signal and the slider movement stage determined in step S71, and further extract the pressure deviation change slope, the material strip position offset, the abnormal propagation sequence, and the degree of non-convergence of the dimensional deviation after each compensation.

[0055] Based on the continuous sampling values ​​of the hydraulic pressure sensor, the rate of change of the pressure deviation when it enters the abnormal range from the stable mold closing pressure range is determined. When the pressure value rises or falls rapidly in a short period of time and recovers within one or a few stamping cycles, the slope of the pressure deviation change is high; when the pressure value deviates slowly from the stable mold closing pressure range and continues for several stamping cycles, the slope of the pressure deviation change is low.

[0056] Based on the strip grating displacement pulses output by the position grating sensor, the deviation between the actual stop position of the strip and the preset stop position after each feeding is determined. Based on the magnitude of the deviation, the direction of the deviation, and the consistency of the deviation direction within multiple consecutive stamping cycles, the degree of strip position offset is determined.

[0057] An anomaly propagation record is established based on the generation time of the operation status marker data of different stamping stations and the stamping station code. When an anomaly first appears at the front stamping station and then appears sequentially at subsequent stamping stations according to the material conveying direction, and the propagation interval corresponds to the number of stamping cycles required for the material conveyor to move from one stamping station to the next, the anomaly propagation sequence is considered to have a high degree of matching with the material conveying sequence.

[0058] Retrieve the dynamic compensation data of the mold generated in step S5 and the dimensional inspection results of the stamped parts after compensation. When the dimensional deviation gradually decreases after compensation and there is no reversal of the deviation direction, the degree of convergence of the dimensional deviation is relatively high; when the dimensional deviation remains unchanged, continues to increase, or changes to the opposite direction after compensation, the degree of non-convergence of the dimensional deviation is relatively high.

[0059] The following parameters are standardized: the duration of pressure deviation, the phase consistency between vibration signal and slider movement stage, the slope of pressure deviation change, the degree of material belt position offset, the degree of matching between abnormal propagation sequence and material belt conveying sequence, and the degree of non-convergence of dimensional deviation. They are then fused according to the preset influence level to obtain the non-structural disturbance characterization results.

[0060] Among them, the more sudden the pressure deviation change, the weaker the stable correspondence between the vibration peak and the slider movement stage, the more obvious the material belt position deviation, the more the anomaly conforms to the characteristics of propagation along the material belt conveying direction, or the less convergent the dimensional deviation after each slider bottom dead point compensation, the higher the non-structural disturbance characterization result.

[0061] When the non-structural disturbance characterization results meet the preset judgment conditions, the pressure deviation change slope is high, the pressure deviation duration is low, the material belt position deviation is low, and the anomaly does not propagate along the material belt conveying direction, the source of the anomaly is initially identified as a hydraulic instantaneous impact.

[0062] When the non-structural disturbance characterization results meet the preset judgment conditions, the material strip position deviation is high, the abnormal propagation sequence matches the material strip conveying sequence to a high degree, and the same abnormality appears sequentially in multiple stamping stations along the material strip feeding direction, the abnormality source is initially identified as material strip feeding deviation.

[0063] When there is a lack of temporal consistency between the pressure signal, slider position deviation, and mold vibration signal, and the anomaly is neither fixed at the same stamping station nor propagates along the material conveying direction, and the actual size of the stamped part remains within the allowable range, the source of the anomaly is initially identified as transient interference from the sensor.

[0064] For transient sensor interference, the abnormal sampling point is further compared with the adjacent sampling points before and after it. When a single sampling point experiences a sudden change, while the adjacent sampling points before and after it are all within the normal range, and other types of sensors do not detect the corresponding abnormality within the same sampling time window, the sampling point is marked as an invalid sampling point.

[0065] S73. Generate an exception handling result set The structural anomaly characterization results of the mold obtained in step S71 are compared with the non-structural disturbance characterization results obtained in step S72, and the anomaly sources are identified to determine the bottom dead center compensation authority of the corresponding stamping station.

[0066] When the source of the anomaly is long-term wear of the mold or elastic deflection of the mold, set the slider bottom dead center compensation permission to the enabled state; when the source of the anomaly is hydraulic instantaneous impact, material strip feeding deviation or sensor instantaneous interference, set the slider bottom dead center compensation permission to the disabled state.

[0067] When the slider bottom dead center compensation permission is enabled, the compensation requirement is determined based on the mold structural anomaly characterization results, and the compensation requirement is suppressed and corrected based on the non-structural disturbance characterization results. The higher the mold structural anomaly characterization result, the higher the slider bottom dead center compensation requirement; the higher the non-structural disturbance characterization result, the more likely the current anomaly is affected by hydraulic, feeding, or sensor anomalies simultaneously, and the slider bottom dead center compensation amount is reduced accordingly.

[0068] The compensation direction is determined based on the actual dimensional deviation of the stamped part. When the dimensional deviation of the stamped part indicates that the slider forming stroke is insufficient, compensation is implemented in the direction of increasing the effective forming stroke; when the dimensional deviation of the stamped part indicates that the slider forming stroke is excessive, compensation is implemented in the direction of decreasing the effective forming stroke.

[0069] Based on the results of mold structural anomaly characterization, non-structural disturbance characterization, stamping part dimensional deviation direction, preset base bottom dead center compensation amount, and position adjustment unit operating boundary, the bottom dead center compensation amount of the slider is determined. The compensation amount must not exceed the safe operating range of the position adjustment unit and the maximum permissible bottom dead center compensation amount determined in step S4.

[0070] The compensation duration was determined based on the source of the anomaly and the results of the two characterization methods. The compensation duration corresponding to long-term mold wear was longer than that corresponding to elastic mold deflection; the higher the characterization result of the non-structural disturbance, the shorter the compensation duration, and the longer the observation period after compensation was correspondingly extended.

[0071] The compensation exit condition is determined based on the allowable dimensional deviation range of the stamped part, the change in dimensional deviation after compensation, and the changes in the two characterization results. When the dimensional deviation of the stamped part is within the allowable range for several consecutive stamping cycles, the characterization result of the mold structural anomaly drops below the preset release condition, and the dimensional deviation has not reversed direction, the current compensation is terminated.

[0072] For long-term mold wear, a graded incremental method is used to apply the bottom dead center compensation amount to the slide block. Each time, a preset compensation level is added, and a preset number of stamping cycles are run at that compensation level. When the dimensional deviation decreases in the expected direction, the current compensation amount is maintained or the next compensation level is entered; when the dimensional deviation does not decrease, continues to increase, or reverses direction, the compensation amount is stopped, and the process returns to the previous effective compensation level.

[0073] For mold elastic deflection, the bottom dead center compensation of the slider is limited to the slider downward forming stage or a small number of continuous stamping cycles, and is gradually removed during the pressure relief and buffering stage. When the mold closing pressure returns to the stable mold closing pressure range, the slider position deviation returns to the allowable range, and the abnormal vibration phase relationship disappears, the compensation is removed.

[0074] For hydraulic instantaneous impact, the compensation amount of the bottom dead center of the slide is kept to zero, the real-time running trajectory of the press slide is maintained as the most recent stable one, the pressure switching process is adjusted through the hydraulic pressure regulating unit, and the buffer pressure relief time is adjusted through the delay buffer module.

[0075] For material strip feeding deviation, the bottom dead center compensation of the slider is kept at zero, and the servo feeding unit is controlled to correct the feeding amount of subsequent stamping cycles based on the material strip position deviation direction and deviation amount detected by the position grating sensor.

[0076] For instantaneous sensor interference, the slider bottom dead center compensation is kept at zero, the corresponding abnormal sampling point is marked as an invalid sampling point, and valid data in adjacent sampling time windows and sampling data from other types of sensors in the same time window are called for cross-validation.

[0077] To prevent repeated switching of the compensation direction, a compensation direction locking period is set after the bottom dead center compensation of the slide block is initiated. During the compensation direction locking period, the compensation direction will not be changed immediately due to changes in the dimensional deviation direction of a single stamping cycle. Only when the dimensional deviation exceeds the allowable range in the opposite direction for multiple consecutive stamping cycles, and the re-determined mold structural anomaly characterization result still meets the preset judgment conditions, will the original compensation direction be released and a new compensation direction be determined.

[0078] To prevent overcompensation, the single slide bottom dead center compensation amount, the cumulative slide bottom dead center compensation amount, and the compensation duration are jointly limited. When any parameter reaches the operating boundary of the position adjustment unit determined in step S4, the compensation amount is stopped from increasing further, and a mold inspection prompt for the corresponding stamping station is output.

[0079] In one specific implementation, an eight-station progressive die is used to continuously stamp 1060 aluminum O state and 6061-T6 aluminum composite coils. The most recent forty stamping cycles are used as the rolling analysis interval to simultaneously acquire the instantaneous values ​​of die closing pressure, vibration amplitude waveform, strip grating displacement pulse and slider position data of each stamping station.

[0080] During continuous stamping, the mold closing pressure of the fourth stamping station is continuously higher than the stable mold closing pressure range. The pressure deviation mainly occurs in the uniform forming section of the slide and continues for multiple stamping cycles. The main vibration peaks occur continuously at the same time position before the slide reaches the bottom dead center.

[0081] Meanwhile, the cumulative number of punches for the corresponding punch has approached the preset maintenance number of punches, and the historical springback deformation of the die has been increasing in the same direction in recent production batches, and has been abnormally and continuously fixed at the fourth stamping station, without spreading with the material feed direction.

[0082] Step S71 determines a higher mold structural anomaly characterization result based on the above data. Step S72 further determines that the pressure deviation change is relatively slow, the strip position offset is within the allowable range, the anomaly does not propagate in the strip conveying direction, and after the previous small-amplitude compensation, the stamping part dimensional deviation decreases in the expected direction, thus determining a lower non-structural disturbance characterization result.

[0083] Step S73 identifies the anomaly as long-term mold wear and sets the slider bottom dead center compensation permission of the fourth stamping station to the enabled state. The control system increases the slider bottom dead center compensation amount in stages along the direction of increasing effective forming stroke according to the direction of the stamped part dimensional deviation. After each compensation level runs for ten stamping cycles, the dimensional deviation of the welding reference surface of the stamped part is re-checked.

[0084] After the current two compensation levels are running, if the dimensional deviation of the stamped part decreases continuously and there is no reversal of direction, the current compensation direction is maintained and the operation continues; when the dimensional deviation of the stamped part is within the allowable range for multiple consecutive stamping cycles, and the result of the mold structural abnormality characterization drops below the preset release condition, the slider bottom dead point compensation is removed step by step, and the punch maintenance prompt of the fourth stamping station is output.

[0085] If the dimensional deviation of the stamped part stops decreasing, continues to increase, or reverses direction during the compensation process, the compensation amount is stopped, the compensation amount is rolled back to the previous effective compensation level, and steps S71 to S73 are re-executed to determine whether the current anomaly is simultaneously affected by hydraulic instantaneous impact, material belt feeding deviation, or sensor instantaneous interference.

[0086] The above technical solution, based on the existing data acquisition and compensation control link in Embodiment 1, further correlates the dynamic compensation data of the mold generated in step S5 and the full state dataset of the stamping process generated in step S6, without the need to add an independent data acquisition device.

[0087] By combining the duration of pressure deviation and the phase consistency between vibration signal and slider movement stage in the analysis of mold structural anomalies and non-structural disturbances, and further combining the cumulative punching times of punch, historical springback trend of die, strip position offset, anomaly propagation sequence and dimensional deviation changes after each compensation, it is possible to distinguish between long-term mold wear, mold elastic deflection, hydraulic instantaneous impact, strip feeding offset and sensor instantaneous interference.

[0088] By directly using the source of the anomaly to determine the bottom dead center compensation authority of the slider, and by jointly controlling the compensation amount, the duration of the compensation, and the conditions for exiting the compensation, it is possible to reduce erroneous compensation caused by non-mold anomalies, avoid the continuous increase of the compensation amount and repeated switching of the compensation direction, and improve the dimensional stability and forming consistency of the battery terminal assembly during continuous stamping.

[0089] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. A method for controlling the stamping process of a battery terminal assembly, characterized in that, The method includes: S1. Perform signal denoising and feature extraction on the collected elemental spectral signals to generate the original elemental composition dataset; perform elemental proportion statistics and distribution labeling on the original elemental composition dataset to generate a material microstructure feature set; S2. Perform work hardening rate matching processing on the material microstructure feature set, obtain the basic processing attributes of the corresponding batch of materials through the preset material property mapping rules, map the basic processing attributes to the preset process parameter initial matching system, and generate the initial process parameter set; perform historical production data association processing on the initial process parameter set of the same batch to generate the extended process parameter set. S3. Perform stamping instruction conversion processing on the extended process parameter set, converting the process requirements in the form of parameter adaptation range into continuous adjustment instructions that the press can execute, and generating a press operation instruction set; perform execution unit matching processing on the press operation instruction set, selecting the adjustment unit combination corresponding to the instruction set from the preset execution module library, and generating execution unit matching data; S4. Perform boundary delineation processing on the matching data of the execution units to generate the operating boundary data of each adjustment unit; perform action timing arrangement on the operating boundary data of each adjustment unit to generate unit action execution sequence data. S5. Perform dynamic compensation calculation on the unit action execution sequence data, combine historical mold deformation data and real-time pressure feedback signal to obtain the deformation correction value of the corresponding stamping station, and generate mold dynamic compensation data; perform bottom dead center position linkage adjustment on the mold dynamic compensation data to generate press slide real-time running trajectory data. S6. Perform multi-dimensional status acquisition and processing on the real-time running trajectory data of the press slide to generate a full status dataset of the stamping process; perform anomaly feature comparison processing on the full status dataset of the stamping process and output the running status marker data of the corresponding workstation.

2. The method for controlling the stamping process of a battery terminal assembly according to claim 1, characterized in that, S1 includes: S11. Multiple sets of synchronous spectral acquisition probes are deployed along the transverse and longitudinal directions of the material roll. They follow the conveying speed of the material belt at a uniform speed to complete the continuous spectral scanning of the entire roll of composite aluminum material, retain complete spectral waveform records at different conveying rates, and summarize them to form the original spectral sampling total data. S12. A multi-level adaptive filtering algorithm is used to remove ambient light noise and electromagnetic interference from the transmission motor from the total sampled data, and to remove blank spectral segments without effective element information, leaving pure element response spectral sequences. S13. Perform three-dimensional feature decomposition on the pure element response spectral sequence: peak amplitude, peak offset, and spectral line half-width. Record all the decomposed numerical indicators into a structured storage unit to generate the original dataset of elemental composition. S14. Traverse all sampling point values ​​in the original dataset of elemental composition, and statistically analyze the percentage of aluminum matrix elements, trace alloy elements, and non-metallic impurity elements at each point. Mark the fluctuation range of each element according to the length of the roll. S15. Associate the spectral characteristics of each sampling point with the metallographic detection benchmark curve of the material, deduce the average grain size and grain size fluctuation range of the corresponding points, match the material yield strength range corresponding to the spectral values, and integrate all the derived indicators to generate a set of material microstructure characteristics.

3. The method for controlling the stamping process of a battery terminal assembly according to claim 1, characterized in that, The S2 includes: S21. Extract three core indicators from the material's micro-characteristic set: grain size range, impurity ratio range, and yield strength range. Substitute these into the hardening rate calculation model to complete the full-domain calculation of the processing hardening rate of a single batch of composite aluminum materials and output a continuous hardening rate variation curve. S22. Compare the global hardening rate change curve with the built-in multilayer material property comparison table segment by segment to match and obtain the three basic processing properties of the material roll: ductility, resilience, and ultimate deformation threshold. S23. Fill the three types of basic processing attributes into the initial process parameter matching system consisting of the stamping pressure reference range, the strip feeding speed reference range, and the mold opening and closing buffer time reference range, respectively. After filling in the complete reference values, generate the initial process parameter set. S24. Retrieve complete past production storage records matching the material batch code, and extract parameter fluctuation records of composite material rolls of the same material and thickness in each stamping stroke segment of shallow stretching, deep forming, trimming, and shaping. S25. Overlay the historical parameter fluctuation range of each stroke segment onto the corresponding parameter entry in the initial process parameter set, expand the floating value range of each process parameter, and integrate all expanded entries to generate an extended process parameter set.

4. The method for controlling the stamping process of a battery terminal assembly according to claim 1, characterized in that, The S3 includes: S31. Split all interval-type parameter entries in the extended process parameter set. The split entries include the stamping main pressure interval, feeding interval, slide descending speed interval, and buffer pressure relief duration interval. After splitting, they are converted into a segmented step-like numerical sequence. S32. Convert the segmented step-type numerical sequence into pulse level signals that can be recognized by the servo drive unit, hydraulic pressure regulating unit, and servo feeding unit, and connect all level signals in series according to the stamping process sequence to form a continuous adjustment command stream. S33. Divide the continuous adjustment instruction stream into independent instruction units according to the stamping process, bind the process execution timing mark and archive and store them uniformly, and summarize all archived instruction units to generate the press operation instruction set. S34. Analyze the drive adjustment type corresponding to each instruction in the press operation instruction set, distinguish the four major instruction categories of pressure adjustment, speed adjustment, position adjustment and duration adjustment, and extract the hardware adjustment function requirements required for each type of instruction. S35. Traverse all voltage regulation modules, speed regulation modules, positioning modules, and delay buffer modules in the locally stored execution module library, filter the module types that perfectly match the functional requirements, arrange the module combinations according to the process execution order, and record the module model and arrangement order to generate execution unit matching data.

5. The method for controlling the stamping process of a battery terminal assembly according to claim 1, characterized in that, The S4 includes: S41. Retrieve all selected adjustment unit models in the execution unit matching data, retrieve the upper limit and lower limit of the rated output of the corresponding model hardware, and form the inherent numerical boundary benchmark of the hardware. S42. Retrieve the limit deformation threshold and crack resistance critical pressure value within the current composite material roll batch attributes, and combine the deformation difference of each stamping stroke segment in the entire process from shallow stretching to shaping to compress the invalid value segment within the inherent hardware boundary. S43. The stable output pressure range of the press hydraulic system is superimposed, and the maximum and minimum allowable output values ​​of each regulating unit are corrected again. A special safe operating range is defined for each type of regulating unit, and all range limits are summarized to generate the operating boundary data of each regulating unit. S44. Analyze the sequence of the complete stamping process and divide it into five continuous process nodes: material strip feeding, mold closing and pre-pressing, slide descent forming, pressure relief and buffering, and mold opening and reset. S45. Bind the operating boundary data of each adjustment unit to the corresponding process node, mark the unit start time, continuous running time and stop exit time in each node, and string all the bound records together in chronological order to generate unit action execution sequence data.

6. The method for controlling the stamping process of a battery terminal assembly according to claim 5, characterized in that, S43 includes: S431. Collect the full-condition operating parameters of the hydraulic system of the press, record the pressure output values ​​of each working condition such as no-load standby, low-pressure pre-pressing, high-pressure forming, and pressure relief, organize the pressure fluctuation data under continuous working conditions, and generate a full-domain pressure operation dataset of the hydraulic system. S432. Filter out stable pressure value segments with fluctuation amplitudes below a preset threshold within the entire pressure operation data, eliminate abnormal data caused by instantaneous pressure shocks and oil circuit pressure fluctuations, and lock in the pressure range for sustainable and stable output of the hydraulic system. S433. The hydraulic stable pressure range is superimposed and compared with the compressed hardware value range of each regulating unit. The maximum and minimum output values ​​of each regulating unit are corrected twice, and the value range with insufficient adaptability to the working condition is eliminated. S434. Combining the pressure bearing characteristics of composite aluminum stamping, and matching the pressure tolerance conditions of different forming processes, independent and dedicated safe operating ranges are defined for various adjustment units such as pressure adjustment, speed adjustment, and position adjustment. S435. Summarize the safe operating range values ​​of all adjustment units after correction, standardize them into a unified range record, and integrate all records to generate the operating boundary data of each adjustment unit.

7. The method for controlling the stamping process of a battery terminal assembly according to claim 6, characterized in that, S433 includes: Retrieve the hardware value ranges after the initial compression of each adjustment unit, collect the upper and lower limit parameters of the values ​​of various adjustment units, and generate the initial compression interval dataset of the units. The initial compression interval dataset of the unit is compared with the pressure interval of the hydraulic system's continuous and stable output by superimposing data dimension by dimension to complete the full interval numerical overlap verification and generate interval overlap comparison data. Check the overlapping comparison data of the intervals to find the unit value segments that exceed the stable hydraulic output range, filter out the invalid value ranges that cannot be adapted to the stamping conditions, and generate the initial screening data of the unit adaptation interval. Numerical accuracy calibration is performed on the initial screening data of the unit adaptation interval, the critical values ​​of the upper and lower limits of the output of each adjustment unit are fine-tuned, the secondary correction of the operating values ​​of all adjustment units is completed, and the unit-corrected interval data is generated.

8. The method for controlling the stamping process of a battery terminal assembly according to claim 1, characterized in that, The S5 includes: S51. Disassemble the complete timing record of the molding process within the unit action execution sequence data, lock the complete running period when the slider arrives at the mold forming area, and extract the reference output values ​​of the pressure adjustment unit and the position adjustment unit during this period. S52. Retrieve the deformation offset archive record corresponding to the cumulative forming number of battery terminal stamping dies of the same specification, and distinguish between two types of long-term deformation values: punch wear offset and die springback deformation. S53. Collect the instantaneous pressure fluctuation values ​​of the forming stage transmitted back in real time by the hydraulic sensor of the press, and substitute the long-term deformation value and the instantaneous pressure fluctuation value into the compensation calculation model to solve the forming dimension deformation correction value for each station. S54. Match all deformation correction values ​​corresponding to punches and dies at each stamping station to the corresponding process timing nodes, mark the duration of the correction value's effect, and integrate all station correction records to generate dynamic mold compensation data. S55. Convert the internal dimension correction value of the mold dynamic compensation data into the longitudinal displacement increase or decrease value of the slider, and synchronously adjust the displacement values ​​of the slider downward acceleration section, uniform speed forming section, and buffer deceleration section. Connect the displacement change values ​​throughout the entire process to generate real-time running trajectory data of the press slider.

9. The method for controlling the stamping process of a battery terminal assembly according to claim 1, characterized in that, The S6 includes: S61. Vibration acquisition sensors, position grating sensors, and hydraulic pressure sensors are respectively installed along the press slide transmission mechanism, mold assembly base, and material belt conveyor rail, and the synchronous sampling program of all sensors is started simultaneously. S62. Divide the sampling time window according to each running segment in the real-time running trajectory data of the slider, and synchronously record three types of sampling information in each time window: vibration amplitude waveform, material strip grating displacement pulse, and instantaneous value of mold closing pressure. S63. Bind the three types of sampling information under different time windows to the corresponding stamping station code and process node code, and unify and standardize them into structured sampling records. All standardized records are merged to generate a full state dataset of the stamping process. S64. Retrieve the normal stamping condition reference feature library in the storage unit. The reference feature library contains three types of standard feature curves: standard vibration amplitude range, allowable strip offset range, and stable die closing pressure range. S65. For each workstation, the sampled information in the full state dataset of the stamping process is compared with the curve in the benchmark feature library segment by segment. Abnormal waveforms and abnormal values ​​that exceed the standard range are identified. Each workstation is marked with three categories: normal, slight deviation, and severe abnormality. The corresponding workstation's operating status label data is output.

10. A stamping process control system for a battery terminal assembly, characterized in that, The system includes: One or more processors; Memory, used to store one or more programs; Wherein, when the one or more programs are executed by the one or more processors, the one or more processors implement the method of any one of claims 1 to 9.

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