A forming device for carbon brush holder machining

Abstract

The utility model discloses a kind of forming devices for carbon brush holder processing, it is related to the technical field of forming technology field, including: compression molding mechanism, including the upper die assembly and lower die assembly of being oppositely arranged, upper die assembly includes carbon brush holder male die, lower die assembly includes carbon brush holder female die;Demoulding mechanism, including demoulding cylinder and demoulding assembly;Pushing mechanism, for pushing out the carbon brush holder that demoulding assembly ejects from between upper die assembly and lower die assembly;Heating furnace, for heating carbon brush holder blank;Mechanical arm, for carrying carbon brush holder blank heated by heating furnace into carbon brush holder female die, and for carrying the carbon brush holder that pushing mechanism pushes out to conveying line.The device integrates multiple key production links such as compression molding, demoulding, pushing, heating and transporting and mould cooling in an overall system, closely links between each link, collaborative operation.

Description

Technical Field

[0001] This utility model relates to the field of molding technology, specifically to a molding device for processing carbon brush holders. Background Technology

[0002] In the manufacturing process of carbon brush holders, the forming process is a crucial step, as its quality and efficiency directly affect the performance of the brush holder and the subsequent use of the product. Traditional carbon brush holder forming methods often have many problems.

[0003] In terms of molding processes, traditional molding equipment has relatively limited functionality, generally only possessing simple pressing and molding capabilities, and lacking comprehensive supporting mechanisms. For example, after pressing and molding, the carbon brush holder tends to adhere tightly to the mold, making demolding difficult and inefficient. Demolding often requires manual assistance with tools, which not only consumes a significant amount of manpower but also increases the labor intensity of operators and reduces production efficiency. Furthermore, after demolding, removing the carbon brush holder from the mold and transporting it to the next process is also cumbersome, usually requiring manual handling. This not only increases operation time but also risks damage to the carbon brush holder during transport due to human error, affecting product quality.

[0004] In the heating and handling stages, the traditional processing method suffers from insufficient coordination between heating the carbon brush holder blank and the pressing and forming process. The heated carbon brush holder blank needs to be manually removed from the heating furnace and placed into the mold. This process is not only inefficient but also prone to temperature fluctuations due to improper manual operation, which can affect the quality of the pressing and forming. Furthermore, the process of transporting the pressed carbon brush holder to the conveyor line lacks automation, increasing production complexity and costs.

[0005] Furthermore, traditional molding equipment often lacks an effective cooling system for mold cooling. During continuous pressing, the mold temperature rises due to repeated heating. If not cooled in time, this can lead to thermal deformation, affecting the molding accuracy of the carbon brush holder and potentially shortening the mold's lifespan, thus increasing production costs. Moreover, the lack of a proper cooling mechanism results in relatively high energy consumption during production, hindering energy conservation, emission reduction, and the sustainable development of enterprises.

[0006] In summary, existing carbon brush holder forming methods have shortcomings in multiple stages, including demolding, material pushing, heating and handling, and cooling, making it difficult to meet the requirements of modern industrial production for high efficiency, high quality, and low cost. Therefore, developing a new forming device for carbon brush holder processing is of significant practical importance. Utility Model Content

[0007] This invention addresses the aforementioned technical problems in the molding process of carbon brush holders, including demolding, material pushing, heating and handling, and mold cooling. It proposes a novel molding device for carbon brush holders to achieve efficient, high-quality, and low-cost production of carbon brush holders.

[0008] To achieve the above objectives, this utility model provides the following technical solution:

[0009] A forming apparatus for carbon brush holder processing, comprising:

[0010] The pressing and forming mechanism includes an upper mold assembly and a lower mold assembly arranged opposite each other. The upper mold assembly includes a carbon brush holder punch, and the lower mold assembly includes a carbon brush holder die.

[0011] Demolding mechanism, including demolding cylinder and demolding assembly;

[0012] A pushing mechanism is used to push the carbon brush holder ejected by the demolding component out from between the upper mold assembly and the lower mold assembly;

[0013] A heating furnace used to heat carbon brush holder blanks;

[0014] A robotic arm is used to transport the carbon brush holder blank heated by the heating furnace into the carbon brush holder die, and to transport the carbon brush holder pushed out by the pushing mechanism to the conveyor line.

[0015] Furthermore, the demolding assembly includes a push plate connected to the piston rod of the demolding cylinder and a plurality of pusher pins mounted on the top of the push plate, wherein the pusher pins are slidably engaged with the guide holes of the lower mold base of the lower mold assembly.

[0016] Furthermore, the lower mold assembly also includes multiple support seats, which are mounted on the worktable of the frame. The lower mold base is supported by the multiple support seats, and the carbon brush holder die is fixed on the lower mold base.

[0017] Furthermore, the upper mold assembly includes an upper mold base, and the carbon brush holder punch is mounted on the lower end face of the upper mold base.

[0018] Furthermore, the pushing mechanism includes an ejector cylinder and an ejector rod. The ejector cylinder is installed on the outer side of the lower side plate of the frame, and the ejector rod is installed on the piston rod of the ejector cylinder. The ejector rod is located on the inner side of the lower side plate.

[0019] Furthermore, the ejector rod is located on the left side of the upper mold assembly and the lower mold assembly.

[0020] Furthermore, the pressing and molding mechanism also includes:

[0021] A forming cylinder is mounted on the horizontal plate of the frame. The piston rod of the forming cylinder is connected to a drive plate, and the upper mold assembly is mounted on the lower end of the drive plate.

[0022] The guiding mechanism includes a pair of guide rods, the lower ends of which are fixed to the upper end of the drive plate and slide in cooperation with the cross plate.

[0023] Furthermore, it also includes a circulating cooling device, comprising:

[0024] The circulating pump is equipped with an inlet and an outlet, and the outlet is connected to the cooling pipes of the upper mold base, the cooling pipes of the carbon brush holder punch, the cooling pipes of the lower mold base, and the cooling pipes of the carbon brush holder die.

[0025] The radiator includes a heat dissipation pipe, which is formed by connecting multiple U-shaped copper tubes end to end. Heat dissipation fins are provided on the outside of the heat dissipation pipe, and a fan is provided on one side of the heat dissipation fins. The water outlet of the heat dissipation pipe is connected to the water outlet, and the water inlet is connected to the cooling pipes of the upper mold base, the carbon brush holder punch, the lower mold base, and the carbon brush holder die.

[0026] As can be seen from the above technical solution, the advantages of this utility model are:

[0027] 1. This device innovatively integrates multiple key production processes, including pressing, demolding, material feeding, heating and handling, and mold cooling, into a single system. These processes are closely interconnected and operate collaboratively. Compared to traditional step-by-step, decentralized production methods, this integrated design significantly simplifies the production process, reduces the time and frequency of material transfer between different devices, effectively avoids damage to raw materials or precision deviations caused by improper transfer, and significantly improves the continuity and stability of production. This lays a solid foundation for the efficient and high-quality production of carbon brush holders.

[0028] 2. The demolding assembly employs a unique combination structure of a push plate and multiple pusher pins. The pusher pins slide in conjunction with the guide holes in the lower mold base. This design not only ensures the smoothness and precision of the demolding process, guaranteeing the brush holder can detach smoothly and without damage from the die, but also significantly improves demolding efficiency due to the simultaneous action of multiple pusher pins. The pusher mechanism cleverly incorporates an ejector cylinder and ejector rod. By precisely controlling the movement of the ejector cylinder, the demolded brush holder can be quickly and accurately pushed out from between the upper and lower mold components, avoiding production stoppages caused by untimely or incomplete ejection, further optimizing the production process.

[0029] 3. The coordination between the heating furnace and the robotic arm is a major highlight of this device. The heating furnace can precisely control the heating temperature and time of the carbon brush holder blank, ensuring that the blank reaches the optimal processing state. The robotic arm, with its high-precision motion control capabilities, accurately transports the heated blank into the carbon brush holder die, and after pressing and forming, quickly transports the formed carbon brush holder to the conveyor line, achieving seamless connection and efficient flow of materials between different processes. This intelligent heating, handling, and precise positioning technology greatly improves production efficiency and product consistency, and reduces errors that may be caused by manual operation.

[0030] 4. The circulating cooling device employs a combination design of a circulating pump and a high-efficiency radiator, forming a closed cooling circulation system. The circulating pump continuously delivers coolant to the cooling pipes of the upper mold base, carbon brush holder punch, lower mold base, and carbon brush holder die, promptly removing the heat generated by the mold during the pressing process and ensuring that the mold remains within a suitable operating temperature range. The radiator's unique heat dissipation pipe structure, made of multiple U-shaped copper tubes connected end to end, combined with heat dissipation fins and a fan, significantly increases the heat dissipation area and improves heat dissipation efficiency. This effectively prevents mold deformation and damage caused by overheating, extends the mold's service life, and ensures the stability of product quality.

[0031] 5. The device features a rational structural design with a clear layout of components, facilitating daily maintenance and upkeep. Key components such as the forming cylinder, demolding cylinder, and ejection cylinder adopt standardized designs, making them easy to procure and replace. Furthermore, the cooling pipeline design of the circulating cooling system is simple, less prone to clogging, and convenient to maintain. In addition, the device's fault diagnosis system can monitor the equipment's operating status in real time, promptly identifying and alerting potential faults, allowing maintenance personnel to perform maintenance and repairs proactively, effectively reducing equipment downtime and lowering maintenance costs.

[0032] 6. The integrated molding process and the efficient collaborative operation between various mechanisms significantly improve the production efficiency of this device. Compared with traditional production methods, this device can complete the pressing, demolding, and material feeding processes of the carbon brush holder in a shorter time, greatly shortening the production cycle. Attached Figure Description

[0033] The accompanying drawings, which form part of this utility model, are used to provide a further understanding of this utility model. The illustrative embodiments of this utility model and their descriptions are used to explain this utility model and do not constitute an improper limitation of this utility model.

[0034] Figure 1 This is a schematic diagram of the structure of this utility model.

[0035] Figure 2 for Figure 1 A magnified view of a portion of the image.

[0036] Figure 3 This is a schematic diagram of the structure of the upper mold base and the carbon brush holder punch of this utility model.

[0037] Figure 4 for Figure 1 Another enlarged view of a portion of the image.

[0038] Figure 5 This is a schematic diagram showing the connection relationship between the circulating cooling device and the upper and lower mold assemblies.

[0039] Figure 6 This is a schematic diagram of the carbon brush holder forming process.

[0040] Explanation of reference numerals in the attached drawings: 1-Workbench; 11-Column; 12-Support platform; 2-Lower side plate; 21-Upper side plate; 22-Horizontal plate; 3-Guide mechanism; 31-Guide rod; 4-Forming cylinder; 41-Drive plate; 5-Conveyor line; 6-Carbon brush holder; 61-Carbon brush holder blank; 7-Ejection cylinder; 71-Ejection rod; 8-Demolding cylinder; 81-Push plate; 82-Push column; 83-Lower mold base; 84-Carbon brush holder die; 85-Support base; 86-Guide hole; 9-Upper mold base; 91-Carbon brush holder punch; 10-Heating furnace; 100-Robotic arm; 101-Circulating pump; 1011-Inlet; 1012-Outlet; 102-Radiator. Detailed Implementation

[0041] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be further described in detail below with reference to the embodiments and accompanying drawings. Here, the illustrative embodiments and descriptions of this utility model are used to explain the present utility model, but are not intended to limit the present utility model.

[0042] This application aims to solve various technical problems existing in the carbon brush holder processing and forming process, so as to improve production efficiency, ensure product quality, and reduce labor intensity and production costs, as follows:

[0043] 1. Demolding process

[0044] Demolding difficulties and low efficiency: In traditional carbon brush holder molding, the pressed carbon brush holder adheres tightly to the mold, making demolding a significant challenge. Due to the lack of a dedicated demolding mechanism, manual demolding with tools is usually required. This manual demolding method not only consumes a lot of manpower and time, leading to low production efficiency, but the uncertainty of manual operation can also damage the mold and carbon brush holder, affecting product quality and mold lifespan.

[0045] Imperfect demolding mechanism: The demolding components of the existing molding device are not designed reasonably. For example, there may be problems such as uneven pushing force and loose fit between the pusher and the mold, resulting in poor demolding effect and inability to stably and efficiently eject the carbon brush holder from the mold, which in turn affects the smoothness of the entire production process.

[0046] 2. Material pushing process

[0047] Manual material pushing is inefficient and easily damages products: After demolding, the process of removing the carbon brush holder from the mold and transporting it to the next process largely relies on manual operation. Manual pushing is slow and cannot meet the efficiency requirements of large-scale production. Furthermore, manual operation is prone to improper control due to factors such as force and angle, leading to damage such as collisions and scratches to the carbon brush holder during transport, reducing product yield and increasing production costs.

[0048] Low level of automation in the feeding mechanism: Traditional molding devices lack automated feeding mechanisms, making it impossible to achieve seamless operation of demolding and feeding. This results in time intervals and operational pauses during the production process, reducing the automation level of the production line and overall production efficiency.

[0049] 3. Heating and handling process

[0050] Inefficient and disjointed heating and handling: In traditional processing methods, there are significant problems with the connection between heating the carbon brush holder blank and the pressing and forming process. The heated carbon brush holder blank needs to be manually removed from the heating furnace and placed into the mold. This process is not only cumbersome but also slow, resulting in a discontinuous production flow and reduced overall production efficiency.

[0051] Manual handling can easily affect the temperature and quality of the blank: During manual handling, the blank is exposed to the environment for a long time, making it susceptible to temperature fluctuations due to changes in ambient temperature. Unstable blank temperature directly impacts the quality of the pressing process, potentially leading to dimensional deviations and internal defects in the carbon brush holder, thus reducing product performance and reliability.

[0052] The lack of automated handling increases costs and risks: Due to the lack of automated handling equipment, it is necessary to arrange special operators to handle raw and finished products. This not only increases labor costs, but may also lead to safety accidents during the handling process due to human factors, thus increasing production risks.

[0053] 4. Mold cooling process

[0054] Lack of cooling system leads to mold thermal deformation: Most traditional molding devices lack an effective cooling system. During continuous pressing, the mold temperature rises continuously due to repeated heating. Excessive mold temperature causes thermal expansion, which in turn causes mold thermal deformation, resulting in dimensional deviations in the carbon brush holder and affecting product precision and quality.

[0055] Thermal deformation shortens mold lifespan: Thermal deformation of molds not only affects product quality but also accelerates mold wear and damage, shortening the mold's lifespan. Frequent mold replacements not only increase production costs but also lead to production interruptions and affect production schedules.

[0056] High energy consumption and unfavorable to sustainable development: Due to the lack of a reasonable cooling mechanism, the heat generated during the molding process cannot be dissipated in time, resulting in an increase in the temperature of the production environment. This requires more energy to maintain the normal operation of the production equipment, which increases production costs and does not meet the requirements of energy conservation, emission reduction and sustainable development.

[0057] refer to Figures 1 to 6 ,like Figure 1 As shown, this embodiment provides a forming device for carbon brush holder processing, mainly including a frame, a pressing and forming mechanism, a demolding mechanism, a pushing mechanism, a heating furnace 10, a robotic arm 100, and a circulating cooling device. The frame provides support and a mounting foundation for the entire device. All mechanisms and components work together to complete the entire process of carbon brush holder processing, from blank heating, pressing and forming, demolding, pushing, to finished product handling.

[0058] The frame serves as the supporting framework for the entire device, providing a stable mounting foundation for other components. Its main structure is welded from high-strength steel to ensure it can withstand the weight of the components and the vibrations and impacts during operation.

[0059] The frame mainly consists of a worktable 1, a lower side plate 2, an upper side plate 21, a horizontal plate 22, uprights 11, and a support platform 12. The worktable 1 provides a stable operating platform for the entire device. The worktable 1 is horizontally positioned, with four uprights 11 installed at its lower end. The uprights 11 are made of round steel with a diameter of 80mm and are evenly distributed at the four corners of the worktable 1, providing stable support. A support platform 12, 30mm thick, is installed between the four uprights 11 and is used to fix the demolding cylinder 8. The lower side plate 2 is vertically welded to the side of the worktable 1, with a height of 1200mm. An upper side plate 21 is installed at its upper end. Both the upper and lower side plates 21 are 20mm thick, and together they form the side frame structure of the device.

[0060] A horizontal plate 22 with a width of 300mm is installed on the inner side of the upper side plate 21. Ribs are welded between the upper end face of the horizontal plate 22 and the inner side face of the upper side plate 21, and ribs are also welded between the lower end face of the horizontal plate 22 and the inner side face of the lower side plate 2. The ribs are 15mm thick and distributed in a triangular pattern to enhance the structural strength and stability of the frame and ensure that the device will not shake or deform during operation.

[0061] After the frame is assembled, each component is precisely installed and positioned according to its function and interrelationship. The pressing and forming mechanism is the core component of this device, used to press and form the carbon brush holder. For example... Figure 2 As shown, the mechanism mainly includes a forming cylinder 4, a drive plate 41, an upper mold assembly, a lower mold assembly, and a guide mechanism 3.

[0062] The forming cylinder 4 is bolted to the center of the horizontal plate 22 of the frame, with an installation error controlled within ±0.5mm to ensure the vertical movement accuracy of the piston rod during the forming process. The piston rod is fixedly connected to the drive plate 41. When the forming cylinder 4 operates, the extension and retraction of the piston rod drives the drive plate 41 to move up and down. The upper mold assembly is installed at the lower end of the drive plate 41. The upper mold assembly includes an upper mold base 9, forged from 45# steel and tempered to a hardness of HRC28-32, exhibiting excellent comprehensive mechanical properties. The carbon brush holder punch 91 is installed on the lower end face of the upper mold base 9 using bolts and other fasteners. The carbon brush holder punch 91 is custom-made according to the shape and size of the carbon brush holder 6, using Cr12MoV mold steel, and undergoes quenching and tempering to achieve a hardness of HRC58-62 and a surface roughness Ra≤0.8μm, ensuring accurate forming during the pressing process and guaranteeing the surface quality of the carbon brush holder 6. The connection between the carbon brush holder punch 91 and the upper die holder 9 adopts a double fixing method of locating pin and bolt. The diameter of the locating pin is 10mm and the tolerance is h6 to ensure the accuracy of the punch installation position. The bolt is an M12 high-strength bolt, and the tightening torque is controlled at 80-100N·m to prevent the punch from loosening during operation.

[0063] The lower mold assembly includes multiple support seats 85, a lower mold base 83, and a brush holder die 84. The multiple support seats 85 are bolted to the worktable 1 of the machine frame. Each support seat 85 is 50mm high and its surface is ground, with a flatness error controlled within ±0.02mm, providing stable and flat support for the lower mold base 83. The lower mold base 83 rests on the multiple support seats 85, providing stable support. The brush holder die 84 is bolted to the lower mold base 83 and is positioned vertically opposite to the brush holder punch 91 of the upper mold assembly. When the drive plate 41 moves the upper mold assembly downwards, the brush holder punch 91 and the brush holder die 84 cooperate to press and shape the brush holder blank 61 placed within the brush holder die 84.

[0064] The lower die holder 83 is placed on multiple support seats 85 and is made of 40Cr steel. After quenching and tempering, its hardness reaches HRC30-35, exhibiting good toughness and wear resistance. The carbon brush holder die 84 is fixed to the lower die holder 83 by bolts. Its material is the same as the carbon brush holder punch 91, Cr12MoV die steel, and it undergoes the same heat treatment process, achieving a hardness of HRC58-62 and a surface roughness Ra≤0.8μm. The connection between the carbon brush holder die 84 and the lower die holder 83 adopts a dovetail groove structure with a dovetail groove slope of 1:10. Bolts are used to ensure the die is firmly installed, preventing loosening and facilitating replacement and maintenance.

[0065] The guiding mechanism 3 includes a pair of guide rods 31. The lower end of the guide rods 31 is fixed to the upper end of the drive plate 41 by bolts of M10 specification, with the tightening torque controlled at 60-80 N·m. The upper end of the guide rods 31 passes through the guide hole on the horizontal plate 22 and slides in fit with the guide hole. The guide mechanism 3 ensures that the drive plate 41 remains stable during up-and-down movement, avoiding deviation or shaking, thereby ensuring the precise fit between the carbon brush holder punch 91 and the carbon brush holder die 84 and improving the forming accuracy of the carbon brush holder.

[0066] The guide rod 31 is made of 30mm diameter chromium steel with chrome plating, and its hardness reaches HRC60-62, which has good wear resistance and corrosion resistance.

[0067] The demolding mechanism is used to eject the pressed carbon brush holder 6 from the carbon brush holder die 84, such as... Figure 1 and Figure 2 As shown, the mechanism mainly includes a demolding cylinder 8 and a demolding assembly.

[0068] The demolding cylinder 8 is fixed to the center of the support platform 12 by bolts of M16 specification. The tightening torque is controlled at 120-150 N·m to ensure that the cylinder is firmly installed. Its piston rod is fixedly connected to the push plate 81. The demolding assembly includes the push plate 81 and multiple pusher pins 82 installed on the top of the push plate 81. The number and position of the pusher pins 82 are designed according to the shape and size of the carbon brush holder 6 to ensure that the carbon brush holder 6 can be uniformly ejected from the carbon brush holder die 84. The pusher pins 82 slide in engagement with the guide holes 86 on the lower die base 83. When the demolding cylinder 8 is working, the piston rod pushes the push plate 81 upward, which in turn drives the pusher pins 82 to slide upward along the guide holes 86, ejecting the carbon brush holder 6 from the carbon brush holder die 84, thus realizing the demolding operation.

[0069] The demolding cylinder 8 is a standard SC160×200 cylinder with a diameter of 160mm, a stroke of 200mm, and a working pressure of 0.4-0.6MPa, providing sufficient thrust to eject the carbon brush holder 6 from the carbon brush holder die 84. Speed ​​control valves are installed at the air inlet and outlet of the demolding cylinder 8. By adjusting the opening of the speed control valves, the movement speed of the piston rod can be controlled, ensuring a smooth and slow demolding process and preventing damage to the carbon brush holder 6 and the mold due to excessive speed.

[0070] The pusher plate 81 is made of Q235 steel plate with a thickness of 25mm and the surface is sandblasted. The pusher column 82 is made of 45# steel with a diameter of 15mm, which is heat treated to achieve a hardness of HRC35-40 and a surface roughness Ra≤1.6μm.

[0071] In one embodiment, such as Figure 1 and Figure 4 As shown, the ejector mechanism is used to push the carbon brush holder 6 ejected from the demolding assembly between the upper mold assembly and the lower mold assembly for subsequent handling and conveying. The ejector mechanism includes an ejector cylinder 7 and an ejector rod 71.

[0072] The ejector cylinder 7 is bolted to the outer side of the lower side plate 2 of the frame. The ejector rod 71 is mounted on the piston rod of the ejector cylinder 7 and is located on the inner side of the lower side plate 2. The ejector rod 71 is located on the left side of the upper mold assembly and the lower mold assembly. When the carbon brush holder 6 after demolding is between the upper mold assembly and the lower mold assembly, the ejector cylinder 7 operates, and the piston rod pushes the ejector rod 71 to the right, pushing the carbon brush holder 6 out from between the upper mold assembly and the lower mold assembly, so that it can enter the subsequent handling process.

[0073] The ejector cylinder 7 is a standard SC100×150 cylinder with a diameter of 100mm, a stroke of 150mm, and a working pressure of 0.4-0.6MPa, providing sufficient thrust to push the brush holder 6 out from between the upper and lower mold assemblies. The ejector cylinder 7 is bolted to the outside of the lower side plate 2 using M12 bolts, with a tightening torque controlled at 80-100 N·m to ensure a secure installation. Speed ​​control valves are also installed at the air inlet and outlet of the ejector cylinder 7 to control the movement speed of the ejector rod 71, ensuring a smooth ejection of the brush holder 6 at a speed of 30-50mm / s.

[0074] The ejector rod 71 is made of 40Cr steel with a diameter of 20mm. After quenching and tempering, the hardness reaches HRC32-36 and the surface roughness Ra≤1.6μm.

[0075] The heating furnace 10 is placed at a designated position on one side of the frame and fixed to the ground with anchor bolts. The heating furnace 10 is used to heat the carbon brush holder blank 61 to a temperature suitable for pressing and molding. Its heating chamber is adapted to the working range of the robotic arm 100, facilitating the gripping and handling of the carbon brush holder blank 61. The heating furnace 10 typically employs resistance heating or induction heating, enabling precise control of heating temperature and time to ensure the heating quality of the carbon brush holder blank 61.

[0076] Preferably, the heating furnace 10 employs medium-frequency induction heating, with an internal heating chamber measuring 300mm × 300mm × 200mm, capable of simultaneously heating multiple carbon brush holder blanks 61. The heating furnace 10 is equipped with a temperature control system, using thermocouples as temperature sensors to monitor the temperature within the heating chamber in real time and feed the temperature signal back to the controller. Based on the material and dimensions of the carbon brush holder blanks 61, the heating temperature is set to 800-900℃, and the heating time is set to 5-8 minutes, ensuring that the carbon brush holder blanks 61 are uniformly heated to a suitable temperature for pressing and molding. During the heating process, a circulating fan creates air convection within the heating chamber, improving heating efficiency and maintaining temperature uniformity within ±10℃.

[0077] The robotic arm 100, as an automated handling device, is used to automatically transport the carbon brush holder blank 61 and the carbon brush holder 6. The robotic arm 100 is installed at a suitable position on the frame, and its end is equipped with grippers and other grasping devices. After the carbon brush holder blank 61 is heated in the heating furnace 10, the robotic arm 100, controlled by a preset program, moves its grippers into the heating furnace 10, grasps the heated carbon brush holder blank 61, and transports it into the carbon brush holder die 84. After the pushing mechanism pushes out the carbon brush holder 6, the robotic arm 100 operates again, grasping the carbon brush holder 6 and transporting it to the conveyor line 5, thus realizing the automated production process of the carbon brush holders.

[0078] The heating furnace 10 and the robotic arm 100 work collaboratively through a PLC control system. After the heating furnace 10 completes heating the carbon brush holder blank 61, it sends a heating completion signal to the PLC control system. Upon receiving the signal, the PLC control system immediately sends a gripping command to the robotic arm 100. The robotic arm 100 moves into the heating furnace 10 according to a preset program, grips the heated carbon brush holder blank 61 using pneumatic grippers, and transports it into the carbon brush holder die 84. After the pushing mechanism pushes the carbon brush holder 6 out, the PLC control system sends another gripping command to the robotic arm 100, which grips the carbon brush holder 6 and transports it to the conveyor line 5, achieving automation and high efficiency in the entire handling process.

[0079] In one embodiment, such as Figure 5As shown, the circulating cooling device is used to cool the mold during the pressing and molding process, preventing the mold from undergoing thermal deformation due to excessive temperature, and ensuring the molding accuracy of the carbon brush holder and the service life of the mold. The circulating cooling device mainly includes a circulating pump 101 and a radiator 102.

[0080] The circulating pump 101 is equipped with an inlet 1011 and an outlet 1012. The outlet 1012 is connected to the cooling pipes of the upper mold base, the carbon brush holder punch, the lower mold base, and the carbon brush holder die via cooling pipes. When the circulating pump 101 is working, it draws in coolant through the inlet 1011 and pumps it to each cooling pipe through the outlet 1012 to cool the mold. The circulating pump 101 is an ISG type pipeline centrifugal pump with a flow rate of 5 m³ / h, a head of 20 m, and a power of 1.5 kW, which meets the circulation requirements of the coolant. The circulating pump 101 is bolted to a bracket on one side of the frame. The bracket is welded from angle steel to ensure a secure installation of the circulating pump 101.

[0081] The radiator 102 includes heat dissipation pipes, which are formed by connecting multiple U-shaped copper tubes end to end. This structure increases the contact area between the coolant and the air, improving heat dissipation efficiency. Heat dissipation fins are installed on the outside of the heat dissipation pipes, further increasing the heat dissipation area and accelerating heat dissipation. A fan is installed on one side of the heat dissipation fins; when the fan operates, it accelerates airflow, quickly carrying away heat from the heat dissipation fins. The outlet of the heat dissipation pipes is connected to the inlet 1011 of the circulation pump 101. The inlet is connected to the cooling pipes of the upper mold base, the carbon brush holder punch, the lower mold base, and the carbon brush holder die, forming a coolant circulation loop. After absorbing heat in the mold, the coolant flows into the heat dissipation pipes for cooling, and is then pumped back into the mold by the circulation pump 101. This cycle repeats continuously, achieving continuous cooling of the mold.

[0082] like Figure 6 As shown, the working process of this device includes the following steps:

[0083] Step 1, Blank Heating: The operator neatly places the carbon brush holder blank 61 into the heating chamber of the heating furnace 10 and closes the furnace door. The heating furnace 10 is started, and the temperature control system begins operation, heating the carbon brush holder blank 61 according to the preset heating temperature and time parameters. During the heating process, the circulating fan runs continuously, creating air convection within the heating chamber to ensure uniform heating of the carbon brush holder blank 61. Simultaneously, the operator monitors the temperature display instrument to track real-time temperature changes.

[0084] Step 2, Blank Handling: After the heating furnace 10 completes heating of the carbon brush holder blank 61, it sends a heating completion signal to the PLC control system. Upon receiving the signal, the PLC control system immediately sends a gripping command to the robotic arm 100. The robotic arm 100 moves into the heating furnace 10 according to the preset program and grips the heated carbon brush holder blank 61 using pneumatic grippers. The robotic arm 100 transports the carbon brush holder blank 61 into the carbon brush holder die 84 and accurately places it in the designated position, preparing for subsequent pressing and molding.

[0085] Step 3, Pressing and Molding: After receiving the start command from the PLC control system, the piston rod of the forming cylinder 4 extends downward, driving the drive plate 41 to move downward. Guided by the guide mechanism 3, the drive plate 41 descends smoothly, allowing the carbon brush holder punch 91 of the upper mold assembly and the carbon brush holder die 84 of the lower mold assembly to cooperate, applying pressure to the carbon brush holder blank 61 for pressing and molding. During the pressing process, the pressure of the forming cylinder 4 is monitored in real time by a pressure sensor, controlling the pressure between 10-15 MPa to ensure that the carbon brush holder 6 can be fully formed. When the pressing time reaches the set value, the piston rod of the forming cylinder 4 begins to return upward, causing the upper mold assembly to separate from the carbon brush holder 6.

[0086] Step 4, Demolding Operation: After the piston rod of the forming cylinder 4 drives the upper mold assembly to reset upwards, the PLC control system sends a start command to the demolding cylinder 8. The piston rod of the demolding cylinder 8 slowly pushes the push plate 81 upwards at a speed of 50-80 mm / s, thereby driving the pusher column 82 to slide upwards along the guide hole 86, pushing the carbon brush holder 6 out of the carbon brush holder cavity 84. During the demolding process, the displacement sensor monitors the moving distance of the push plate 81 in real time. When the push plate 81 moves to the set position, that is, when the carbon brush holder 6 is completely separated from the carbon brush holder cavity 84, the displacement sensor sends a signal, and the PLC control system controls the demolding cylinder 8 to stop working, completing the demolding operation.

[0087] Step 5, Pushing Operation: When the demolded carbon brush holder 6 is between the upper and lower mold assemblies, the PLC control system sends a start command to the ejector cylinder 7. The piston rod of the ejector cylinder 7 pushes the ejector rod 71 to the right at a speed of 30-50 mm / s, pushing the carbon brush holder 6 out from between the upper and lower mold assemblies. During the pushing process, the proximity switch monitors the position of the ejector rod 71 in real time. When the ejector rod 71 has completely pushed the carbon brush holder 6 out of the upper and lower mold assemblies and has moved to the set position, the proximity switch sends a signal, the PLC control system controls the ejector cylinder 7 to stop working, and resets the ejector rod 71, completing the pushing operation.

[0088] Step Six, Finished Product Handling: After the material pushing operation is completed, the PLC control system sends a gripping command to the robotic arm 100 again. The robotic arm 100 moves above the carbon brush holder 6, grips the carbon brush holder 6 with pneumatic grippers, and transports it to the conveyor line 5. The conveyor line 5 uses a belt conveyor with a speed of 0.5-1m / s to transport the carbon brush holder 6 to the next process for subsequent processing or inspection.

[0089] Throughout the entire process, the circulating cooling device operates continuously to cool the mold, ensuring that the mold temperature remains stable between 50-60℃, thus guaranteeing the molding quality of the carbon brush holder 6 and the service life of the mold. Simultaneously, the actions of each component are precisely controlled by a PLC control system, achieving automation and high efficiency in the carbon brush holder processing and molding process.

[0090] In summary, the forming device for carbon brush holder processing of the present invention, through the coordinated work of its various components, comprehensively solves the technical problems existing in traditional processing methods, such as difficulty in demolding, low material pushing efficiency, poor connection between heating and handling, and insufficient mold cooling, and has significant technical advantages and application value.

[0091] The above description is merely a preferred embodiment of the present utility model and is not intended to limit the present utility model. For those skilled in the art, various modifications and variations can be made to the embodiments of the present utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A forming device for processing carbon brush holders, characterized in that, include: The pressing and forming mechanism includes an upper mold assembly and a lower mold assembly arranged opposite each other. The upper mold assembly includes a carbon brush holder punch (91), and the lower mold assembly includes a carbon brush holder die (84). The demolding mechanism includes a demolding cylinder (8) and a demolding assembly; A pushing mechanism is used to push the carbon brush holder (6) ejected by the demolding component out from between the upper mold assembly and the lower mold assembly; A heating furnace (10) is used to heat carbon brush holder blanks (61). The robotic arm (100) is used to transport the carbon brush holder blank (61) heated by the heating furnace (10) into the carbon brush holder die (84) and to transport the carbon brush holder (6) pushed out by the pushing mechanism to the conveyor line (5).

2. The molding apparatus for carbon brush holder machining according to claim 1, characterized by The demolding assembly includes a push plate (81) connected to the piston rod of the demolding cylinder (8) and a plurality of pusher pins (82) mounted on the top of the push plate (81). The pusher pins (82) are slidably engaged with the guide hole (86) of the lower mold base (83) of the lower mold assembly.

3. The molding apparatus for carbon brush holder machining according to claim 2, characterized by The lower mold assembly also includes multiple support seats (85), which are mounted on the worktable (1) of the frame. The lower mold base (83) is supported by the multiple support seats (85), and the carbon brush holder die (84) is fixed on the lower mold base (83).

4. The molding apparatus for carbon brush holder machining according to claim 1, characterized by The upper mold assembly includes an upper mold base (9), and the carbon brush holder punch (91) is mounted on the lower end face of the upper mold base (9).

5. The molding apparatus for carbon brush holder machining according to claim 1, characterized by The pushing mechanism includes an ejector cylinder (7) and an ejector rod (71). The ejector cylinder (7) is installed on the outside of the lower side plate (2) of the frame, and the ejector rod (71) is installed on the piston rod of the ejector cylinder (7). The ejector rod (71) is located on the inside of the lower side plate (2).

6. The molding apparatus for carbon brush holder machining according to claim 5, wherein The ejector rod (71) is located on the left side of the upper mold assembly and the lower mold assembly.

7. The molding apparatus for carbon brush holder machining according to claim 1, characterized by The compression molding mechanism further includes: A forming cylinder (4) is mounted on a horizontal plate (22) of the frame. The piston rod of the forming cylinder (4) is connected to a drive plate (41). The upper mold assembly is mounted on the lower end of the drive plate (41). The guide mechanism (3) includes a pair of guide rods (31), the lower end of which is fixed to the upper end of the drive plate (41) and slides in cooperation with the cross plate (22).

8. The molding apparatus for carbon brush holder machining according to claim 1, characterized by It also includes a circulating cooling device, comprising: The circulating pump (101) is provided with an inlet (1011) and an outlet (1012), and the outlet (1012) is connected to the cooling pipe of the upper mold base, the cooling pipe of the carbon brush holder punch, the cooling pipe of the lower mold base, and the cooling pipe of the carbon brush holder die. The radiator (102) includes a heat dissipation pipe, which is made by connecting multiple U-shaped copper pipes end to end. Heat dissipation fins are provided on the outside of the heat dissipation pipe, and a fan is provided on one side of the heat dissipation fins. The water outlet of the heat dissipation pipe is connected to the water outlet (1012), and the water inlet is connected to the cooling pipes of the upper mold base, the carbon brush holder punch, the lower mold base, and the carbon brush holder die.

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