Busbar Forming Tool With Movable Plunger for Round Wire Preforms
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Solution Overview
Problem
Existing methods for producing busbars require additional time-consuming and expensive preparatory steps to convert round copper wires into flat materials, which are traditionally supplied in coils, for forming flexible sections.
Innovation Solution
A tool and forming device are developed with a multi-part upper die and a coupling mechanism that allows for sequential or overlapping phases of die forging and stretch drawing in a single press stroke, using a movable ram to form busbars directly from round wire preforms, combining these processes to create flexible sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If round copper wires are used as preform material, then material supply efficiency is improved, but additional preparatory steps are required to convert round wire into flat material
Solution Approach 1:
The patent combines die forging and stretch drawing into a single integrated tool and press stroke. The upper die with movable ram performs both functions sequentially: first forging the round wire into a flat preform, then drawing it to create the flexible section. This eliminates the need for separate preparatory steps and directly processes round copper wire into the final busbar geometry.
Solution Approach 2:
The upper die is divided into two functional parts: a main body for die forging and a movable ram for stretch drawing. This segmentation allows each component to perform its specific function while being integrated into a single tool, enabling the combination of two process steps without requiring separate equipment.
2Manufacturing precision
If separate preparatory steps are used to convert round wire to flat material, then material form requirements are met, but production time and cost increase
Solution Approach 1:
The patent merges die forging and stretch drawing into a single integrated tool and press stroke. The upper die with movable ram performs both functions sequentially: first forging the round wire into a flat preform, then drawing it to create the flexible section. This eliminates the need for separate preparatory steps and directly processes round copper wire into the final busbar geometry.
Solution Approach 2:
The die forging action is performed first within the same press stroke to pre-form the round wire into a flat preform with correct thickness, preparing the material for the subsequent stretch drawing operation that creates the flexible section. This preliminary shaping enables the final forming step to achieve the desired geometry efficiently.
3Manufacturing precision
If traditional multi-step processes are used, then each process step can be optimized, but overall process complexity and cost increase
Solution Approach 1:
The patent merges die forging and stretch drawing into a single integrated tool and press stroke. The upper die with movable ram performs both functions sequentially: first forging the round wire into a flat preform, then drawing it to create the flexible section. This eliminates the need for separate preparatory steps and directly processes round copper wire into the final busbar geometry.
Solution Approach 2:
The upper die assembly serves multiple functions: it acts as both the forging die and the drawing tool through its movable ram. This multi-functionality allows a single tool to perform what traditionally required separate equipment, simplifying the manufacturing process while maintaining precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the direct formation of busbars with flexible sections from round wire, reducing the need for separate preparatory steps and enhancing efficiency by integrating die forging and stretch drawing in a single press stroke.
Implementation Method 1
the preform is pressed between the pressing surface of the upper die and the bearing surface of the lower die... the material of the preform flows into the spaces provided by the die engraving
Data Source
Figure 1~2
Figure 3a~3b
Figure 3c~3d
AI summary
The invention relates to a tool (20) for forming a preform (30) into a busbar blank with an elastically flexible bending section (12, 12'), comprising: - a lower die (21) with a preform holder having a support surface (212) with a local depression (213), and - an upper die (22) which can be positioned perpendicularly to the lower die (21) and has a pressing surface (222) with a projection spatially corresponding to the depression (213). The invention is characterized in that the upper die (22) is designed in multiple parts, wherein the projection is designed as a plunger (223) that is movable in the positioning direction relative to an upper die main body (221) and can be positioned beyond the pressing surface (222) towards the lower die (21).