Welding Wire Cutting Structure for Burr-Free, Offset-Free Shearing
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Solution Overview
Problem
Existing welding wire cutting structures in silicon wafer series production suffer from issues such as wire rollover, burrs, and offset due to single-cylinder structures and independent cutter movements, leading to inefficiencies and quality concerns.
Innovation Solution
A dual-plate cutting structure with synchronized upper and lower cutters, guided by cams and sliding rails, utilizing pistons and springs to stabilize the wire, and arc-shaped kerfs to ensure precise cutting without offset or burrs, combined with gas ventilation for controlled wire release.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single cylinder structure is used to press and hold multiple welding wires simultaneously, then the device complexity is reduced, but the welding wires affect each other causing rollover and cutting precision deteriorates
Solution Approach 1:
The single cylinder structure is segmented into multiple independent cylinders (first cylinder for upper cutter, second cylinder for lower cutter). Each cylinder independently controls its respective cutter, eliminating the interference between multiple wires that occurs with a single cylinder. This segmentation allows each wire to be processed independently while maintaining device functionality.
Solution Approach 2:
Guide holes are introduced as intermediary elements to constrain and guide the welding wires during the cutting process. The wires pass through these guide holes which prevent them from rolling over or deviating during cutting, thereby improving cutting precision without requiring complex additional structures.
2Device complexity
If the upper cutter moves alone or the lower cutter moves alone, then the device complexity is reduced, but the welding wire容易产生 burrs and offset
Solution Approach 1:
The movement mechanisms of the upper and lower cutters are merged through synchronized control. Both cutters move simultaneously toward each other under independent cylinder control, ensuring they meet at the precise cutting position. This coordinated movement eliminates burrs and offset by ensuring both cutters engage the wire simultaneously and symmetrically.
Solution Approach 2:
The system incorporates feedback through the guide holes and synchronized movement mechanism. The guide holes provide positional feedback that ensures the cutters remain aligned, while the independent cylinder control allows for precise adjustment of each cutter's position to maintain cutting accuracy throughout the process.
3Device complexity
If a single cylinder structure presses and holds multiple welding wires, then the device complexity is reduced, but the wires roll over at certain angles
Solution Approach 1:
The pressure holding function is segmented into two independent systems: the first cylinder with its piston controlling the upper cutter's pressure, and the second cylinder with its piston controlling the lower cutter's pressure. This segmentation allows each wire to be independently stabilized without interference from adjacent wires, preventing rollover while maintaining structural simplicity.
Solution Approach 2:
Guide holes serve as intermediary structures that physically constrain the welding wires during the pressing and holding process. These guide holes prevent the wires from rolling over at critical angles by providing lateral support and maintaining proper wire alignment throughout the cutting operation.
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
The structure effectively prevents wire rollover and burrs, ensures precise cutting without offset, and allows independent handling of multiple wires, enhancing production efficiency and quality.
Implementation Method 1
the upper end of the piston is connected with a pressure holding spring
Implementation Method 2
the driving end of the welding wire cutting motor is connected with a welding wire cutting cam
Data Source
AI summary
The invention discloses a welding wire cutting structure, comprising a welding wire cutting support, an upper plate, a lower plate, a welding wire base plate and a pressure holding cylinder. The upper and lower plates move vertically towards each other, with an upper cutter connected to the upper plate’s lower end and a lower cutter to the lower plate’s upper end. The pressure holding cylinder, mounted at the support’s lower end, has multiple movable cavities each equipped with a piston linked to a pressure holding spring. The base plate is provided with flat holes for welding wires to pass through, preventing turnover. The upper and lower cutters cut simultaneously to avoid burrs and offset at the cutting position. The lower cutter’s arc-shaped edge guides position correction, and the pistons independently press each welding wire, ensuring no mutual interference during cutting.