Wire Part Separation With Notched Cutting for Burr-Free Ends
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Solution Overview
Problem
Existing wire processing methods fail to produce prefabricated molded parts with well-defined wire ends, leading to inefficiencies in applications such as electric vehicle busbars and electric motors, where reliable and burr-free wire ends are crucial for efficient energy transfer and assembly.
Innovation Solution
A two-stage process involving notching and biting cutting or shear cutting is employed in a wire processing machine, where notching tools create a tapered wire cross-section without material removal, followed by cutting tools that sever the wire at the tapered section using wedge-shaped cutting edges or shearing tools, ensuring precise separation and burr-free ends.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional wire cutting methods are used, then wire separation is achieved, but wire ends have burrs and poor geometric definition
Solution Approach 1:
The wire is first notched from two opposite sides to create a tapered cross-section before the final cutting operation. This preliminary notching action prepares the wire by concentrating material at the separation point, which then enables the cutting tools to produce burr-free, geometrically precise wire ends when the wire is severed.
2Manufacturing precision
If notching tools are used to create tapered wire cross-section, then wire end precision is improved, but device complexity increases
Solution Approach 1:
The notching and cutting operations are combined into a single integrated processing sequence within one wire processing machine. The notching tools and cutting tools work in succession on the same wire section, merging two functions into one coordinated operation that achieves precise wire end geometry without requiring separate processing equipment.
3Ease of manufacture
If wire is separated by tensile force after forming, then separation is achieved, but wire end quality deteriorates
Solution Approach 1:
The conventional tensile force separation method is replaced with a mechanical cutting system using notching tools followed by cutting tools. Instead of pulling the wire apart which creates poor-quality ends, the new system uses controlled mechanical notching and cutting actions that produce precise, burr-free wire ends suitable for high-quality applications.
Data Source
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AI summary
In a method for producing prepared shaped parts from wire, wire (W) is drawn in from a wire stock and fed to a wire processing machine (100). The wire is straightened in the wire processing machine (100) and shaped parts of a predefinable wire length are separated from the straightened wire by means of a separating device (300). In order to separate a shaped part from the fed wire, at a separating position provided for the separation, the wire (W) is first notched in at least one notching operation from two opposite sides by means of notching tools in such a way that a tapered wire cross-section remains between opposing notches at the separating position. Then, in a dividing operation, the notched wire is separated at the separating position in the region of the tapered wire cross-section, by the engagement of two dividing tools on opposite sides of the wire and their synchronous advancement in opposing advancement directions transversely, in particular perpendicularly, to the wire axis until the wire material is severed at the separating position (TP). The invention also relates to a wire processing machine designed to carry out said method.