Design And Research Of The Equipment For The Electrical Terminals With The Technologies Of Affixing And Forming

The electrical terminals are widely used in the field of electrical connectors. Belonging to the labor-intensive industries, the electrical terminals are in the manual production stage at present. However, with rapid growth of the market demand and dramatic increase in labor cost, the development of automated or semi-automated terminals generating device is imminent. For this demand, the project develops and designs a kind of automated equipment of terminals with technologies of film affixing and forming, to achieve the purpose of metal terminals’self-adhesive covering the PET film in the process of punching molding. This project carries out the relevant design, calculation and theoretical analysis.First of all, by analyzing the film affixing and forming process of terminals with PET film, the thesis defines the structural features of terminals and difficult problems in the forming process of affix film, i.e. how to form the PET film and how to affix the PET film and internal metal terminals; proposes several process flows of affixing and forming, demonstrates the design of PET film forming equipment through compared analysis, and finishes the working sequence of automated production.Second, according to the process flow, the project completed the mechanical structural design of the terminal equipment with the technologies of affixing and forming, including the design of disc winding mechanism tensioning PET film, die cutting and mould design of PET film, mechanism design of strip material’s fixed pitch conveyor, PET film forming design and manipulator design; highlighted the methods of tension control of PET film (has applied for patents); calculated and designed die cutting of PET film, carrying out the simulation analysis of process of die cutting by using the analytical software DEFORM-3D and providing parameter in the die cutting design of PET film with foundation; proposed a structure of fixed pitch conveyor with needle wheel to ensure accurate conveying of PET film.Finally, the project completed the design of control system and production and debugging of a prototype. After debugging, the prototype produced equipment of electrical terminals which meet the product requirement. This prototype is also believed to meet the design requirement after practical testing and data analysis.