Voltage test equipment and test method for flexible copper busbars used in new energy vehicles

Abstract

The present invention discloses a flexible copper busbar pressure test device for new energy vehicles, which belongs to the field of material pressure test. It includes a frame and an industrial computer, the industrial computer is connected to a main control cabinet, an industrial computer display, a main control panel, a detection device, a barcode scanner and a printer, a linear guide and a lifting mechanism are provided on the front side of the upper end of the frame, the linear guide is connected to a tooling, a studio is provided in the frame, the lifting mechanism is connected to a transporter, the transporter and the studio are provided with an output port and a sealing plate for blocking the output port facing each other, and both sides of the transporter and the studio are provided with a slide rail and a cylinder, the output end of the cylinder is connected to the sealing plate, and the sealing plate is slidably connected to the slide rail. The present invention provides a flexible copper busbar pressure test device for new energy vehicles, which adopts fine steel sand as the contact medium for pressure test. The contact medium has fluidity and can effectively meet the use of different test products, ensuring that different products can share tooling when testing, and reducing product switching time.

Description

Technical Field

[0001] The present invention relates to the field of material withstand voltage testing, and more specifically, to a withstand voltage testing device and a testing method for a flexible copper busbar for new energy vehicles. Background Art

[0002] At present, niche new energy vehicles have put forward higher requirements on assembly flexibility and development costs for connecting copper busbars. Due to the large number of special shapes and bending angles of existing connecting copper busbar products, flexible connections of different shapes have different requirements for test tooling, and the differences are huge. For the internal insulation layer withstand voltage test of the flexible connection at a 45° angle or less, blind spots are prone to occur, making it impossible to perform the insulation layer withstand voltage test of the product. In addition, different test tooling needs to be replaced each time a different flexible connection is tested.

[0003] In response to the above problems, the present invention proposes a pressure test equipment for flexible copper busbars for new energy vehicles. It uses fine steel sand as the contact medium for pressure test. The contact medium has fluidity and can effectively meet the use of different test products, ensuring that different products can share the same tooling and reducing product switching time. Summary of the Invention

[0004] The technical solution adopted by the present invention is: to provide a soft-connect copper busbar pressure test equipment for new energy vehicles, including a frame and an industrial computer installed in the frame, the industrial computer is connected to a main control cabinet, an industrial computer display, a main control panel, a detection device, a barcode scanner and a printer, a linear guide is provided on the front side of the upper end of the frame, the movable end of the linear guide is connected to a tooling, a studio is provided in the frame and the studio is located directly below the tooling, a lifting mechanism is provided on the rear side of the upper end of the frame, the movable end of the lifting mechanism is connected to a transport vehicle, and the transport vehicle is located inside the frame, the transport vehicle and the studio are provided with output ports and sealing plates for blocking the output ports facing each other, slide rails and cylinders are provided on both sides of the transport vehicle and the studio, the output end of the cylinder is connected to the sealing plate, and the sealing plate is slidably connected to the slide rails.

[0005] With the above structure, the workroom can be used as a space for the tooling to be tested. Driven by a lifting mechanism, the transporter moves up and down, transferring the contact medium for the withstand voltage test in and out. After the contact medium fills the test piece, the conductive workroom box is connected to the negative pole and the test piece is connected to the positive pole. Defective locations in the test piece will be broken down and conductive. Compared with the existing technology, this invention effectively meets the needs of different test products, ensuring that tooling can be shared for testing different products, reducing product switching time. The industrial computer can store test data in real time, giving the equipment product test record tracking function.

[0006] Preferably, the detection device includes a withstand voltage meter and a resistance meter, and the detection ends of the withstand voltage meter and the resistance meter are external detection parts on the tooling.

[0007] Preferably, an air source box is provided in the frame, and an output end of the air source box is connected to the lifting mechanism.

[0008] Preferably, the contact medium of the pressure test equipment is steel grit; the steel grit can well cover every corner of the copper busbar and can meet the pressure test requirements of the product.

[0009] Preferably, the diameter of the steel sand is 0.5-20 mm.

[0010] Preferably, a sand falling box is placed at the bottom of the frame; the sand falling box is used to receive steel sand.

[0011] Preferably, a tower light is installed on the rack; the tower light is controlled by the main control machine and can be used as a warning mechanism.

[0012] A method for testing a flexible copper busbar pressure test device, using a flexible copper busbar pressure test device for new energy vehicles, comprising the following steps:

[0013] S1. Install the test piece on the tooling, connect both ends of the test piece to the output test voltage of the pressure test machine, and seal the middle surface of the test piece with a polyurethane sleeve;

[0014] S2, the device is placed in the working room, and the conductive steel sand fills the working room;

[0015] S3. The pressure test is turned on. If the polyurethane sleeve is not penetrated, the test piece is qualified. The qualified test piece will be saved in the temporary database by the industrial computer according to the data number;

[0016] S4. The test piece is transferred to the resistance meter, and the qualified test piece will save the data into the temporary database of the industrial computer according to the number;

[0017] S5. The industrial computer sends the data to the printer, which prints out the generated code to be pasted on the test piece;

[0018] S6. The operator scans the generated code with a barcode scanner, compares the scanned information with the data in the temporary database of the industrial computer, and verifies the generated code;

[0019] S7. After verification, the temporary database is saved to the historical database.

[0020] Preferably, in step S3, when the polyurethane sleeve on the detection piece is penetrated, the tower light is turned on.

[0021] Compared with the prior art, the present invention has the following advantages:

[0022] 1. Compared with the existing technology, the present invention effectively meets the use of different test products, ensures that tooling can be shared for testing different products, reduces product switching time, and the industrial computer can store the test data in real time, so that the equipment has the function of product test record tracking.

[0023] 2. Compared with the prior art in which the contact medium is manually transferred, the present invention transfers the contact medium back and forth through a studio and a transport vehicle, which can effectively reduce the loss of the contact medium during transfer; the contact medium is steel grit, which can evenly cover the surface of the copper busbar and meet the product's pressure test requirements. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 It is a structural schematic diagram of the front side of the present invention;

[0025] Figure 2 It is a structural schematic diagram of the back side of the present invention;

[0026] Figure 3 It is a schematic diagram of the partial structure inside the present invention;

[0027] Figure 4 for Figure 3 A partial enlarged view of point A in the middle;

[0028] Figure 5 It is a schematic diagram of the principle of steel grit transfer in the present invention.

[0029] Description of the numbers in the figure:

[0030] Among them: 1. Main control cabinet; 2. Air source box; 3. Pressure tester; 4. Industrial computer display; 5. Tower lamp; 6. Tooling; 7. Lifting mechanism; 8. Resistance meter; 9. Main control panel; 10. Barcode scanner; 11. Printer; 12. Industrial computer; 13. Sand box; 14. Linear guide; 15. Workroom; 16. Transport vehicle; 17. Sealing plate; 18. Cylinder; 19. Slide rail. DETAILED DESCRIPTION

[0031] The technical solution of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the embodiments described are only some embodiments of the present invention, not all embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.

[0032] In the description of the present invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are intended solely to facilitate and simplify the description of the present invention. They are not intended to indicate or imply that the devices or components referred to must have, be constructed, or operate in a specific orientation, and therefore should not be construed as limitations on the present invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0033] The withstand voltage test or high voltage test (HIPOT test) is used to verify the quality and electrical safety characteristics of the product. The flexible copper busbar is also called the copper busbar or busbar, and is mainly used in high-voltage and high-current connectors. In the field of new energy vehicles, the flexible copper busbar is mainly used as the electrical connection between the battery modules in the battery pack. The two ends of the flexible copper busbar are exposed electrical connection terminals. A layer of polyurethane sleeve is wrapped in the middle of the flexible copper busbar. The two ends of the flexible copper busbar are connected to the positive pole, and the outer surface of the polyurethane sleeve is evenly covered with a layer of steel grit as the negative pole. The application of steel grit can provide a uniform point field. If the insulation layer of the test piece fails to meet the requirements, the polyurethane sleeve will be punctured.

[0034] Example 1

[0035] like Figure 1 As shown, the bottom of the rack is a closed box-type structure. In order to facilitate observation of the structural distribution inside the rack, the figure is hollowed out. A main control cabinet 1 and an air source box 2 are provided on the left side of the rack. The air source box 2 is located in front of the main control cabinet 1, and the operating end of the main control cabinet 1 is provided on the left surface of the rack. A pressure tester 3 is placed on the left side of the upper end of the rack, and an industrial computer display 4 is placed on the upper surface of the pressure tester 3. A tower lamp 5 is also provided on the left side of the upper end of the rack, and the tower lamp 5 extends upward to the upper end of the rack ceiling. A resistance meter 8, a barcode scanner 10 and a printer 11 are placed on the right side of the upper end of the rack, and a main control panel 9 is provided above the barcode scanner 10; two linear guide rails 14 are vertically provided on the rack, and the active end of the linear guide rail 14 is connected to a tooling 6 for placing the detection part. A lifting mechanism 7 is also provided on the rack, and the lifting mechanism 7 is located on the rear side of the tooling 6. An industrial computer 12 is installed inside the frame, which is connected to the main control cabinet 1, the air source box 2, the pressure tester 3, the industrial computer display 4, the tower light 5, the main control panel 9, the barcode scanner 10 and the printer 11. The main control panel 9 controls the tooling 6, the lifting mechanism 7 and the linear guide rail 14.

[0036] like Figure 2 As shown, the heat dissipation port of the industrial computer 12 is arranged on the left side of the back of the rack, a sand falling box 13 is placed at the bottom of the rack, and the control end of the lifting mechanism 7 extends into the interior of the rack.

[0037] like Figure 3-4As shown, a workroom 15 and a transporter 16 are provided within the frame. The workroom 15 is located directly below the tooling 6, and the transporter 16 is connected to the movable end of the lifting mechanism 7. The transporter 16 and the workroom 15 have output ports facing each other. Cylinders 18 and slide rails 19 are provided on both sides of the transporter 16 and the workroom 15. A sealing plate 17 is connected between the cylinders 18 on both sides. The sealing plate 17 is slidably connected to the slide rails 19 and is used to open and close the output port. The transporter 16 is located behind the workroom 15, and the bottom of the transporter 16 is tilted toward the workroom 15. That is, the lowest point of the transporter 16 on the side facing the workroom 15 is lower than that on the side away from the workroom 15. The bottom of the workroom 15 is tilted toward the transporter 16.

[0038] In some examples, the control object of the main control panel 9 also includes a cylinder 18 .

[0039] The usage of this embodiment is:

[0040] The detection method of the flexible copper busbar pressure test equipment for new energy vehicles includes the following steps:

[0041] S1. Install the test piece on the tooling 6. Connect both ends of the test piece to the output test voltage of the pressure test machine. Use a polyurethane sleeve to seal the middle surface of the test piece.

[0042] S2, the tool 6 is placed in the working room 15, and the conductive steel sand fills the working room 15;

[0043] S3, the pressure test is turned on, and the test piece whose polyurethane sleeve is not broken is qualified. The qualified test piece will be saved in the temporary database by the industrial computer 12 according to the data number;

[0044] S4, the test piece is transferred to the resistance meter 8, and the qualified test piece saves the data according to the number in the temporary database of the industrial computer 12;

[0045] S5. The industrial computer 12 sends the data to the printer 11. The printer 11 prints out the generated code for pasting on the test piece.

[0046] S6. The operator scans the generated code with the barcode scanner 10, compares the scanned information with the data in the temporary database of the industrial computer 12, and verifies the generated code;

[0047] S7. After verification, the temporary database is saved to the historical database.

[0048] The motion trajectory of step S2 is as follows: After the test piece is installed on the tooling 6, the linear guide 14 starts working, and its moving end drives the tooling 6 to move into the interior of the working room 15. The transport vehicle 16 filled with steel grit moves upward under the action of the lifting mechanism 7 until the output port of the transport vehicle 16 is higher than the upper edge of the working room 15. The cylinders 18 on both sides of the transport vehicle 16 open, and the sealing plate 17 on the transport vehicle 16 moves upward along the slide rail 19. The output port of the transport vehicle 16 opens, and the steel grit inside it pours into the working room 15. The setting of the inclined surface at the bottom of the transport vehicle 16 ensures that the steel grit has a certain initial velocity when pouring out of the output port, so that the steel grit can completely cover the tooling 6 inside the working room 15. Similarly, there are two ways to implement the discharge of the steel grit inside the working room 15. One is to move the transport vehicle 16 downward, so that the steel grit in the working room 15 is poured into the transport vehicle 16, and the other is to pour the steel grit in the working room 15 directly into the sand drop box 13.

[0049] In step S3, when an unqualified test piece is detected, the tower light 5 is turned on.

[0050] In this embodiment, the duration of the mold immersion pressure resistance is 30 seconds. The steel grit in this embodiment uses steel grit with a diameter of 0.5 mm. When the minimum electrical gap is 0.5 mm, the rated impulse voltage is 330 volts.

[0051] Example 2

[0052] This embodiment is different from the previous embodiment in that the linear guide rail 14 is a multi-step guide rail, that is, the linear guide rail 14 has two moving ends, wherein the main moving end is connected to the working room 15 and the secondary moving end is connected to the tooling 6 .

[0053] The implementation of this embodiment differs from that of Example 1 in that the initial position of the working chamber 15 in this embodiment is close to the inner surface of the frame, that is, there is no gap between the working chamber 15 and the upper end of the frame for the transport vehicle 16 to dump the steel grit, and the upper edge of the working chamber 15 is close to the inner surface of the frame. The motion trajectory of step S2 is as follows: After the detection part is installed on the tooling 6, the linear guide 14 is activated, and its main moving end working chamber 15 moves downward, leaving sufficient gap above the working chamber 15 for the transport vehicle 16 to dump the steel grit into it. Then, the secondary moving end of the linear guide 14 drives the tooling 6 to move into the working chamber 15. The transport vehicle 16 loaded with steel grit moves upward under the action of the lifting mechanism 7 until the output port of the transport vehicle 16 is higher than the upper edge of the working chamber 15. The cylinders 18 on both sides of the transport vehicle 16 open, and the sealing plate 17 on the transport vehicle 16 moves upward along the slide rail 19. The output port of the transport vehicle 16 opens, and the steel grit inside it is dumped into the working chamber 15. The setting of the inclined surface at the bottom of the transport vehicle 16 makes the steel sand have a certain initial velocity when pouring out of the output port, so that the steel sand can completely cover the tooling 6 inside the working room 15.

[0054] In some examples, an upper edge of the working chamber 15 close to the inner surface of the frame is provided with insulating material.

[0055] The steel grit in this embodiment has a diameter of 11.5 mm. When the minimum electrical gap is 11.5 mm, the rated impulse voltage is 10,000 volts.

[0056] Example 3

[0057] This embodiment is different from Embodiments 1 and 2 in that the implementation method in this embodiment is:

[0058] The detection method of the flexible copper busbar pressure test equipment for new energy vehicles includes the following steps:

[0059] S1, the test piece is transferred to the resistance meter 8, the resistivity of the test piece is measured, and the data of the qualified test piece is saved in the temporary database of the industrial computer 12 according to the number;

[0060] S2. Install the test piece on the tooling 6, connect one end of the test piece to the output test voltage of the pressure test machine, and seal the other end with a polyurethane sleeve;

[0061] S3, the tool 6 is placed in the working room 15, and the conductive steel sand fills the working room 15;

[0062] S4, the withstand voltage test is started, and the qualified test pieces save the data according to the number in the temporary database of the industrial computer 12;

[0063] S5, the industrial computer 12 sends the data to the printer 11, and the printer 11 generates a code and sticks it on the test piece;

[0064] S6, the barcode scanner 10 verifies the generated code on the detection part;

[0065] S7. After verification, the temporary database is saved to the historical database.

[0066] The above description is based on the preferred embodiments of the present invention, but it should not be understood as limiting the claims. The present invention is not limited to the above embodiments, and its specific structure is allowed to be varied. All variations made within the scope of protection of the independent claims of the present invention are within the scope of protection of the present invention.

Claims

1. A new energy vehicle flexible copper busbar withstand voltage test device, comprising a rack and an industrial computer installed in the rack, the industrial computer being connected to a main control cabinet, an industrial computer display, a main control panel, a detection device, a barcode scanner, and a printer, characterized in that: The front side of the upper end of the frame is provided with a linear guide rail, the movable end of the linear guide rail is connected to the tooling, a studio is provided in the frame and the studio is located directly below the tooling, a lifting mechanism is provided on the rear side of the upper end of the frame, the movable end of the lifting mechanism is connected to a transport vehicle, and the transport vehicle is located inside the frame, the transport vehicle and the studio are provided with output ports and sealing plates for blocking the output ports facing each other, slide rails and cylinders are provided on both sides of the transport vehicle and the studio, the output end of the cylinder is connected to the sealing plate, and the sealing plate is slidably connected to the slide rails; the bottom of the transport vehicle is inclined toward the studio, that is, the lowest point of the transport vehicle facing the studio is away from the side of the studio, and the bottom of the studio is inclined toward the transport vehicle; the contact medium of the pressure test equipment is steel sand, and a tower lamp is installed on the frame.

2. The flexible copper busbar withstand voltage test equipment for new energy vehicles according to claim 1, characterized in that: The detection device includes a withstand voltage meter and a resistance meter, and the detection ends of the withstand voltage meter and the resistance meter are detection parts externally connected to the tooling.

3. The flexible copper busbar withstand voltage test equipment for new energy vehicles according to claim 1, characterized in that: An air source box is provided in the frame, and an output end of the air source box is connected to the lifting mechanism.

4. The flexible copper busbar withstand voltage test equipment for new energy vehicles according to claim 1, characterized in that: The diameter of the steel sand is 0.5-20 mm.

5. The flexible copper busbar withstand voltage test equipment for new energy vehicles according to claim 1, characterized in that: A sand falling box is placed at the bottom of the frame.

6. A method for detecting a flexible copper busbar withstand voltage test device, characterized in that: The application of the flexible copper busbar withstand voltage test equipment for new energy vehicles according to any one of claims 1 to 5 comprises the following steps: S1. Install the test piece on the fixture. Connect both ends of the test piece to the output test voltage of the pressure test machine. Use a polyurethane sleeve to seal the middle surface of the test piece. S2. Place the device in the studio and fill the studio with conductive steel sand; S3. The pressure test is started. Parts whose polyurethane sleeves are not punctured are considered qualified. Qualified parts are stored in a temporary database by the industrial computer according to their data numbers. S4. The test piece is transferred to the resistance meter, and the data of the qualified test piece is saved in the temporary database of the industrial computer according to the number; S5. The industrial computer sends the data to the printer, which prints out a generated code for affixment to the test piece. S6. The operator scans the generated code with a barcode scanner, compares the scanned information with the data in the temporary database of the industrial computer, and verifies the generated code; S7. After verification, save the temporary database to the historical database.

7. The method for detecting a flexible copper busbar withstand voltage test device according to claim 6, wherein: In step S3, when the polyurethane sleeve on the detection piece is penetrated, the tower light is turned on.

Images