Manufacturing process of a motor main frame control system

Abstract

This invention discloses a manufacturing process for a motor main frame control system. The process includes: S1, preparing a lead wire frame module; S2, preparing a stacked busbar module, the stacked busbar module comprising a first stacked busbar base plate, a second stacked busbar base plate, and a third stacked busbar, the first stacked busbar base plate comprising a first welding plate and a second welding plate, and the second stacked busbar base plate having bushing mounting holes; S3, placing the frame housing, the lead wire frame module, and the stacked busbar module into an injection molding module for injection molding. The metal pins in the lead wire frame area of ​​this invention are pre-injected and then cut, greatly improving pin insertion efficiency and ensuring stable product quality. This not only meets customer production capacity requirements and reduces product manufacturing costs but also significantly shortens the molding cycle.

Description

Technical Field

[0001] This invention relates to the field of control system manufacturing technology, and in particular to a manufacturing process for a motor main frame control system. Background Technology

[0002] Currently, the motor main frame control system used in the automotive industry mostly adopts the manufacturing process of stamping, electroplating, welding and injection molding. The process is complex, the functions are not integrated, the processing and production costs are high, and the product stability is poor.

[0003] In existing technologies, the large disparity in the proportion of metal pins relative to the entire injection-molded part and their wide distribution lead to low assembly production efficiency, high defect rates in mass production, and the inability to meet the positional accuracy requirements of the metal pins during injection molding. In addition, the metal pins in the lead frame area of ​​the motor main frame are widely distributed, have limited space, and are thin in molding thickness, making it difficult to inject glue for molding. Furthermore, since the metal parts in the stacked busbar area of ​​the motor main frame are directly welded and assembled, if the welding and assembly sequence is not considered, it will lead to a decline in the quality of semi-finished products and the outflow of defective products. Summary of the Invention

[0004] To address the above problems, this invention proposes a manufacturing process for a motor main frame control system.

[0005] The main contents of this invention include:

[0006] A manufacturing process for a motor main frame control system, the motor main frame control system comprising a frame housing, a lead frame module, a laminated busbar module, and a plurality of signal metal pins, comprising the following steps:

[0007] S1. Fabrication of the lead frame module;

[0008] S2. Fabricate a stacked busbar module. The stacked busbar module has several metal pins and capacitor leads welded onto it. The stacked busbar module includes a first stacked busbar base plate, a second stacked busbar base plate, and a third stacked busbar. The first stacked busbar base plate includes a first welding plate and a second welding plate, which are connected by a curved surface. The second welding plate is higher than the first welding plate. The first welding plate has brazing contacts extending vertically upwards on its side, and the second welding plate has bolt mounting holes extending vertically upwards on its side. The second stacked busbar base plate has bushing mounting holes, and barbs extending vertically upwards on its side.

[0009] S3. The frame housing, the lead frame module, the stacked busbar module, and several signal metal pins are placed into the injection molding module and injection molded to obtain a motor main frame control system with the frame housing.

[0010] Preferably, the step of fabricating the lead frame module in S1 includes:

[0011] S1-1, Stamping of metal pins for lead frame module: First, the metal pins are stamped into a coiled form;

[0012] S1-2, The burr side of the stamped metal needle roll is facing down and towards the core;

[0013] S1-3, Electroplating: Electroplating the metal needles that have been stamped into coils, and confirming the electroplating feeding and discharging method;

[0014] S1-4. Secondary stamping: After electroplating, the metal needle coil is subjected to secondary stamping to fold the metal needle coil.

[0015] Bending into a row of continuous metal needles;

[0016] S1-5, Pre-injection molding: The connecting metal needle is placed into the pre-injection mold for injection molding;

[0017] S1-6, Cutting the connecting material: Cutting the connecting material area of ​​the metal needles after injection molding to form different numbers of needle groups;

[0018] S1-7. Merging: Merge the metal needles after cutting the two rows of continuous material into a whole to complete the preparation of the lead frame module.

[0019] Preferably, in S1-3, the burr side of the electroplated metal needle roll is facing down and towards the core.

[0020] Preferably, the preparation steps of the stacked busbar in S2 include:

[0021] S2-1, Stamping No. 1 laminated busbar: Stamping the No. 1 laminated busbar base plate according to the product shape;

[0022] S2-2, Riveting: Rivet bolts in the bolt mounting holes of the No. 1 laminated busbar base plate;

[0023] S2-3, Welding: Weld several capacitor leads and metal pins onto the base plate of the No. 1 stacked busbar;

[0024] S2-4, Stamping No. 2 laminated busbar: Stamping the No. 2 laminated busbar base plate according to the product shape;

[0025] S2-5. Welding: Weld capacitor leads to the base plate of the No. 2 stacked busbar.

[0026] S2-6, Injection Molding: The frame housing, the lead frame module, the first stacked busbar, the second stacked busbar, several signal metal pins, and several third stacked busbars are injected into the injection mold for injection molding.

[0027] Preferably, the capacitor pin in S2-3 is an electromagnetic compatibility capacitor pin, and the metal pin is an integrated circuit board metal pin.

[0028] Preferably, the processing steps for the electromagnetic compatibility capacitor pins and the integrated circuit board metal pins are stamping – rolling and electroplating – secondary stamping.

[0029] Preferably, the metal pins welded in S2-5 are electromagnetic compatibility capacitor pins.

[0030] Preferably, the processing steps for the electromagnetic compatibility capacitor pins are stamping – roll-to-roll electroplating – secondary stamping.

[0031] Preferably, there are three third-layer busbars in S2-6.

[0032] Preferably, there are 15 signal metal needles.

[0033] This invention proposes a manufacturing process for a motor main frame control system, the advantages of which are:

[0034] (1) The metal pins in the lead frame area are pre-injected and then cut, which greatly improves the pin insertion efficiency and ensures stable product quality. This not only meets the customer's production capacity requirements but also reduces the product manufacturing cost. Furthermore, it has significant cost advantages in stamping, electroplating, and injection molding, and can greatly shorten the molding cycle.

[0035] (2) In the above solution, the side-by-side metal pins are assembled into a whole using pre-injection molding, achieving an integrated molding process for the upper and lower pin rows, thus ensuring stable product quality and dimensions. Furthermore, this process allows for the integrated molding of six pin rows, avoiding the inefficiency of individual pin injection molding by workers, and preventing errors in the selection of six pins from two rows, which can lead to mold failure. Therefore, this process is suitable for production needs with numerous and complex pin rows, offering high capacity and significant benefits. Attached Figure Description

[0036] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0037] Figure 2 This is a schematic diagram of the lead frame module of the present invention;

[0038] Figure 3 This is a schematic diagram of the metal needle coil of the present invention;

[0039] Figure 4 This is a schematic diagram of the continuous metal needle of the present invention.

[0040] Figure 5 This is a schematic diagram of the No. 1 stacked busbar module of the present invention;

[0041] Figure 6This is a schematic diagram of the second stacked busbar module of the present invention;

[0042] Figure 7 This is a schematic diagram of the third stacked busbar of the present invention;

[0043] Figure 8 This is a schematic diagram of the stacked busbar module of the present invention.

[0044] The components in the attached diagram are labeled as follows: 1-Frame housing, 2-Leader frame module, 21-Metal pin reel, 22-Connecting metal pin, 3-Laminated busbar module, 31-Laminated busbar base plate 1, 311-Welding plate 1, 312-Welding plate 2, 313-Bolt, 314-Bracket, 32-Laminated busbar base plate 2, 33-Laminated busbar 3, 4-Integrated circuit board metal pin, 5-Electromagnetic compatibility capacitor pin, 6-Bushing, 7-Signal metal pin. Detailed Implementation

[0045] The technical solution protected by this invention will be described in detail below with reference to the accompanying drawings.

[0046] Please see Figures 1 to 8 This invention proposes a manufacturing process for a motor main frame control system, which includes a frame housing 1, a lead frame module 2, a stacked busbar module 3, and several signal metal pins 7, comprising the following steps:

[0047] S1. Prepare lead frame module 2. First, stamp the metal pins of lead frame module 2 into a coil. Arrange the pins as designed in the product style, with the burr side of the stamped metal pin coil 21 facing down towards the core. Next, electroplate the metal pin coil 21. Depending on the product function, different types of plating are required for the metal pins. It is necessary to confirm the plating type for different parts of each metal pin and design the electroplating steps for the metal pin coil 21 accordingly. After designing the electroplating steps for the metal pin coil 21, the electroplating feeding and discharging method needs to be confirmed. The electroplating discharging method determines the feeding method of the subsequent secondary stamping die. If the feeding method is incorrect, the metal pin coil 21 will not be able to enter the die synchronously and be formed in the secondary stamping.

[0048] The secondary stamping process involves the following steps: After electroplating, the burr side of the electroplated metal needle coil 21 faces downwards towards the core. Therefore, the metal needle coil 21 is first flattened, and then subjected to secondary stamping to bend it into parallel connected metal needles 22. Next, the product structure is designed for pre-injection molding. The main requirement of this structure is to ensure that the relative positions of the entire row of metal needles do not deform during production and injection molding, and to also serve as an injection molding positioning structure. The connected metal needles 22 are placed into the pre-injection mold for injection molding. After pre-injection molding, the connected area of ​​the injection-molded metal needles 22 is cut off, ensuring that the metal parts do not short-circuit. Finally, the two rows of cut connected metal needles are merged into a whole to complete the fabrication of the lead frame module 2.

[0049] S2. Prepare a stacked busbar module 3. The stacked busbar module 3 is welded with several metal pins and capacitor leads. The stacked busbar module 3 includes a first stacked busbar base plate 31, a second stacked busbar base plate 32, and a third stacked busbar 33. The first stacked busbar base plate 31 includes a first welding plate 311 and a second welding plate 312. The first welding plate 311 and the second welding plate 312 are connected by a curved surface. The second welding plate 312 is higher than the first welding plate 311. The first welding plate 311 has brazing contacts 314 extending vertically upward on its side. The second welding plate 312 has bolt mounting holes extending vertically upward on its side. A bushing 6 is installed on the second stacked busbar base plate 32. A barb extends vertically upward on the side of the second stacked busbar base plate 32.

[0050] First, the first stacked busbar is stamped, and the base plate 31 of the first stacked busbar is stamped according to the product shape. Then, bolts 313 are riveted into the bolt mounting holes of the base plate 31 of the first stacked busbar. Then, the electromagnetic compatibility capacitor pin 5 and the integrated circuit board metal pin 4 are welded onto the base plate 31 of the first stacked busbar. The processing steps for the electromagnetic compatibility capacitor pin 5 and the integrated circuit board metal pin 4 are stamping, rolling electroplating, and secondary stamping. Next, the second stacked busbar is stamped, and the base plate 32 of the second stacked busbar is stamped according to the product shape. Then, the electromagnetic compatibility capacitor pin 5 is welded onto the base plate 32 of the second stacked busbar.

[0051] S3. Finally, the frame housing 1, the lead frame module 2, the first stacked busbar, the second stacked busbar, the 15 signal metal pins 7, and the 3 third stacked busbars 33 are placed into the injection mold and injection molded to obtain the motor main frame control system with the frame housing.

[0052] The above description is merely an embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention's specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A manufacturing process of a motor main frame control system, the motor main frame control system comprising a frame housing, a lead frame module, a laminated busbar module, and a plurality of signal metal pins, characterized in that, It comprises the following steps: S1, preparing a lead frame module, comprising: S1-1, stamping the metal pins of the lead frame module, first stamping the metal pins into a coil; S1-2, the burr surface of the stamped metal pin coil faces downward and faces the coil core; S1-3, electroplating: electroplating the metal pin coil stamped into a coil, and confirming the electroplating in-out mode; S1-4, secondary stamping: after electroplating, the metal pin coil is subjected to secondary stamping to bend the metal pin coil into a parallel continuous metal pin; S1-5, pre-injection molding: placing the continuous metal pin into a pre-injection molding mold for injection molding; S1-6, continuous cutting: cutting the continuous area of the continuous metal pin after injection molding to form different numbers of pin groups; S1-7, merging: merging the two rows of continuous metal pins after cutting into a whole to complete the preparation of the lead frame module S2, preparing a laminated busbar module, the laminated busbar module is welded with a plurality of metal pins and capacitor pins, the laminated busbar module comprises a first laminated busbar bottom plate, a second laminated busbar bottom plate and a third laminated busbar; the first laminated busbar bottom plate comprises a first welding plate and a second welding plate, the first welding plate and the second welding plate are connected by a curved surface, the second welding plate is higher than the first welding plate, the side edge of the first welding plate is vertically upwardly provided with a brazing contact, and the side edge of the second welding plate is vertically upwardly provided with a bolt mounting hole; the second laminated busbar bottom plate is provided with a bushing mounting hole, and the side edge of the second laminated busbar bottom plate is vertically provided with a barb; S3, placing the frame shell, the lead frame module, the first laminated busbar, the second laminated busbar, a plurality of signal metal pins and the third laminated busbar into an injection molding mold to obtain a motor main frame control system with the frame shell.

2. A manufacturing process for a motor body frame control system according to claim 1, wherein, The burr surface of the metal pin coil after electroplating in S1-3 faces downward and faces the coil core.

3. A manufacturing process for a motor body frame control system according to claim 1, wherein, The preparation steps of the laminated busbar in S2 comprise: S2-1, stamping a first laminated busbar: stamping a first laminated busbar bottom plate according to the shape of the product; S2-2, riveting: riveting a bolt in the bolt mounting hole of the first laminated busbar bottom plate; S2-3, welding: welding a plurality of capacitor pins and metal pins on the first laminated busbar bottom plate, the capacitor pins are welded on the first welding plate, and the metal pins are welded on the second welding plate; S2-4, stamping a second laminated busbar: stamping a second laminated busbar bottom plate according to the shape of the product; S2-5, welding: welding capacitor pins on the second laminated busbar bottom plate.

4. A manufacturing process for a motor body frame control system according to claim 3, wherein, The capacitor pins in S2-3 are electromagnetic compatibility capacitor pins, and the metal pins are integrated circuit board metal pins.

5. A manufacturing process for a motor body frame control system according to claim 4, wherein, The processing procedures of the electromagnetic compatibility capacitor pins and the integrated circuit board metal pins are stamping-coiling electroplating-secondary stamping.

6. A manufacturing process for a motor body frame control system according to claim 3, wherein, In S2-5 The welded metal pins are electromagnetic compatibility capacitor pins.

7. A manufacturing process for a motor body frame control system according to claim 6, wherein, The processing procedure of the electromagnetic compatibility capacitor pins is stamping-coiling electroplating-secondary stamping.

8. The manufacturing process of a motor body frame control system according to claim 1, wherein, The third laminated busbar in S3 is three.

9. The manufacturing process of a motor body frame control system according to claim 1, wherein, The signal metal pins are 15.

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