A method for repairing a busbar splicing device and junction box after welding.

Abstract

This invention provides a busbar splicing device and a method for post-weld repair of junction boxes. The busbar splicing device is used to splice a remaining first busbar on a battery string assembly after it has been cut to a new second busbar. The busbar splicing device includes a base plate, a fixing component, and a welding device. The fixing component is mounted on the base plate. The base plate is configured to be inserted between the first busbar and the battery string assembly, such that the first busbar is supported on the upper surface of the base plate. The base plate also supports the second busbar, with the first end of the second busbar overlapping the first busbar above or below it. The fixing component is configured to press the second end of the second busbar against the upper surface of the base plate. The welding device is used to weld the overlapping portion of the first and second busbars together. The busbar splicing device provided by this invention can splice a new busbar to the remaining busbar on a battery string assembly, and weld the new busbar to a new junction box, ensuring the quality of the repair.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of battery production, in particular to a busbar continuation device and a post-weld repair method of a terminal box. BACKGROUND

[0002] The terminal box welding refers to welding a conductive sheet on the terminal box with a reserved busbar on the laminated assembly. The previous welding method is mostly resistance soldering, and after welding, the terminal box needs to be filled with glue, the box cover is installed, and then IV testing is performed. If unqualified is found after testing, the terminal box needs to be disassembled for repair. The repair process is roughly as follows: manually disassemble the box cover, remove the glue in the terminal box, draw the adhesive glue at the bottom of the terminal box, melt the tin at the busbar welding position with an electric soldering iron to separate the busbar from the terminal box, remove the terminal box, clean the residual tin slag and glue on the busbar, and then install a new terminal box and perform resistance soldering with the original busbar. However, in the above repair method, if the busbar is damaged seriously after disassembly, the welding quality will be unreliable after resistance soldering.

[0003] With the development of technology, a new terminal box welding method, i.e. laser welding, has appeared. When laser welding is used, no tin is needed between the busbar and the terminal box, and the laser can directly make the busbar base and the conductive sheet realize alloying connection. In this case, if the welding is found to be unqualified, the busbar cannot be disassembled by the electric soldering iron as described above, and the busbar can only be forcibly pulled off to separate the busbar from the terminal box, which will inevitably cause more damage to the busbar. Using the damaged busbar for resistance soldering repair will also lead to unreliable welding quality after repair. SUMMARY

[0004] In order to solve the above technical problems, the present application provides a busbar continuation device, which adopts the following technical scheme:

[0005] A busbar continuation device for connecting a first busbar remaining after being cut on a battery string assembly with a new second busbar, the busbar continuation device comprising a base plate, a fixing assembly and a welding device, wherein:

[0006] The fixing assembly is installed on the base plate;

[0007] The base plate is configured to be inserted into a gap between the first busbar and the battery string assembly, so that the first busbar is supported on the upper surface of the base plate, and the base plate is also used to carry the second busbar, and the first end of the second busbar is overlapped above or below the first busbar;

[0008] The fixing assembly is configured to press the second end of the second busbar against the upper surface of the base plate; and the welding device is used to weld the overlapped part of the first busbar and the second busbar together.

[0009] The busbar splicing device provided by this invention can splice a new busbar to the remaining busbar after it has been cut from the battery string assembly, thus ensuring that the length of the spliced ​​busbar meets the installation and welding requirements of the new junction box. Since a new busbar has been spliced ​​to the first busbar of the battery string assembly, during rework, the spliced ​​new busbar can be welded to the junction box, thereby ensuring the welding quality of the new junction box.

[0010] In some embodiments, the side of the substrate is formed with at least one scraping ramp that slopes inward from top to bottom. The substrate is configured to be inserted in an inclined state between the first busbar and the battery string assembly, such that the scraping ramp moves close to the battery string assembly to scrape the first busbar away from the battery string assembly.

[0011] Typically, the first busbar is inclined toward the upper surface of the battery string assembly. By setting a scraping slope that slopes inward from top to bottom on the side of the substrate, the scraping slope can move closely against the upper surface of the battery string assembly, thereby scraping the first busbar away from the battery string assembly, and ultimately ensuring that the substrate can be smoothly inserted into the gap between the first busbar and the battery string assembly.

[0012] In some embodiments, at least one limiting groove extending from the fixing component to the edge of the substrate is provided on the upper surface of the substrate.

[0013] When the substrate is inserted into the gap between the first busbar and the battery string assembly, the first busbar enters into a corresponding limiting groove;

[0014] The second busbar and the first busbar are housed in the same limiting groove, which is used to limit the swing of the first busbar and the second busbar in the width direction.

[0015] By setting a limiting groove on the upper surface of the substrate, the first busbar and the second busbar are limited in the width direction, preventing the first busbar and the second busbar from swinging in the width direction, and ensuring the accuracy and stability of the upper and lower overlap of the first busbar and the second busbar.

[0016] In some embodiments, two or more limiting grooves with different widths are provided at intervals on the upper surface of the substrate.

[0017] By providing two or more limiting grooves of different widths at intervals on the upper surface of the substrate, the substrate can support and limit busbars of different widths, thereby improving the compatibility of the present invention.

[0018] In some embodiments, the fixing assembly includes a pressure plate and a clamping assembly, wherein: the pressure plate is connected to the substrate via the clamping assembly, the pressure plate is configured to be able to move away from the substrate to leave space for the second end of the second busbar to extend under the pressure plate; the clamping assembly is used to press the pressure plate against the upper surface of the substrate so that the pressure plate presses the second end of the second busbar against the upper surface of the substrate.

[0019] A simple and easy-to-adjust fixing component is provided, which can easily press and fix the second end of the second busbar to the substrate.

[0020] In some embodiments, the pressure plate is an iron pressure plate, and the clamping assembly includes a bolt, a magnet, and a limiting nut, wherein: the magnet is mounted on the lower surface of the substrate, the pressure plate is fixedly connected to the screw of the bolt, and the substrate and the magnet are respectively provided with insertion holes for the screw to pass through. The screw located below the pressure plate passes through the insertion holes on the substrate and the magnet in sequence and is screwed into the limiting nut; the screw can move up and down in the insertion hole so that the pressure plate can move away from the substrate and can be attached to the substrate under the attraction of the magnet.

[0021] In the initial state, the pressure plate is pressed onto the substrate by the attraction of the magnet. When in use, the pressure plate is manually lifted, the second end of the second busbar is inserted between the pressure plate and the substrate, and then the pressure plate is released. The pressure plate is then attracted back to its position by the magnet, pressing the second busbar tightly onto the substrate. By setting a limit nut, the bolt can be prevented from coming off the substrate when the pressure plate is lifted.

[0022] In some embodiments, the substrate is provided with an overlap clearance hole that penetrates the substrate, the overlap portion of the second busbar and the first busbar is exposed in the overlap clearance hole, the welding device is a first butt welding device, one of the clamps of the first butt welding device passes through the overlap clearance hole and abuts against the lower surface of the overlap portion, and the other clamp of the first butt welding device abuts against the upper surface of the overlap portion to perform butt welding on the overlap portion.

[0023] By providing a through-hole on the substrate, the overlap portion of the second busbar and the first busbar is exposed in the overlap hole, thereby enabling the integrated welding device to abut against the overlap portion of the second busbar and the first busbar from both the top and bottom sides to perform welding on the overlap portion.

[0024] In some embodiments, an overlap clearance groove is provided on the substrate; the welding device is a second butt welding device, which includes a first electrode and a second electrode with opposite polarities. The first electrode is embedded in the overlap clearance groove, and the overlap portion of the second busbar and the first busbar is supported on the first electrode. The second electrode is configured to abut against the upper surface of the overlap portion to cooperate with the second electrode to perform butt welding.

[0025] By setting an overlap clearance groove on the substrate, the first electrode of the split welding device is embedded in the overlap clearance groove, so that the overlap part of the second busbar and the first busbar can be supported on the first electrode of the split welding device. Finally, the second electrode of the split welding device can abut against the upper surface of the overlap part to perform butt welding on the overlap part.

[0026] The present invention also provides a method for reworking a junction box after soldering, comprising:

[0027] Remove the junction box from the battery string assembly, cut off the busbar segment that was welded to the junction box on the battery string assembly, and the remaining busbar on the battery string assembly after cutting is the first busbar.

[0028] The first busbar and the new second busbar are overlapped and welded together using any of the above-described busbar splicing devices to obtain a spliced ​​busbar, wherein the second busbar has the same specifications as the first busbar.

[0029] Install the new junction box onto the battery string assembly and solder the reconnected busbar to the new junction box.

[0030] The present invention provides a method for post-weld repair of junction boxes, which realizes the post-weld repair of junction boxes by removing the junction box to be replaced from the battery string assembly and then welding a new junction box onto the battery string assembly. After removing the junction box to be replaced from the battery string assembly, the present invention cuts the busbar on the battery string assembly, extends the remaining busbar after cutting, and then welds the extended busbar to the new junction box. Because the busbar segment welded to the junction box on the battery string assembly is cut off, a new busbar is extended to the first busbar, and then welded to the new junction box, the welding quality of the new junction box can be guaranteed, ensuring reliable repair quality.

[0031] In some embodiments, removing the junction box from the battery string assembly and cutting off the busbar segment welded to the junction box on the battery string assembly includes:

[0032] Remove the cover of the junction box and remove the potting compound from inside the junction box;

[0033] Cut the adhesive between the junction box and the battery string assembly;

[0034] Cut the busbar away from the solder joint between the busbar and the junction box on the battery string assembly, and remove the junction box; or, detach the busbar from the solder joint between the busbar and the junction box on the battery string assembly, remove the junction box, and cut the busbar away from the solder joint between the busbar and the junction box on the battery string assembly.

[0035] The method enables the cutting of the busbar segment that has been welded to the junction box on the battery string assembly, while ensuring that the remaining first busbar has a certain length after cutting, so as to ensure that the first busbar can be connected to the new second busbar.

[0036] In some embodiments, welding the first busbar to the new second busbar after overlapping includes:

[0037] Sand off the adhesive on the first busbar;

[0038] At least the surface coating on the side of the first busbar to overlap with the second busbar is sanded off to expose the substrate of the first busbar; and / or, at least the surface coating on the side of the second busbar to overlap with the first busbar is sanded off to expose the substrate of the second busbar.

[0039] Connect the first busbar to the second busbar;

[0040] Butt welding is performed at the overlap position of the first busbar and the second busbar.

[0041] Since the adhesive on the first busbar has been removed before the lap welding is performed, and the surface coating on the lap surface of at least one of the first and second busbars has been removed, it is easier to form a strong alloyed connection between the first and second busbars after the lap welding, thereby improving the welding quality.

[0042] In some embodiments, before or after overlapping the first busbar with a new second busbar, the junction box rework method further includes applying flux to the overlap area of ​​the first busbar and the second busbar.

[0043] By applying flux to the overlap area of ​​the first and second busbars, the welding effect of the first and second busbars can be further improved. Attached Figure Description

[0044] Figure 1 This is a schematic diagram of the busbar splicing device in operation according to an embodiment of the present invention, viewed from one perspective.

[0045] Figure 2 This is a schematic diagram of the busbar splicing device in operation in an embodiment of the present invention from another perspective.

[0046] Figure 3 This is a schematic diagram of the structure of the substrate and fixing assembly in an embodiment of the present invention;

[0047] Figure 4 This is a schematic diagram of the assembly of a welding device and a substrate in one embodiment of the present invention;

[0048] Figure 5 This is a schematic diagram of the assembly of another welding device and a substrate in another embodiment of the present invention;

[0049] Figures 1 to 5 Includes:

[0050] Substrate 1:

[0051] 11. Material shovel slope; 12. Limiting groove; 13. Overlapping clearance groove;

[0052] Fixed component 2:

[0053] Pressure plate 21, clamping assembly 22, bolt 221, magnet 222, limit nut 223;

[0054] Welding device 3:

[0055] First clamp 31, second clamp 32, first electrode 33;

[0056] First busbar 100, second busbar 200. Detailed Implementation

[0057] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0058] The existing method for repairing junction boxes involves either desoldering the busbar from the battery string assembly to the junction box, or forcibly pulling the busbar detached from the junction box, to solder the new junction box onto the battery string assembly.

[0059] Because the busbars themselves are severely damaged after desoldering or stretching, the welding quality of the new junction box is unreliable. To address the aforementioned problems with existing junction box repair methods, this invention provides a busbar splicing device. This device splices the remaining first busbar after it has been cut from the battery string assembly to a new second busbar, ensuring that the length of the spliced ​​busbar meets the welding requirements of the new junction box. Using the spliced ​​busbar to weld the new junction box to the battery string assembly guarantees the welding quality of the junction box.

[0060] like Figure 1 and Figure 2 As shown, the busbar splicing device in this embodiment of the invention includes a base plate 1, a fixing component 2, and a welding device 3, wherein:

[0061] The fixing component 2 is mounted on the base plate 1.

[0062] The substrate 1 is configured to be inserted into the gap between the first busbar 100 and the battery string assembly, such that the first busbar 100 is supported on the upper surface of the substrate 1. The substrate 1 is also used to support the second busbar 200, the first end of which overlaps above or below the first busbar 100.

[0063] The fixing component 2 is configured to press the second end of the second busbar 200 against the upper surface of the substrate 1. The welding device 3 is used to weld the overlapping portion of the first busbar 100 and the second busbar 200 together.

[0064] Before using the busbar splicing device of this embodiment to splice the busbar, the junction box to be replaced needs to be removed from the battery string assembly, and the busbar segment welded to the junction box to be replaced on the battery string assembly needs to be cut off. The remaining busbar on the battery string assembly after cutting off is the first busbar 100.

[0065] The busbar splicing device of this embodiment of the invention can perform the splicing process of the busbar as follows, for example:

[0066] First, the substrate 1 is inserted into the gap between the first busbar 100 and the battery string assembly, so that the first busbar 100 is supported on the upper surface of the substrate 1.

[0067] Next, the second end of the second busbar 200 is pressed onto the upper surface of the substrate 1 by the fixing component 2, and the position of the first end of the second busbar 200 is adjusted so that the first end of the second busbar 200 overlaps the first busbar 100.

[0068] Finally, the overlapping parts of the first busbar 100 and the second busbar 200 are welded together using the welding device 3.

[0069] Of course, the second busbar 200 can be fixed on the upper surface of the substrate 1 first, and then the substrate 1 can be inserted into the gap between the first busbar 100 and the battery string assembly. Then, by adjusting the position of the second end of the first busbar 100 and the second busbar 200, the first end of the second busbar 200 can overlap the bottom of the first busbar 100.

[0070] As can be seen, the busbar splicing device provided by this invention can splice a new busbar to the remaining busbar after it has been cut off from the battery string assembly, thereby ensuring that the length of the spliced ​​busbar meets the installation and welding requirements of the new junction box. Since a new busbar has been spliced ​​to the first busbar of the battery string assembly, during rework, the spliced ​​new busbar can be welded to the junction box, thus ensuring the welding quality of the new junction box.

[0071] Since the first busbar 100 is typically inclined toward the upper surface of the battery string assembly, in order to ensure that the substrate 1 can be smoothly inserted between the first busbar 100 and the battery string assembly, optionally, a scraping slope 11 that slopes inward from top to bottom is formed on the side of the substrate 1.

[0072] like Figure 1 and Figure 2 As shown, firstly, the substrate 1 is adjusted to an inclined state, so that the scraping slope 11 is parallel to the upper surface of the battery string assembly. Next, the substrate 1 is controlled to descend, so that the scraping slope 11 is pressed against the upper surface of the battery string assembly. Finally, the substrate 1 is pushed to move towards the first busbar 100, and finally abuts against the root of the first busbar 100, so that the substrate 1 can scrape the first busbar 100 from the battery string assembly, ultimately ensuring that the substrate 1 can smoothly enter the gap between the first busbar 100 and the battery string assembly.

[0073] like Figure 5 As shown, optionally, at least one limiting groove 12 extending from the fixing component 2 to the edge of the substrate 1 is provided on the upper surface of the substrate 1. When the substrate 1 is inserted into the gap between the first busbar 100 and the battery string assembly, the first busbar 100 enters the corresponding limiting groove 12. Of course, when the second busbar 200 is fixed to the substrate 1, the second busbar 200 also needs to be adjusted into the limiting groove 12. In this way, the first busbar 100 and the second busbar 200 can be limited in the width direction, restricting the swing of the first busbar 100 and the second busbar 200 in the width direction, and ensuring the accuracy and stability of the overlapping of the first busbar 100 and the second busbar 200.

[0074] To further enhance the limiting effect of the limiting groove 12 on the first busbar 100 and the second busbar 200, the width of the limiting groove 12 needs to be approximately equal to the width of the first busbar 100 and the second busbar 200. To enable the substrate 1 to support and limit two or more busbars with different widths, optionally, two or more limiting grooves 12 with different widths are provided at intervals on the upper surface of the substrate 1. Figure 5 In the embodiment shown, four limiting grooves 12 of different widths are provided on the upper surface of the substrate 1. The widths of the four limiting grooves 12 are 4mm, 5mm, 6mm and 8mm respectively.

[0075] When two or more limiting grooves 12 of different widths are provided on the upper surface of the substrate 1, a scraping slope 11 is provided on the side of the substrate 1 at the position of each limiting groove 12. Each limiting groove 12 extends from the fixing component 2 to the corresponding scraping slope 11.

[0076] like Figure 3As shown, optionally, the fixing assembly 2 includes a pressure plate 21 and a clamping assembly 22, wherein: the pressure plate 21 is connected to the substrate 1 via the clamping assembly 22, and the pressure plate 21 is configured to be able to move away from the substrate 1 to leave space for the second end of the second busbar 200 to extend under the pressure plate 21. The clamping assembly 22 is used to press the pressure plate 21 against the upper surface of the substrate 1, so that the pressure plate 21 presses the second end of the second busbar 200 against the upper surface of the substrate 1.

[0077] The pressing process of the fixing component 2 on the second end of the second busbar 200 is as follows: First, the pressure plate 21 is controlled to move away from the substrate 1, so that a reserved space is created between the pressure plate 21 and the substrate 1; then, the second end of the second busbar 200 is inserted into the reserved space; finally, the pressure plate 21 is pressed against the upper surface of the substrate 1 by the pressing component 22, so that the pressure plate 21 presses the second end of the second busbar 200 against the upper surface of the substrate 1.

[0078] Optionally, the pressure plate 21 is an iron pressure plate, and the clamping assembly 22 includes a bolt 221, a magnet 222, and a limiting nut 223. The magnet 222 is mounted on the lower surface of the substrate 1, and the pressure plate 21 is fixedly connected to the screw of the bolt 221. The substrate 1 and the magnet 222 are respectively provided with insertion holes for the screw to pass through. The screw located below the pressure plate 21 passes through the insertion holes on the substrate 1 and the magnet 222 in sequence and is screwed onto the limiting nut 223. The screw can move up and down within the insertion holes so that the pressure plate 21 can move away from the substrate 1 and can adhere tightly to the substrate 1 under the attraction of the magnet 222.

[0079] In the initial state, the pressure plate 21 is pressed onto the substrate 1 by the attraction of the magnet 222. In use, the pressure plate 21 is manually lifted, and the second end of the second busbar 200 is inserted between the pressure plate 21 and the substrate 1. Then, the pressure plate 21 is lowered, and it is attracted back into place by the magnet 222, thereby pressing the second end of the second busbar 200 onto the substrate 1. Since the lower end of the bolt 221 is provided with a limit nut 223, the bolt 221 will not detach from the substrate 1 during the process of lifting the pressure plate 21.

[0080] Of course, other existing clamping components 22 can also be used to clamp the pressure plate 21.

[0081] Optionally, the welding device 3 in this embodiment of the invention is a butt welding device. The butt welding device is provided with two clamps or electrodes of opposite polarity. It applies instantaneous current to the overlapping portion of the first busbar 100 and the second busbar 200 through the two clamps or electrodes of opposite polarity, thereby causing an alloyed connection at the overlapping portion. To further improve the weld strength, the butt welding device may optionally weld multiple points at intervals along the overlapping portion of the first busbar 100 and the second busbar 200.

[0082] likeFigure 4 As shown, in some optional embodiments, a first welding device (i.e., an integrated welding device) comprising two pairs of clamps with opposite polarities is used as welding device 3 to perform welding on the overlapping portion of the first busbar 100 and the second busbar 200.

[0083] To enable the two clamps of the first welding device to abut against the overlapping portion of the first busbar 100 and the second busbar 200 from both the top and bottom sides for welding, an overlap clearance hole is optionally provided on the substrate 1. After the first busbar 100 and the second busbar 200 are overlapped, the lower surface of the overlapping portion of the second busbar 200 and the first busbar 100 exposes the overlap clearance hole. In this way, the first clamp 31 of the first welding device can be controlled to pass through the overlap clearance hole and abut against the lower surface of the overlapping portion, and the second clamp 32 of the first welding device can abut against the upper surface of the overlapping portion, thereby performing welding of the overlapping portion.

[0084] like Figure 5 As shown, in some alternative embodiments, a second welding device with two electrodes (i.e., a split welding device) is used as the welding device 3 to perform welding on the overlapping part of the first busbar 100 and the second busbar 200, and the first electrode 33 and the second electrode (not shown in the figure) of the second welding device are separately arranged.

[0085] To enable the first electrode 33 and the second electrode of the first welding device to abut against the overlapping portion of the first busbar 100 and the second busbar 200 from both the top and bottom, thereby performing welding at the overlapping portion, an overlap clearance groove 13 is optionally provided on the substrate 1, and the first electrode 33 of the second welding device is embedded in the overlap clearance groove 13. After the overlap of the first busbar 100 and the second busbar is completed, the overlapping portion of the second busbar 200 and the first busbar 100 is supported by the first electrode 33. In this way, by controlling the second electrode of the second welding device to abut against the upper surface of the overlapping portion, the second welding device can perform welding at the overlapping portion.

[0086] The present invention also provides a method for reworking a junction box after soldering, which includes the following steps:

[0087] S100. Remove the junction box from the battery string assembly, cut off the busbar segment that was welded to the junction box on the battery string assembly, and the remaining busbar on the battery string assembly after cutting is the first busbar.

[0088] S200. Using the busbar splicing device provided in any of the above embodiments, the first busbar and the new second busbar are overlapped and welded together to obtain a spliced ​​busbar, wherein the second busbar has the same specifications as the first busbar.

[0089] The specific overlapping process of the busbar splicing device between the first busbar and the new second busbar has been described in detail above, and will not be repeated here for the sake of brevity.

[0090] S300. Install the new junction box onto the battery string assembly and solder the continued busbar to the new junction box.

[0091] The present invention provides a method for post-weld repair of junction boxes, which realizes the post-weld repair of junction boxes by removing the junction box to be replaced from the battery string assembly and then welding a new junction box onto the battery string assembly. After removing the junction box to be replaced from the battery string assembly, the present invention cuts the busbar on the battery string assembly, extends the remaining busbar after cutting, and then welds the extended busbar to the new junction box. Because the busbar segment welded to the junction box on the battery string assembly is cut off, a new busbar is extended to the first busbar, and then welded to the new junction box, the welding quality of the new junction box can be guaranteed, ensuring reliable repair quality.

[0092] Optionally, step S100, which involves removing the junction box from the battery string assembly and cutting off the busbar segment welded to the junction box on the battery string assembly, specifically includes the following sub-steps:

[0093] S101. Remove the cover of the junction box and clean the glue inside the junction box.

[0094] S102. Cut the adhesive between the junction box and the battery string assembly.

[0095] S103,

[0096] First, avoid the soldered joint between the busbar and the junction box on the battery string assembly before cutting the busbar, then remove the junction box. Alternatively, first detach the busbar from the soldered joint on the battery string assembly, remove the junction box, and then, avoiding the soldered joint, cut the busbar. For detaching the busbar from the junction box, if the connection is made by soldering, you can use a soldering iron to melt the solder and detach the busbar from the junction box. If the connection is made by laser welding, you can pull the busbar forcefully to detach it from the junction box.

[0097] Optionally, the step S200 of overlapping and welding the first busbar with the new second busbar includes the following sub-steps:

[0098] S201. Sand off the adhesive on the first busbar.

[0099] S202, at least the surface coating on the side of the first busbar to overlap with the second busbar is sanded off to expose the substrate of the first busbar; and / or, at least the surface coating on the side of the second busbar to overlap with the first busbar is sanded off to expose the substrate of the second busbar.

[0100] S203. Connect the first busbar to the second busbar.

[0101] S204. Butt welding is performed at the lap joint of the first busbar and the second busbar.

[0102] Since the adhesive on the first busbar has been removed before the lap welding is performed, and the surface coating on the lap surface of at least one of the first and second busbars has been removed, it is easier to form a strong alloyed connection between the first and second busbars after the lap welding, thereby improving the welding quality.

[0103] Optionally, in step S200, before or after overlapping the first busbar with the new second busbar, the junction box rework method in this embodiment of the invention further includes: applying flux to the overlapping portion of the first busbar and the second busbar.

[0104] By applying flux to the overlap area of ​​the first and second busbars, the welding effect of the first and second busbars can be further improved.

[0105] The present invention has been described above in sufficient detail and with certain specificities. Those skilled in the art should understand that the descriptions in the embodiments are merely exemplary, and all changes made without departing from the true spirit and scope of the invention should fall within the protection scope of the invention. The scope of protection claimed by the present invention is defined by the claims, and not by the above descriptions in the embodiments.

Claims

1. A busbar splicing device, characterized in that, The busbar splicing device is used to connect the remaining first busbar after it has been cut from a battery string assembly to a new second busbar. The busbar splicing device includes a substrate, a fixing assembly, and a welding device, wherein: The fixing component is mounted on the substrate; The substrate is configured to be inserted into the gap between the first busbar and the battery string assembly, such that the first busbar is supported on the upper surface of the substrate. The substrate is also configured to support the second busbar, the first end of which overlaps above or below the first busbar. The fixing assembly is configured to press the second end of the second busbar against the upper surface of the substrate. The welding device is used to weld the overlapping parts of the first busbar and the second busbar together; The substrate has at least one shovel-shaped inclined surface that slopes inward from top to bottom on its side. The substrate is configured to be inserted into the first busbar and the battery string assembly in an inclined state, such that the shovel-shaped inclined surface moves close to the battery string assembly to shovel the first busbar away from the battery string assembly.

2. The busbar splicing device as described in claim 1, characterized in that, At least one limiting groove is provided on the upper surface of the substrate, extending from the fixing component to the edge of the substrate. When the substrate is inserted into the gap between the first busbar and the battery string assembly, the first busbar enters into a corresponding limiting groove; The second busbar and the first busbar are housed in the same limiting groove, which is used to restrict the swing of the first busbar and the second busbar in the width direction.

3. The busbar splicing device as described in claim 2, characterized in that, The upper surface of the substrate is provided with two or more limiting grooves of different widths at intervals.

4. The busbar splicing device as described in claim 1, characterized in that, The fixing assembly includes a pressure plate and a clamping assembly, wherein: The pressure plate is connected to the substrate via the clamping assembly. The pressure plate is configured to be able to move away from the substrate so that space is left for the second end of the second busbar to extend under the pressure plate. The clamping assembly is used to press the pressure plate against the upper surface of the substrate so that the pressure plate presses the second end of the second busbar against the upper surface of the substrate.

5. The busbar splicing device as described in claim 4, characterized in that, The pressure plate is made of iron, and the clamping assembly includes bolts, magnets, and limit nuts, wherein: The magnet is mounted on the lower surface of the substrate, and the pressure plate is fixedly connected to the screw of the bolt. The substrate and the magnet are respectively provided with insertion holes for the screw to pass through. The screw located below the pressure plate passes through the insertion holes on the substrate and the magnet in sequence and is screwed into the limiting nut. The screw can move up and down in the insertion hole so that the pressure plate can move away from the substrate and can stick to the substrate under the attraction of the magnet.

6. The busbar splicing device as described in claim 1, characterized in that, The substrate is provided with an overlap clearance hole that penetrates the substrate. The overlap portion of the second busbar and the first busbar is exposed in the overlap clearance hole. The welding device is a first butt welding device. One of the clamps of the first butt welding device passes through the overlap clearance hole and abuts against the lower surface of the overlap portion. The other clamp of the first butt welding device abuts against the upper surface of the overlap portion to perform butt welding on the overlap portion.

7. The busbar splicing device as described in claim 1, characterized in that, The substrate is provided with an overlap clearance groove; The welding device is a second butt welding device, which includes a first electrode and a second electrode with opposite polarities. The first electrode is embedded in the overlap clearance groove. The overlap portion of the second busbar and the first busbar is supported on the first electrode. The second electrode is configured to abut against the upper surface of the overlap portion to cooperate with the second electrode to perform butt welding.

8. A method for reworking a junction box after soldering, characterized in that, The post-welding repair method for the junction box includes: Remove the junction box from the battery string assembly, cut off the busbar segment that was welded to the junction box on the battery string assembly, and the remaining busbar on the battery string assembly after cutting off is the first busbar; The first busbar and a new second busbar are overlapped and welded together using the busbar splicing device according to any one of claims 1 to 7 to obtain a spliced ​​busbar, wherein the second busbar has the same specifications as the first busbar. Install the new junction box onto the battery string assembly, and weld the reconnected busbar to the new junction box.

9. The method for reworking a junction box after welding as described in claim 8, characterized in that, The step of removing the junction box from the battery string assembly and cutting off the busbar segment on the battery string assembly that was welded to the junction box includes: Remove the cover of the junction box and remove the potting compound from inside the junction box; Cut the adhesive between the junction box and the battery string assembly; Cut the busbar away from the welding point between the busbar on the battery string assembly and the junction box, and remove the junction box; or, detach the busbar from the welding point between the busbar on the battery string assembly and the junction box, remove the junction box, and cut the busbar away from the welding point between the busbar on the battery string assembly and the junction box.

10. The method for reworking a junction box after welding as described in claim 8, characterized in that, The step of overlapping and welding the first busbar with the new second busbar includes: Grind off the adhesive on the first busbar; At least the surface coating on the side of the first busbar to overlap with the second busbar is sanded off to expose the substrate of the first busbar; and / or, at least the surface coating on the side of the second busbar to overlap with the first busbar is sanded off to expose the substrate of the second busbar. The first busbar and the second busbar are joined together; Butt welding is performed at the overlap position of the first busbar and the second busbar.

11. The method for re-repairing a junction box after welding as described in claim 10, characterized in that, Before or after overlapping the first busbar with the new second busbar, the post-weld repair method for the junction box further includes: Apply flux to the overlapping area of ​​the first busbar and the second busbar.

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