A new energy vehicle resolver stator wiring harness with shielding function and its preparation process

Abstract

The present invention relates to the field of automotive cable technology, and discloses a preparation process for a new energy vehicle rotary transformer stator wiring harness with a shielding function, comprising the following steps: selecting high-purity electrolytic copper for smelting, and adding equal proportions of arsenic, tin, zinc and nickel elements to the smelting pool; the copper material is heat-treated and then enters a rolling mill for rolling, and the rolling process requires multiple hot rolling and cold rolling to form copper foil; the copper foil formed after rolling and annealing needs to be surface treated; the copper foil is wound around eight low-voltage wires, and is wound in a spiral forward winding manner; a heat shrink tube is again put on the surface of the wiring harness with the copper foil, and the heat shrink tube shrinks on the copper foil after uniform heating treatment. The present invention first applies resin on the surface of the wiring harness, and then passes the wiring harness coated with the resin through a composite material to achieve mixing of the composite material and the resin, and also achieves uniform coverage of the composite material on the wiring harness. This process design can greatly improve the production efficiency of the wiring harness.

Description

Technical Field

[0001] The present invention relates to the technical field of automobile cables, and more specifically to a new energy automobile resolver stator wiring harness with a shielding function and a preparation process thereof. Background Art

[0002] The existing resolver stator wiring harnesses on the market usually adopt the structure of single-core twisted pair or multi-core shielded wire. The shielding effect of single-core twisted pair can no longer meet the increasingly centralized needs of electrical design; and the multi-core shielded wire has a complicated process in the wiring harness processing, and the shielding layer produced during the processing will also affect the overall cleanliness requirements of the wiring harness. The shielding effect is not good and cannot meet the cleanliness requirements.

[0003] And now a new energy vehicle battery wiring harness production process (publication number CN113937590A) is disclosed, which relates to the technical field of new energy vehicle battery wiring harness production. In order to solve the problem that the detection part of the wiring harness in the existing new energy vehicle battery wiring harness production process is generally inefficient, and the wiring harness production process detection function is also relatively single, which is easy to affect the progress of the entire production process and the quality of the finished product. Step 1: Wire harness marking and printing: mark and print the wires to be produced, print different colors according to different wire types, and mark different wire diameters; Step 2: Cutting and opening of the wire harness. In the technology disclosed in this patent, the production process of the wire harness adopts an insulating layer that is placed on the surface of the battery cell, which will also cause a gap between the battery cell and the insulating layer. Summary of the invention

[0004] The main technical problem solved by the present invention is to provide a new energy vehicle resolver stator wiring harness with shielding function and a preparation process thereof, which solves the problems in the above-mentioned background technology.

[0005] To solve the above technical problems, according to one aspect of the present invention, more specifically, a new energy vehicle resolver stator wiring harness with a shielding function, comprising a female connector, a wiring harness, a resolver stator and a grounding terminal;

[0006] The wiring harness comprises eight low-voltage wires, and the wiring harness is connected to the female connector and the resolver stator through the eight low-voltage wires;

[0007] After the eight low-voltage wires are twisted, a layer of copper foil is attached, a heat shrink tube is sheathed on the outside of the copper foil, and a corrugated tube is sheathed on the outside of the heat shrink tube, and heat shrink tubes are sheathed again on both ends of the corrugated tube to be fixed by heat shrinkage.

[0008] The preparation process of the resolver stator harness is as follows:

[0009] S1. Select high-purity electrolytic copper for smelting, and add equal proportions of arsenic, tin, zinc and nickel elements into the smelting pool;

[0010] S2. After the copper material is heat treated, it enters the rolling mill for rolling. The rolling process requires multiple hot rolling and cold rolling to form copper foil;

[0011] S3. The copper foil formed after rolling and annealing needs to be surface treated;

[0012] S4. Wrap the copper foil around eight low-voltage wires in a spiral forward winding manner, with no less than two layers of winding;

[0013] S5. Put the heat shrink tube again on the surface of the wire harness covered with the copper foil, and the heat shrink tube shrinks on the copper foil after being evenly heated;

[0014] S6, immersing the wire harness wrapped with the heat shrink tube into the resin, and passing it through the pultrusion equipment to set the glass fiber tube;

[0015] S7. The formed fiberglass tube enters the curing furnace for curing. The temperature and time of the curing process need to be controlled.

[0016] Furthermore, in the step S1, the copper material formed in the smelting pool has a copper element mass ratio of 95-98%, an arsenic element mass ratio of 0.1-0.23%, a tin element mass ratio of 0.43-0.6%, a zinc element mass ratio of 0.06-0.12%, and a nickel element mass ratio of 0.35-0.57%.

[0017] Furthermore, in step S2, the copper material is deformed by rolling to gradually reduce the thickness, and the copper foil of the required thickness is finally obtained by multiple rolling. The thickness of the copper foil is obtained and the surface quality of the copper foil is improved by multiple hot rolling and cold rolling alternating methods.

[0018] Furthermore, after the copper material is rolled to prepare the copper foil, the copper foil needs to be cut to form strip copper foil, and the formed strip copper foil has a uniform width.

[0019] Furthermore, in step S6, the raw materials of the glass fiber include glass fiber yarn, resin, and curing agent, and these raw materials need to be first inspected for quality to ensure that they meet production requirements, including:

[0020]

[0021] Among them, C represents the grade index of the composite material formed by mixing glass fiber yarn, resin and curing agent, T represents the bonding coefficient between different materials after mixing, and d i represents the transmittance index of the composite material collected at the i-th sampling point; and:

[0022]

[0023] Wherein, d represents the comprehensive transmittance index of the composite material after three samples are collected, and d0 represents the average transmittance index of the composite material after three samples are collected; and:

[0024]

[0025] Wherein, s represents the concentration ratio of the composite material after collecting three portions, k represents the flow coefficient of the fluid, and m represents the concentration coefficient of the composite material after three samplings.

[0026] Furthermore, the wiring harness is immersed in the mixed resin solution, the surface of the wiring harness will be covered with the resin solution, and the resin solution can fill the gap between the glass fiber tube and the heat shrink tube.

[0027] Furthermore, in step S6, the wire harness is passed through a pultrusion device, and the resin on the surface of the wire harness is contacted and mixed with a composite material composed of glass fiber yarn and a curing agent in the pultrusion device, and is evenly covered on the surface of the wire harness as the wire harness is pulled out.

[0028] Furthermore, the glass fiber tube covered on the wire harness and solidified was sampled and cut, and the material ratio test was performed on the sample after cutting, and the results were:

[0029]

[0030] Wherein, M represents the concentration deviation index between the prepared composite material and the cured glass fiber tube material, u represents the comprehensive volume content of glass fiber yarn and resin in the cut sample, and h represents the volume content of curing agent; and:

[0031]

[0032] Where p represents the coefficient of influence of the comprehensive volume content u of glass fiber yarn and resin and the volume content h of curing agent on the thickness d of the sampling sample;

[0033] When M≥7.6, the concentration deviation index of the pre-prepared composite material and the cured glass fiber tube material does not meet the requirements;

[0034] When M<7.6, the concentration deviation index of the pre-prepared composite material and the cured glass fiber tube material meets the requirements.

[0035] The beneficial effects of the new energy vehicle resolver stator wiring harness with shielding function and the preparation process thereof of the present invention are:

[0036] 1. The present invention adopts a design of twisting multiple wire cores in pairs, and covers the twisted wire harnesses with copper foil and heat shrink tubing. This not only effectively meets the needs of electrical centralization, but also improves the firmness and freedom of movement of the wire harness.

[0037] 2. The present invention first applies resin on the surface of the wiring harness, and then passes the wiring harness coated with resin through the composite material to achieve mixing of the composite material and the resin, and also to achieve uniform coverage of the composite material on the wiring harness. This process design can greatly improve the production efficiency of the wiring harness and reduce the gap between the battery cell and the insulating layer.

[0038] 3. The present invention tests the quality and concentration of the composite material and the resin before the glass fiber tube is sheathed on the wire harness, and samples and tests the formed glass fiber tube after the composite material and the resin are mixed. The two tests are calibrated at the same time to ensure that the formed cable has better comprehensive capabilities. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] The present invention is further described in detail below with reference to the accompanying drawings and specific implementation methods.

[0040] Figure 1 It is a schematic diagram of the structure of the present invention;

[0041] Figure 2 It is a process flow chart of the present invention.

[0042] In the figure: 1. Female connector; 2. Low-voltage wire; 3. Heat shrink tubing; 4. Wiring harness; 5. Resolver stator; 6. Ground terminal. DETAILED DESCRIPTION

[0043] The present invention will be described in detail below with reference to the accompanying drawings and in combination with embodiments. It should be noted that the embodiments and features in the embodiments of the present application can be combined with each other without conflict.

[0044] like Figure 1 As shown, according to one aspect of the present invention, a new energy vehicle resolver stator wiring harness with a shielding function is provided, comprising a female connector 1, a wiring harness 4, a resolver stator 5 and a grounding terminal 6; the wiring harness 4 comprises eight low-voltage wires 2, and the wiring harness 4 is connected to the female connector 1 and the resolver stator 5 through eight low-voltage wires 2; the eight low-voltage wires 2 are twisted into pairs and then a layer of copper foil is attached, a heat shrink tube 3 is covered on the outside of the copper foil, and a corrugated tube is covered on the outside of the heat shrink tube 3, and a corrugated tube is covered on the outside of the heat shrink tube 3, and the two ends of the corrugated tube are again covered with the heat shrink tube 3 for heat shrinkage and fixation.

[0045] The wiring process of the wiring harness is as follows: the female connector 1 and the resolver stator 5 are packaged, eight low-voltage wires 2 are twisted in pairs and buried in the ground terminal 6; copper foil, heat pipe and glass fiber tube are attached to the outside of the wiring harness 4 in turn, and finally heat shrink tubes are put on both ends of the glass fiber tube for fixing; one end of the wiring harness 4 is connected to the motor controller through the female connector 1, and the other end of the wiring harness 4 is connected to the resolver stator; and the wiring harness of the ground terminal 6 is connected to the copper foil, and the ground terminal 6 is connected to the vehicle body.

[0046] like Figure 2As shown, a preparation process of a new energy vehicle resolver stator wiring harness with a shielding function comprises the following steps:

[0047] Step 1: Select high-purity electrolytic copper for smelting, and add equal proportions of arsenic, tin, zinc and nickel elements into the smelting pool;

[0048] Step 2: After the copper material is heat treated, it enters the rolling mill for rolling. The rolling process requires multiple hot rolling and cold rolling to form copper foil;

[0049] Step 3: The copper foil formed after rolling and annealing needs to be surface treated;

[0050] Step 4: Wrap the copper foil around eight low-voltage wires in a spiral forward winding manner, with no less than two layers of winding;

[0051] Step 5: Put the heat shrink tube again on the surface of the wire harness covered with copper foil, and the heat shrink tube shrinks on the copper foil after uniform heating;

[0052] Step 6: Dip the wire harness wrapped with the heat shrink tube into the resin and pass it through the pultrusion equipment to set the glass fiber tube;

[0053] Step 7: The formed fiberglass tube enters the curing furnace for curing. The temperature and time during the curing process need to be controlled.

[0054] In step 1 of this embodiment, the copper material formed in the smelting pool has a copper element mass ratio of 95-98%, an arsenic element mass ratio of 0.1-0.23%, a tin element mass ratio of 0.43-0.6%, a zinc element mass ratio of 0.06-0.12%, and a nickel element mass ratio of 0.35-0.57%.

[0055] In step 2 of this embodiment, the copper material is deformed by rolling, the thickness is gradually reduced, and the copper foil of the desired thickness is finally obtained by multiple rolling. The thickness of the copper foil is obtained and the surface quality of the copper foil is improved by multiple hot rolling and cold rolling alternately. After the copper material is rolled into copper foil, the copper foil needs to be cut to form a strip copper foil, and the formed strip copper foil has a uniform width. By cutting the copper foil into strips, it can better cover and wrap around the surface of the wiring harness.

[0056] In step six of this embodiment, the raw materials of the glass fiber include glass fiber yarn, resin, and curing agent, and these raw materials need to be first inspected for quality to ensure that they meet production requirements, including:

[0057]

[0058] Among them, C represents the grade index of the composite material formed by mixing glass fiber yarn, resin and curing agent, T represents the bonding coefficient between different materials after mixing, and di represents the transmittance index of the composite material collected at the i-th sampling point; and:

[0059]

[0060] Wherein, d represents the comprehensive transmittance index of the composite material after three samples are collected, and d0 represents the average transmittance index of the composite material after three samples are collected; and:

[0061]

[0062] Wherein, s represents the concentration ratio after collecting three portions of the composite material, k represents the flow coefficient of the fluid, and m represents the concentration coefficient of the composite material after three samplings; the wiring harness is immersed in the mixed resin solution, the surface of the wiring harness will be covered with the resin solution, and the resin solution can fill the gap between the glass fiber tube and the heat shrink tube.

[0063] The composite material of the glass tube was sampled. After collecting three samples, the concentration coefficients of the composite material were m1=0.12, m2=0.16, and m3=0.09. The flow coefficient of the fluid was k=1.4, and we have:

[0064]

[0065] The composite material collected three times for sampling has a comprehensive transmittance index of d1=0.08, d2=0.07, d3=0.1, that is, the average transmittance index of the composite material of the three samples is d0=0.083, and:

[0066]

[0067] When the bonding coefficient between different materials after mixing is T=3.2, we have:

[0068]

[0069] From the above sampling and calculation of the composite material, it can be known that the grade index C of the composite material of the raw material for preparing the glass fiber tube is 3.1.

[0070] In step six of this embodiment, the wire harness is passed through the pultrusion equipment, and the resin on the surface of the wire harness is contacted and mixed with the composite material composed of the glass fiber yarn and the curing agent in the pultrusion equipment, and is evenly covered on the surface of the wire harness as the wire harness is pulled out; the glass fiber tube covered on the wire harness and solidified is sampled and cut, and the sample is tested for material ratio, and the results are:

[0071]

[0072] Wherein, M represents the concentration deviation index between the prepared composite material and the cured glass fiber tube material, u represents the comprehensive volume content of glass fiber yarn and resin in the cut sample, and h represents the volume content of curing agent; and:

[0073]

[0074] Where p represents the coefficient of influence of the comprehensive volume content u of glass fiber yarn and resin and the volume content h of curing agent on the thickness d of the sampling sample;

[0075] When M≥7.6, the concentration deviation index of the pre-prepared composite material and the cured glass fiber tube material does not meet the requirements;

[0076] When M<7.6, the concentration deviation index of the pre-prepared composite material and the cured glass fiber tube material meets the requirements.

[0077] The finished glass fiber tube material was sampled, and the comprehensive volume content of glass fiber yarn and resin in the sample was u=0.75, and the volume content of curing agent was h=0.22. The comprehensive light transmittance index d=0.04 after collecting three samples of the composite material was obtained:

[0078]

[0079] That is, the grade index of the composite material formed by mixing glass fiber yarn, resin and curing agent is C=3.1, and the concentration deviation index of the prepared composite material and the cured glass fiber tube material is:

[0080]

[0081] From the above, it can be seen that the concentration deviation index M of the sample used this time is less than 7.6, and the concentration deviation index of the pre-prepared composite material and the cured glass fiber tube material meets the requirements.

[0082] Of course, the above description is not a limitation of the present invention, and the present invention is not limited to the above examples. Changes, modifications, additions or substitutions made by ordinary technicians in this technical field within the essential scope of the present invention also fall within the protection scope of the present invention.

Claims

1. A new energy vehicle resolver stator wiring harness with shielding function, characterized in that: It comprises a female connector (1), a wiring harness (4), a resolver stator (5) and a grounding terminal (6); The wiring harness (4) comprises eight low-voltage electric wires (2), and the wiring harness (4) is connected to the female connector (1) and the resolver stator (5) via the eight low-voltage electric wires (2); The eight low-voltage electric wires (2) are twisted into a pair and then a layer of copper foil is attached. A heat shrink tube (3) is sheathed on the outside of the copper foil, and a glass fiber tube is sheathed on the outside of the heat shrink tube (3). The two ends of the glass fiber tube are again sheathed with heat shrink tubes (3) to be fixed by heat shrinkage; The preparation process of the resolver stator harness is as follows: S1. Select high-purity electrolytic copper for smelting, and add equal proportions of arsenic, tin, zinc and nickel elements into the smelting pool; S2. After the copper material is heat treated, it enters the rolling mill for rolling. The rolling process requires multiple hot rolling and cold rolling to form copper foil; S3. The copper foil formed after rolling and annealing needs to be surface treated; S4. Wrap the copper foil around eight low-voltage wires in a spiral forward winding manner, with no less than two layers of winding; S5. Put the heat shrink tube again on the surface of the wire harness covered with the copper foil, and the heat shrink tube shrinks on the copper foil after being evenly heated; S6, immersing the wire harness wrapped with the heat shrink tube into the resin, and passing it through the pultrusion equipment to set the glass fiber tube; S7. The formed glass fiber tube enters the curing furnace for curing. The temperature and time during the curing process need to be controlled. In step S6, the raw materials of the glass fiber include glass fiber yarn, resin, and curing agent, and these raw materials need to be first inspected for quality to ensure that they meet production requirements, including: Among them, C represents the grade index of the composite material formed by mixing glass fiber yarn, resin and curing agent, T represents the bonding coefficient between different materials after mixing, and d i represents the transmittance index of the composite material collected at the i-th sampling point; and: Wherein, d represents the comprehensive transmittance index of the composite material after three samples are collected, and d0 represents the average transmittance index of the composite material after three samples are collected; and: In the formula, s represents the concentration ratio after collecting three portions of the composite material, k represents the flow coefficient of the fluid, and m represents the concentration coefficient of the composite material after three samplings; Soak the wire harness in the mixed resin solution. The surface of the wire harness will be covered with the resin solution, and the resin solution can fill the gap between the glass fiber tube and the heat shrink tube. In the step S6, the wire harness is passed through the pultrusion device, and the resin on the surface of the wire harness is contacted and mixed with the composite material composed of the glass fiber yarn and the curing agent in the pultrusion device, and is evenly covered on the surface of the wire harness as the wire harness is pulled out; The glass fiber tube covered on the wire harness and solidified is sampled and cut, and the sample is tested for material ratio. The results are: Wherein, M represents the concentration deviation index between the prepared composite material and the cured glass fiber tube material, u represents the comprehensive volume content of glass fiber yarn and resin in the cut sample, and h represents the volume content of curing agent; and: Where p represents the coefficient of influence of the comprehensive volume content u of glass fiber yarn and resin and the volume content h of curing agent on the thickness d of the sampling sample; When M≥7.6, the concentration deviation index of the pre-prepared composite material and the cured glass fiber tube material does not meet the requirements; When M<7.6, the concentration deviation index of the pre-prepared composite material and the cured glass fiber tube material meets the requirements.

2. The preparation process of the new energy vehicle resolver stator wiring harness with shielding function according to claim 1, characterized in that: In the step S1, the copper material formed in the smelting pool has a copper element mass ratio of 95-98%, an arsenic element mass ratio of 0.1-0.23%, a tin element mass ratio of 0.43-0.6%, a zinc element mass ratio of 0.06-0.12%, and a nickel element mass ratio of 0.35-0.57%.

3. The preparation process of the new energy vehicle resolver stator wiring harness with shielding function according to claim 1, characterized in that: In step S2, the copper material is deformed by rolling to gradually reduce the thickness, and the copper foil of the required thickness is finally obtained by multiple rolling. The thickness of the copper foil is obtained and the surface quality of the copper foil is improved by multiple hot rolling and cold rolling alternately.

4. The preparation process of the new energy vehicle resolver stator wiring harness with shielding function according to claim 3 is characterized in that: After the copper material is rolled to form copper foil, the copper foil needs to be cut to form strip copper foil, and the formed strip copper foil has a uniform width.

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