A manufacturing method of a direct current high voltage bus filter

Abstract

This application belongs to the field of integrated circuit manufacturing technology and discloses a method for manufacturing a DC high-voltage bus filter, including: riveting a first set of embedded nuts onto a connecting copper busbar; acquiring a first image of the riveted connecting copper busbar and determining whether the riveted connecting copper busbar is qualified; injection molding a second set of embedded nuts onto the qualified riveted connecting copper busbar to obtain a connecting copper busbar injection molded part; acquiring a second image of the connecting copper busbar injection molded part and determining whether the connecting copper busbar injection molded part is qualified; installing X capacitor and X2 capacitor into the mounting groove of the qualified connecting copper busbar injection molded part; welding Y capacitor and Y2 capacitor to the grounding copper busbar and then installing them into the mounting groove of the connecting copper busbar injection molded part; installing a magnetic ring into the magnetic ring fixing groove of the connecting copper busbar injection molded part; and welding each capacitor to the positive and negative copper busbars to obtain a DC high-voltage bus filter. This application can realize online quality inspection of DC high-voltage bus filters, improving yield and production efficiency.

Description

Technical Field

[0001] This application relates to the field of integrated circuit manufacturing technology, and in particular to a method for manufacturing a DC high-voltage bus filter. Background Technology

[0002] With the rapid development of new energy vehicles, operating under high-power vehicle electricity presents significant design challenges for the electrical connections of filters in the motor controller system. In electric drive systems, filters are crucial components for filtering, removing low-frequency noise, and optimizing EMC electromagnetic parameters. Due to the compact space of the electric drive controller and the structural requirements of the filter itself, multiple functional components such as capacitors, magnetic rings, and positive and negative high-voltage busbars need to be connected, increasing the filter's complexity.

[0003] However, in existing filter production systems, it is impossible to monitor the production status of products online during the manufacturing process, resulting in a high rate of defective filters, low production efficiency, and significant waste of raw materials. Summary of the Invention

[0004] This application provides a method for manufacturing a DC high-voltage bus filter, which enables online quality inspection of the DC high-voltage bus filter and improves the yield and production efficiency of the DC high-voltage bus filter.

[0005] This application provides a method for manufacturing a DC high-voltage bus filter, including:

[0006] The first set of embedded nuts is riveted to the nut through holes of the connecting copper busbar to form a riveted connecting copper busbar;

[0007] Acquire the first image of the riveted copper busbar;

[0008] Determine whether the riveted copper busbar is qualified based on the first image;

[0009] The second set of inlaid nuts and qualified riveted copper busbars are injection molded to obtain the injection molded copper busbar parts;

[0010] Acquire a second image of the injection-molded copper busbar connection;

[0011] Determine whether the injection-molded copper busbar is qualified based on the second image;

[0012] Install capacitors X and X2 into the mounting grooves of the qualified copper busbar injection molded parts;

[0013] After welding the Y capacitor and Y2 capacitor to the grounding copper busbar, they are installed into the mounting groove of the injection-molded copper busbar connecting part;

[0014] Install the magnetic ring into the magnetic ring fixing groove of the copper busbar injection molded part;

[0015] By welding capacitors X, X2, Y, and Y2 to the positive and negative copper busbars, a DC high-voltage bus filter is obtained.

[0016] Furthermore, the first set of insert nuts includes M6 insert nuts and M5 insert nuts.

[0017] Furthermore, the second set of insert nuts includes two M8 insert nuts, one M6 insert nut, and three M5 insert nuts.

[0018] Furthermore, the above-mentioned determination of whether the riveted copper busbar is qualified based on the first image includes:

[0019] The first image is input into the image recognition model to obtain the first gap between the first set of inlaid nuts and the riveted copper busbar and the scratch depth of the riveted copper busbar; it is determined whether the first gap is greater than the preset gap threshold or whether the scratch depth is greater than the preset depth threshold; if so, the riveted copper busbar is unqualified.

[0020] Furthermore, the above-mentioned determination of whether the injection-molded copper busbar is qualified based on the second image includes:

[0021] The second image is input into the image recognition model to obtain the center offset distance of the second set of embedded nuts and the crack, missing material location and missing material area on the injection molded copper busbar.

[0022] Determine whether there are cracks in the injection-molded copper busbar, or whether the missing material location is within the preset range of the second set of embedded nuts; if so, the injection-molded copper busbar is unqualified.

[0023] If not, determine whether the center offset distance is greater than the preset offset threshold, or whether the missing material area is greater than the preset missing material threshold; if so, the connecting copper busbar injection molded part is unqualified.

[0024] Furthermore, the process of welding the Y capacitor and Y2 capacitor to the grounding copper busbar and then inserting them into the mounting groove of the injection-molded copper busbar includes:

[0025] Bend one lead of the Y capacitor and the Y2 capacitor;

[0026] Solder the bent leads of the Y capacitor and Y2 capacitor to the grounding copper busbar;

[0027] Insert the grounding copper busbar into the positioning groove of the injection-molded copper busbar;

[0028] Insert the Y capacitor and Y2 capacitor into the mounting groove of the injection-molded copper busbar.

[0029] Furthermore, the method also includes: after installing the Y capacitor and Y2 capacitor into the mounting groove of the connecting copper busbar injection molding part, applying glue and drying the mounting grooves of the X capacitor and X2 capacitor, as well as the mounting grooves of the Y capacitor and Y2 capacitor.

[0030] Furthermore, the above-mentioned welding of capacitors X, X2, Y, and Y2 to positive and negative copper busbars to obtain a DC high-voltage busbar filter includes: connecting the positive and negative copper busbars to the injection-molded copper busbars using screws; welding the leads of capacitors X and X2 and the unbent leads of capacitors Y and Y2 to the positive and negative copper busbars to obtain a DC high-voltage busbar filter.

[0031] Furthermore, the preset gap threshold is 1 mm, and the preset depth threshold is 3 micrometers.

[0032] Furthermore, the preset offset threshold is 0.2 mm, and the preset material shortage threshold is 0.2 square millimeters.

[0033] In summary, compared with the prior art, the beneficial effects of the technical solution provided in this application include at least the following:

[0034] This application provides a method for manufacturing a DC high-voltage bus filter. During the filter manufacturing process, image acquisition and recognition are used to perform quality inspection on the semi-finished products. This not only ensures fast quality inspection without affecting the efficiency of the production line, but also allows for the timely screening of unqualified semi-finished products, preventing the waste of materials in subsequent processes. This achieves efficient production of DC high-voltage bus filters and improves the yield and production efficiency of DC high-voltage bus filters. Attached Figure Description

[0035] Figure 1 A flowchart illustrating a method for manufacturing a DC high-voltage bus filter, provided as an exemplary embodiment of this application.

[0036] Figure 2 A flowchart illustrating the installation steps of the Y capacitor and Y2 capacitor provided in an exemplary embodiment of this application. Detailed Implementation

[0037] The technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments.

[0038] Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0039] Please see Figure 1 This application provides a method for manufacturing a DC high-voltage bus filter, comprising:

[0040] Step S1: Rivet the first set of embedded nuts onto the nut through holes of the connecting copper busbar to form a riveted connecting copper busbar.

[0041] The first set of inlaid nuts includes M6 inlaid nuts and M5 inlaid nuts.

[0042] Specifically, the connecting copper busbar is fed onto the connecting copper busbar fixture and then transferred to the riveting station by the first conveyor line. The insert nut loading robot clamps the M6 ​​insert nuts and M5 insert nuts onto the nut through holes of the connecting copper busbar. The first conveyor line drives the connecting copper busbar fixture to continue moving to the nut riveting station. The riveting cylinder feeds in to complete the riveting of the M6 ​​insert nuts and M5 insert nuts. The connecting copper busbar is made of T2 copper with a nickel base and a matte tin surface.

[0043] Step S2: Acquire the first image of the riveted copper busbar; determine whether the riveted copper busbar is qualified based on the first image.

[0044] If the test fails, the riveted copper busbar will be sent directly into the recycling bin without proceeding with the subsequent process.

[0045] Step S3: Inject the second set of embedded nuts and qualified riveted copper busbars into a molded copper busbar to obtain the injection molded copper busbar part.

[0046] The second set of inlaid nuts includes two M8 inlaid nuts, one M6 inlaid nut, and three M5 inlaid nuts.

[0047] Specifically, the injection molding loading robot picks up qualified riveted copper busbars and places them into the injection mold. The robot then picks up two M8 insert nuts, one M6 insert nut, and three M5 insert nuts and places them into the mold. Each insert nut and the riveted copper busbar are then injection molded together. The injection molding process includes: inserting the injection mold into the corresponding position in the injection molding machine, tightening the mold mounting screws, connecting the mold water supply, setting the injection parameters, confirming that no parts are missing, and starting the injection process. Injection parameters are shown in the table below.

[0048]

[0049]

[0050] Step S4: Acquire a second image of the injection-molded copper busbar; determine whether the injection-molded copper busbar is qualified based on the second image.

[0051] Similarly, if the test fails, the riveted copper busbar is directly sent to the recycling bin without proceeding with the subsequent process.

[0052] Step S5: Install capacitor X and capacitor X2 into the mounting groove of the qualified copper busbar injection molded part.

[0053] Step S6: After welding Y capacitor and Y2 capacitor to the grounding copper busbar, install them into the mounting groove of the injection molded part of the connecting copper busbar.

[0054] The mounting grooves for capacitors X and X2 are not the same as those for capacitors Y and Y2.

[0055] Step S7: Install the magnetic ring into the magnetic ring fixing groove of the copper busbar injection molded part.

[0056] Specifically, the first conveyor line transports the injection-molded copper busbar to the magnetic ring assembly station. An automatic glue dispensing machine injects 2-3mm high fixing glue into the bottom of the magnetic ring fixing groove of the injection-molded copper busbar. The magnetic ring loading robot places the cleaned magnetic ring in the magnetic ring fixing groove and presses the magnetic ring to the bottom of the groove to make it tightly bonded with the fixing glue. The first conveyor line continues to transport the injection-molded copper busbar to the magnetic ring glue dispensing station. The automatic glue dispensing machine dispenses glue at multiple points along the gap between the magnetic ring and the fixing groove until the glue is basically level with the top surface of the magnetic ring.

[0057] Step S8: Weld capacitors X, X2, Y, and Y2 to the positive and negative copper busbars to obtain the DC high-voltage bus filter. Specifically, the welding process parameters are shown in the table below:

[0058]

[0059] After obtaining the DC high-voltage bus filter, it is necessary to transport the DC high-voltage bus filter to the cold insulation resistance testing station, withstand voltage testing station, inter-electrode capacitance station, polar capacitance station, and inductance testing station for various electrical performance tests.

[0060] The inductance measurement includes selecting the LS-Q test item on the digital bridge instrument. Test condition ①: 10KHZ 0.3V result ≥13μH; Test condition ②: 100KHZ 0.3V result ≥5μH, for a total of 2 times.

[0061] The capacitor test includes selecting the CS-Q test item on the digital bridge instrument. The test conditions are: test voltage 1V, frequency 1KHZ, and a total of 3 tests. ① Test the positive copper busbar and the negative copper busbar, and the test result should be 1170μH±10%. ② Test the positive copper busbar and the ground copper busbar, and the test result should be 563μH±20%. ③ Test the negative copper busbar and the ground copper busbar, and the test result should be 563μH±20%.

[0062] Torque testing includes: 1) M5 inserts should be able to withstand a torque ≥ 7.5 Nm; 2) M6 inserts should be able to withstand a torque ≥ 10 N·m; 3) M8 inserts should be able to withstand an installation torque ≥ 25 N·m. Finally, qualified products are packaged and stored.

[0063] The above embodiment provides a method for manufacturing a DC high-voltage bus filter. During the filter manufacturing process, image acquisition and recognition are used to perform quality inspection on the semi-finished products. This not only ensures fast quality inspection without affecting the efficiency of the production line, but also allows for timely screening of unqualified semi-finished products, preventing waste of materials in subsequent processes. This achieves efficient production of DC high-voltage bus filters and improves the yield and production efficiency of DC high-voltage bus filters.

[0064] In some embodiments, determining whether the riveted copper busbar is qualified based on the first image includes:

[0065] The first image is input into the image recognition model to obtain the first gap between the first set of inlaid nuts and the riveted copper busbar and the scratch depth of the riveted copper busbar; it is determined whether the first gap is greater than the preset gap threshold or whether the scratch depth is greater than the preset depth threshold; if so, the riveted copper busbar is unqualified.

[0066] The image recognition model is a machine learning model trained on an image of a riveted copper busbar with the first gap and scratch depth already labeled. The preset gap threshold can be 1 mm and the preset depth threshold can be 3 micrometers.

[0067] Specifically, after the inlaid nut and the connecting copper busbar are riveted, there should be no gap of more than 1mm. The allowable deformation of the copper busbar is that the deformation of the relevant hole line is within the range of 0.1mm. As for scratches, the main thing is not to scrape off the tin plating on the surface of the copper busbar. The standard tin plating thickness at the copper busbar connection is generally 3-10 micrometers. Therefore, the scratch depth should not exceed 3 micrometers.

[0068] The above embodiments, through image recognition, can quickly identify and obtain various parameters on the riveted copper busbars, enabling rapid quality inspection of semi-finished products without affecting the production line's operating efficiency.

[0069] In some embodiments, determining whether the injection-molded copper busbar is qualified based on the second image includes:

[0070] The second image is input into the image recognition model to obtain the center offset distance of the second set of embedded nuts and the crack, missing material location and missing material area on the connecting copper bus injection molded part; it is determined whether there is a crack in the connecting copper bus injection molded part, or whether the missing material location is within the preset range of the second set of embedded nuts; if so, the connecting copper bus injection molded part is unqualified; if not, it is determined whether the center offset distance is greater than the preset offset threshold, or whether the missing material area is greater than the preset missing material threshold; if so, the connecting copper bus injection molded part is unqualified.

[0071] The image recognition model is a machine learning model trained on images of the injection-molded copper busbars, pre-labeled with information on scratches, missing material areas and their corresponding locations, as well as the offset distance from the center. The preset offset threshold is 0.2 mm, and the preset missing material threshold is 0.2 square millimeters. Specifically, the injection-molded copper busbars must not have any scratches, and there must be no missing material within a preset range for each nut; these are necessary conditions for acceptance. Secondly, after meeting the above conditions, the offset distance of the center position of each embedded nut must be within 0.2 mm; if any nut does not meet this requirement, it is considered unacceptable. Finally, if the missing material area outside the preset range for each nut is greater than 0.2 square millimeters, it will also be considered unacceptable.

[0072] The above embodiments can quickly identify and obtain various parameters on the injection-molded copper busbars through image recognition, enabling rapid quality inspection of semi-finished products without affecting the production line's operating efficiency.

[0073] Please see Figure 2 In some embodiments, the process of welding the Y capacitor and Y2 capacitor to the grounding copper busbar and then inserting them into the mounting groove of the injection-molded copper busbar includes:

[0074] Step S61: Bend one pin of the Y capacitor and the Y2 capacitor.

[0075] Step S62: Solder the bent leads of Y capacitor and Y2 capacitor to the grounding copper busbar.

[0076] Step S63: Insert the grounding copper busbar into the positioning groove of the connecting copper busbar injection molded part.

[0077] Step S64: Insert the Y capacitor and Y2 capacitor into the mounting groove of the copper busbar injection molded part.

[0078] Specifically, the first conveyor line transports the injection-molded copper busbar to the grounding copper busbar assembly station; the Y capacitor feeder and the Y2 capacitor feeder feed the Y capacitor and the Y2 capacitor respectively. The Y capacitor and the Y2 capacitor are placed on the capacitor fixture and transported by the conveyor line. During the feeding process, they pass through the capacitor pin bending guide. The guiding angle of the capacitor pin bending guide bends one of the capacitor pins of the Y capacitor and the Y2 capacitor respectively. The bending height is adapted to the height of the corresponding positioning groove of the grounding copper busbar.

[0079] The second conveyor line automatically feeds the grounding copper busbar to the first welding station. A Y-capacitor feeding robot picks up two bent Y-capacitors and places them at the first welding station, with one pin of each Y-capacitor contacting the grounding copper busbar for welding. The second conveyor line continues to feed the welded grounding copper busbar to the second welding station. A Y2 capacitor feeding robot picks up two bent Y2 capacitors and places them at the second welding station, with one pin of each Y2 capacitor contacting the grounding copper busbar for welding. The grounding copper busbar feeding robot picks up the grounding copper busbar with welded capacitors from the second conveyor line and places it at the grounding copper busbar assembly station. The grounding copper busbar is then placed into the positioning groove of the connecting copper busbar injection molding part, and the Y-capacitors and Y2 capacitors are installed into the mounting groove of the connecting copper busbar injection molding part.

[0080] In some embodiments, the method further includes: after installing the Y capacitor and the Y2 capacitor into the mounting groove of the connecting copper busbar injection molding part, applying glue and drying the mounting grooves of the X capacitor and the X2 capacitor, as well as the mounting grooves of the Y capacitor and the Y2 capacitor.

[0081] Specifically, the first conveyor line continues to transport the connecting copper busbar injection molded parts to the capacitor potting station. The automatic potting machine pours insulating glue into the gap between the X capacitor, X2 capacitor, Y2 capacitor and the mounting groove of the connecting copper busbar injection molded parts, so that the capacitors are fixed in the mounting grooves. The connecting copper busbar injection molded parts are then transported to the drying station, where the automatic dryer dries the capacitor fixing glue.

[0082] The above embodiments use potting compound to fix the capacitors on the filter, ensuring the stability of the capacitors and indirectly improving the lifespan of the filter.

[0083] In some embodiments, the above-mentioned welding of X capacitor, X2 capacitor, Y capacitor and Y2 capacitor to positive and negative copper busbars to obtain a DC high voltage busbar filter includes: connecting the positive and negative copper busbars to the injection-molded copper busbars using screws; welding the leads of X capacitor and X2 capacitor and the unbent leads of Y capacitor and Y2 capacitor to the positive and negative copper busbars to obtain a DC high voltage busbar filter.

[0084] Specifically, the first conveyor line continues to transport the injection molded connecting copper busbar to the positive and negative copper busbar assembly station. The positive and negative copper busbar robotic arms pick up the positive and negative copper busbars and place them on the injection molded connecting copper busbar respectively. The positive and negative copper busbar robotic arms tighten the M6 ​​and M8 screws on the positive copper busbar, and the positive copper busbar is firmly in contact with the connecting copper busbar through the M6 ​​screw. The positive and negative copper busbar robotic arms tighten the M5 and M8 screws on the negative copper busbar.

[0085] Furthermore, before the DC high-voltage bus filter is transported to the cold insulation resistance testing station, the first conveyor line can first transport the DC high-voltage bus filter to the bolt removal station, where the two M8 bolts used to fix the positive and negative copper busbars for auxiliary welding are removed by the bolt removal robot; thus, the step of manually removing the bolts can be eliminated, improving automation capabilities.

[0086] The above embodiment ensures the accuracy of the welding by fixing the positive and negative copper busbars with screws before welding the capacitor, reducing the possibility of product defects due to errors during the welding process, and indirectly improving the yield rate.

[0087] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0088] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. A method for manufacturing a DC high-voltage bus filter, characterized in that, include: The first set of embedded nuts is riveted to the nut through holes of the connecting copper busbar to form a riveted connecting copper busbar; Acquire a first image of the riveted copper busbar; Based on the first image, determine whether the riveted copper busbar is qualified; specifically, input the first image into the image recognition model to obtain the first gap between the first set of inlaid nuts and the riveted copper busbar and the scratch depth of the riveted copper busbar; determine whether the first gap is greater than a preset gap threshold, or whether the scratch depth is greater than a preset depth threshold; If so, the riveted copper busbar is unqualified, and the riveted copper busbar is sent to the recycling bin and the subsequent process is not executed. The second set of embedded nuts and the qualified riveted copper busbars are injection molded to obtain the injection molded copper busbar parts; Acquire a second image of the injection-molded copper busbar; Based on the second image, it is determined whether the connecting copper busbar injection molded part is qualified. Unqualified connecting copper busbar injection molded parts are sent to a recycling bin and not processed further. Specifically, the second image is input into an image recognition model to obtain the center offset distance of the second set of embedded nuts and the crack, missing material location, and missing material area on the connecting copper busbar injection molded part. It is determined whether the connecting copper busbar injection molded part has cracks, or whether the missing material location is within a preset range of the second set of embedded nuts. If so, the connecting copper busbar injection molded part is unqualified. If not, it is determined whether the center offset distance is greater than a preset offset threshold, or whether the missing material area is greater than a preset missing material threshold. If so, the connecting copper busbar injection molded part is unqualified. Install capacitors X and X2 into the mounting grooves of the qualified copper busbar injection molded parts; After welding the Y capacitor and Y2 capacitor to the grounding copper busbar, they are installed into the mounting groove of the injection-molded connecting copper busbar. Install the magnetic ring into the magnetic ring fixing groove of the connecting copper busbar injection molded part; By welding capacitors X, X2, Y, and Y2 to the positive and negative copper busbars, a DC high-voltage bus filter is obtained.

2. The manufacturing method of the DC high-voltage bus filter according to claim 1, characterized in that, The first set of insert nuts includes M6 insert nuts and M5 insert nuts.

3. The manufacturing method of the DC high-voltage bus filter according to claim 1, characterized in that, The second set of inlaid nuts includes two M8 inlaid nuts, one M6 inlaid nut, and three M5 inlaid nuts.

4. The method for manufacturing a DC high-voltage bus filter according to claim 1, characterized in that, The step of welding the Y capacitor and Y2 capacitor to the grounding copper busbar and then inserting them into the mounting groove of the injection-molded connecting copper busbar includes: Bend one pin of the Y capacitor and the Y2 capacitor; The bent leads of the Y capacitor and the Y2 capacitor are soldered to the grounding copper busbar; The grounding copper busbar is inserted into the positioning groove of the connecting copper busbar injection molding part; The Y capacitor and the Y2 capacitor are installed into the mounting groove of the injection-molded copper busbar.

5. The method for manufacturing a DC high-voltage bus filter according to claim 4, characterized in that, Also includes: After the Y capacitor and the Y2 capacitor are installed into the mounting groove of the connecting copper busbar injection molding part, the mounting grooves of the X capacitor and the X2 capacitor, as well as the mounting grooves of the Y capacitor and the Y2 capacitor, are filled with glue and dried.

6. The method for manufacturing a DC high-voltage bus filter according to claim 4, characterized in that, The process of welding capacitors X, X2, Y, and Y2 to positive and negative copper busbars to obtain a DC high-voltage bus filter includes: The positive and negative copper busbars are connected to the injection-molded connecting copper busbar using screws. The pins of capacitor X and capacitor X2, and the unbent pins of capacitor Y and capacitor Y2 are welded to the positive and negative copper busbars to obtain the DC high voltage bus filter.

7. The method for manufacturing a DC high-voltage bus filter according to claim 1, characterized in that, The preset gap threshold is 1 mm, and the preset depth threshold is 3 micrometers.

8. The method for manufacturing a DC high-voltage bus filter according to claim 1, characterized in that, The preset offset threshold is 0.2 mm, and the preset material shortage threshold is 0.2 square millimeters.

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