Insulating powder-dipping shielding jig for N-wire switching copper bar of electric vehicle and powder dipping method

Abstract

The invention relates to the technical field of electrical engineering, in particular to an electric vehicle N wire switching copper bar insulation powder dipping shielding jig and a powder dipping method.The electric vehicle N wire switching copper bar insulation powder dipping shielding jig comprises a first jig body and a second jig body which are each provided with an installation channel and an installation cavity and used for shielding a non-powder-attached area of an N wire switching copper bar; and through cooperation of the sealing piece and the sealing groove, powder subjected to powder soaking treatment is prevented from entering the mounting channel and being attached to the copper bar or the inner wall of the first jig. The invention discloses an insulating powder dipping method for an N-wire switching copper bar of an electric vehicle. The insulating powder dipping method comprises the steps of heating the copper bar, mounting a jig, shielding, dipping powder and the like, and aims to improve the insulating powder dipping efficiency and quality of the N-wire switching copper bar of the electric vehicle.

Description

Technical Field

[0001] The present application relates to the field of electrical engineering technology, and in particular to an insulation powder dipping shielding fixture and a powder dipping method for an N-line copper busbar of an electric vehicle. Background Art

[0002] Between the battery pack and the motor controller of an electric vehicle, or between multiple electrical devices, the N-line copper busbar can achieve reliable electrical connection to ensure the normal operation of the electric vehicle. In some electric engineering vehicles that are often exposed to harsh environments, the N-line copper busbar treated with insulation powder can better cope with harsh working conditions and ensure the continuous and stable operation of the vehicle; in high-performance electric cars, insulation powder helps reduce electromagnetic interference and improve the overall performance and reliability of the vehicle's electronic system.

[0003] The general traditional process is to use high-temperature film to manually wrap and shield the parts of the N-line transfer copper busbar that do not need to be powdered, and then the parts that need to be powdered are dipped and solidified, and then the high-temperature film is manually peeled off. Manual film wrapping is inefficient, cumbersome to operate, and has low production capacity, which cannot meet delivery requirements. In existing technical means, male and female mold bases are usually used to shield the parts of the N-line transfer copper busbar that do not need to be powdered. The male and female bases are processed with bakelite and embedded with male and female silicone cavities. Bakelite is easy to adhere to the powder of the dipped powder, which is not convenient to remove, affecting the efficiency of reuse, and the silicone cavity is not convenient to process, which increases production costs.

[0004] Therefore, based on the above problems, the prior art needs to be improved. Summary of the invention

[0005] The purpose of this application is to improve the insulation powder dipping efficiency and quality of the N-line transfer copper busbar of an electric vehicle.

[0006] The above-mentioned technical purpose of the present application is achieved through the following technical solutions: an insulating powder-impregnated shielding fixture for an N-line transfer copper busbar of an electric vehicle, comprising a first fixture and a second fixture, the first fixture comprising a first base and a first top cover, the first base being provided with a first mounting groove, the first mounting groove wall and the first top cover together forming an installation channel for the N-line transfer copper busbar to be passed through; the second fixture comprising a second base and a second top cover, the second base being provided with a second mounting groove, the second mounting groove wall and the second top cover together forming an installation chamber; a sealing member is provided on the first base along the direction in which the groove walls on both sides of the first mounting groove are set, a sealing groove is recessed in the position of the first top cover corresponding to the sealing member, the sealing member can be embedded in the sealing groove, and an insulating film is provided on the inner wall of the installation channel and the inner wall of the installation chamber.

[0007] By adopting the above technical solution, the precise design of the first fixture and the second fixture, especially the coordination of the mounting groove and the top cover, can accurately shield the area of ​​the copper busbar that does not need to be dipped in powder, avoiding accidental dip in powder. The engagement of the seal and the sealing groove effectively prevents the powder from entering the installation channel during the dip in powder process, ensuring the uniformity and integrity of the copper busbar dip in powder, and improving the insulation effect. The provision of the thermal insulation film can keep the temperature of the copper busbar stable during the dip in powder process, which is beneficial to the adhesion and solidification of the powder, and further improves the quality of the dip in powder. The thermal insulation film creates a temperature difference between the N-line transfer copper busbar and the first fixture or the second fixture body, so that the powder is not easy to adhere to the surface of the first fixture or the second fixture, which facilitates the recycling of the first fixture and the second fixture.

[0008] Optionally, a first guide pin is provided on the first base, and a first guide groove is provided on the first top cover, and the first guide pin can be embedded in the first guide groove.

[0009] By adopting the above technical solution, the cooperation of the first guide pin and the first guide groove can ensure that the first base and the first top cover are accurately aligned during assembly to avoid deviation, thereby ensuring that the shielding effect of the fixture on the copper busbar is optimal. The guide structure enables operators to quickly and accurately complete the installation of the top cover without repeatedly adjusting the position, which greatly simplifies the operation process and improves work efficiency. The fit of the guide pin and the guide groove can effectively prevent the top cover from shifting relative to the base during use, enhance the overall structural stability of the fixture, and ensure that the fixture always maintains good shielding performance during the powder dipping process.

[0010] Optionally, a second guide pin is provided on the second top cover, and a second guide groove is provided on the second base, and the second guide pin can be embedded in the second guide groove.

[0011] By adopting the above technical solution, the cooperation of the second guide pin and the second guide groove can realize the accurate and rapid alignment of the second top cover and the second base, ensure the shape and size of the installation chamber are accurate, and improve the shielding accuracy of the non-powder dipping area of ​​the copper bar. When the operator assembles the second fixture, the guide pin and the guide groove can quickly complete the combination of the top cover and the base, reduce the assembly time, and improve production efficiency. The embedded guide structure enhances the stability of the second fixture during use, effectively prevents relative sliding or dislocation between the top cover and the base, and ensures the smooth progress of the powder dipping operation.

[0012] Optionally, a plurality of first magnets are disposed on the first base, and a plurality of second magnets are disposed on the first top cover, and the first magnets and the second magnets cooperate to be adsorbed.

[0013] By adopting the above technical solution, the coordinated adsorption of the first magnet and the second magnet can quickly fix the first base and the first top cover together, reducing the cumbersome operations during the installation process and improving the assembly efficiency. The adsorption force of the magnet makes the base and the top cover fit tightly, enhancing the sealing effect, further preventing the powder from entering the unnecessary area during the powder dipping process, and ensuring the quality of the powder dipping. No additional fastening tools or complicated fixing methods are required, and the fixing can be completed by relying on the magnetic adsorption, which is convenient for operators to assemble and disassemble.

[0014] Optionally, a plurality of third magnets are provided on the second base, and a plurality of fourth magnets are provided on the second top cover, and the third magnets and the fourth magnets cooperate to be adsorbed.

[0015] By adopting the above technical solution, the coordinated adsorption of the third magnet and the fourth magnet enables the second base and the second top cover to be firmly connected, ensuring that the top cover will not accidentally detach during the powder dipping process, thereby maintaining the stability of the fixture. With the help of the adsorption effect of the magnet, the second fixture can be assembled quickly, saving time and labor costs and improving production efficiency. When the fixture needs to be disassembled after the powder dipping is completed, the magnetic adsorption method makes it easy to separate the second base and the second top cover, which is convenient for subsequent operations.

[0016] Optionally, the first base, the first top cover, the second base and the second top cover are all made of aluminum alloy material.

[0017] By adopting the above technical solution, the aluminum alloy material has good thermal conductivity, which helps to maintain a certain temperature difference between the powder dipping process and the heated copper bar, prevents powder from hanging, and facilitates the cooling and cleaning of the first fixture and the second fixture, which is convenient for recycling. The use of aluminum alloy to make various parts of the fixture can reduce the overall weight of the fixture, facilitate operation and handling, and reduce the labor intensity of operators. Aluminum alloy has good corrosion resistance and can resist the erosion of chemical substances in the powder dipping environment during long-term use, thereby extending the service life of the fixture.

[0018] A method for insulating and powder dipping a copper busbar for N-line transfer of an electric vehicle, comprising: S1: Heat the N line transfer copper busbar to 220℃~250℃; S2: Install the heated N-line copper busbar on the first base and the second base, so that the first base and the second base bear the non-powdered area of ​​the N-line copper busbar; S3: The first top cover and the second top cover are aligned and attached to the first base and the second base respectively, so that the first fixture and the second fixture can complete shielding the non-powdered area of ​​the N-line transfer copper busbar; S4: After the first base and the first top cover are attached, the sealing member is embedded and installed into the sealing groove, which can effectively shield the semi-fluid resin powder from entering the installation channel; S5: A heat-insulating film is provided on the inner wall of the installation channel and the installation chamber to effectively prevent the heat conduction loss of the heated N-wire transfer copper busbar. The N-wire transfer copper busbar, the first fixture and the second fixture are subjected to powder dipping treatment, and the powder is effectively coated on the surface of the N-wire transfer copper busbar at 210°C; a temperature difference is formed between the N-wire transfer copper busbar and the first fixture or the second fixture body, and the powder is not easy to adhere to the surface of the first fixture or the second fixture.

[0019] By adopting the above technical solution, the heating temperature of the copper busbar is accurately controlled, and through perfect shielding and sealing measures, the uniformity and integrity of the dip powder are ensured, effectively improving the insulation performance. The entire dip powder process has clear steps and simple operation. Each link is closely coordinated, which reduces unnecessary waiting and adjustment time and greatly improves production efficiency. Reasonable temperature control and effective shielding methods reduce the adhesion and waste of powder on the jig, while extending the service life of the jig and reducing production costs.

[0020] Optionally, also include: S6: After the powder layer of the powdered area of ​​the N-line copper busbar is solidified, the first base and the first top cover are removed from the N-line copper busbar, and the second base and the second top cover are removed from the N-line copper busbar; S7: performing a cooling process on the first fixture and the second fixture; S8: Clean the surfaces of the first fixture and the second fixture.

[0021] By adopting the above technical solution, waiting for the powder layer to solidify before removing the jig can ensure the firm adhesion of the powder layer, avoid uneven or incomplete powder dipping caused by removal before solidification, and thus improve product quality. Cooling the jig after use can reduce the damage of high temperature to the jig material, extend its service life, and reduce the cost of jig replacement. Cleaning the surface of the jig can remove residual powder and impurities, prepare for the next powder dipping operation, ensure the consistency of the powder dipping effect each time, and improve the stability and reliability of production.

[0022] In summary, this application has at least the following beneficial effects: 1. The combination design of the first fixture and the second fixture is adopted to effectively shield the non-powdering area of ​​the N-line transfer copper busbar of the electric vehicle, thereby improving the powder dipping quality and efficiency.

[0023] 2. The seal and sealing groove structure design can effectively shield the semi-fluid resin powder and prevent the powder from penetrating into the inner cavity of the installation channel; 3. The first fixture and the second fixture are made of aluminum alloy material, which has excellent thermal conductivity and mechanical strength. At the same time, the inner wall is provided with a heat insulation film to effectively prevent heat loss and ensure the quality of powder dipping. The heat insulation film creates a temperature difference between the N-line transfer copper bar and the first fixture or the second fixture body, and the powder is not easy to adhere to the surface of the first fixture or the second fixture, which facilitates the recycling of the first fixture and the second fixture. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 This is a schematic diagram of the structure of an insulation powder-impregnated shielding fixture for N-line copper busbar transfer in electric vehicles; Figure 2 This is a schematic diagram of the state of an insulation powder-impregnated shielding fixture for the N-line copper busbar of an electric vehicle; Figure 3 is a schematic diagram of the structure of the first base; Figure 4 is a schematic diagram of the structure of the first top cover; Figure 5 is a schematic diagram of the structure of the second base; Figure 6 is a schematic diagram of the structure of the second top cover; Figure 7 The invention discloses a flow chart of the steps of a method for insulating and powder dipping a copper busbar for N-line transfer in an electric vehicle.

[0025] Reference numerals 1. First fixture; 101. First base; 102. First top cover; 2. Second fixture; 201. Second base; 202. Second top cover; 3. First mounting groove; 4. Mounting channel; 5. Second mounting groove; 6. Mounting chamber; 7. Seal; 8. Sealing groove; 9. First guide pin; 10. First guide groove; 11. Second guide pin; 12. Second guide groove; 13. First magnet; 14. Second magnet; 15. Third magnet; 16. Fourth magnet. DETAILED DESCRIPTION

[0026] The present application is further described in detail below in conjunction with the accompanying drawings.

[0027] In this embodiment, refer to Figure 1-6, an insulating powder-dipping shielding jig for the N-line transfer copper busbar of an electric vehicle, comprising a first jig 1 and a second jig 2. The first jig 1 is composed of a first base 101 and a first top cover 102, and a first mounting groove 3 is processed on the first base 101, and the groove cooperates with the first top cover 102 to form an installation channel 4 for the N-line transfer copper busbar to pass through. The second jig 2 has a similar structure, including a second base 201 and a second top cover 202, which together form an installation chamber 6. In order to ensure that the powder does not penetrate into the interior of the jig during the powder dipping process, seals 7 are arranged along both sides of the first mounting groove 3, and these seals 7 can be engaged with the sealing grooves 8 on the first top cover 102 to form a tightly closed environment. In addition, in order to keep the temperature of the copper busbar stable during the powder dipping process, the inner walls of the installation channel 4 and the installation chamber 6 are covered with a heat-insulating film to reduce heat loss. A temperature difference is formed between the N-line transfer copper bar and the first fixture 1 or the second fixture 2 body, and the powder is not easy to adhere to the surface of the first fixture 1 or the second fixture 2, so the first fixture 1 and the second fixture 2 are easy to recycle.

[0028] The implementation principle of Example 1 is as follows: In the powder dipping process, the N-wire transfer copper busbar needs to be heated to a specific temperature first, and then placed in the first jig 1 and the second jig 2. The design of the jig can accurately shield the non-powdered areas on the copper busbar, while the areas that need to be powdered are exposed. The engagement of the seal 7 and the sealing groove 8 ensures that the powder will not penetrate into the interior of the jig during the powder dipping process, thereby ensuring the accuracy of the shielding effect. The thermal insulation film is used to reduce heat loss and ensure the temperature of the copper busbar is stable during the powder dipping process, thereby ensuring the quality of the powder dipping. A temperature difference is formed between the N-wire transfer copper busbar and the main body of the first jig 1 or the second jig 2, and the powder is not easy to adhere to the surface of the first jig 1 or the second jig 2, which facilitates the recycling of the first jig 1 and the second jig 2.

[0029] Example 2 Reference Figure 3-4 The difference of this embodiment is that a first guide pin 9 is added to the first base 101, and a first guide groove 10 is correspondingly provided on the first top cover 102. This design enables the first top cover 102 to be more accurately aligned when it is attached to the first base 101, ensuring the accuracy of the shielding effect. At the same time, the first base 101 and the first top cover 102 are also respectively provided with a first magnet 13 and a second magnet 14, which can be attracted to each other when the top cover is attached to the base, thereby enhancing the stability and sealing of the fixture.

[0030] Reference Figure 4-5Similarly, the second fixture 2 is also improved accordingly, with a second guide pin 11 added to the second top cover 202 and a second guide groove 12 provided on the second base 201 to ensure the precise alignment of the second top cover 202 and the second base 201. At the same time, the second base 201 and the second top cover 202 are also respectively provided with a third magnet 15 and a fourth magnet 16 to enhance the stability and sealing of the fixture.

[0031] Example 3 The difference of this embodiment is that the first base 101, the first top cover 102, the second base 201 and the second top cover 202 are all made of aluminum alloy. Aluminum alloy has good thermal conductivity and mechanical strength, and can effectively transfer and maintain the temperature of the copper busbar during the powder dipping process. At the same time, aluminum alloy also has light weight and corrosion resistance, making the fixture more durable and easy to operate.

[0032] Example 4 Reference Figure 7 This embodiment discloses a method for insulating and powder dipping an N-line copper busbar of an electric vehicle using the above-mentioned shielding fixture. The method comprises the following steps: S1: Heat the N line transfer copper busbar to 220℃~250℃; Specifically, use professional heating equipment, such as infrared heating furnace. Place the N-wire copper busbar into the heating furnace, set the temperature at 230℃, and the heating time depends on the size and thickness of the copper busbar. For example, for common copper busbar sizes, heat for 10-15 minutes to ensure that the entire copper busbar reaches a uniform 230℃.

[0033] S2: Install the heated N-line copper busbar on the first base 101 and the second base 201, so that the first base 101 and the second base 201 bear the non-powdered area of ​​the N-line copper busbar; Specifically, the operator wears protective gloves and carefully places the heated copper busbar on the first base 101 and the second base 201, ensuring that the non-powdered area of ​​the copper busbar is completely supported by the base and the position is accurate.

[0034] S3: The first top cover 102 and the second top cover 202 are aligned and attached to the first base 101 and the second base 201 respectively, so that the first fixture 1 and the second fixture 2 can complete the shielding of the non-powdered area of ​​the N-line transfer copper busbar; Specifically, with the aid of positioning tooling, the first top cover 102 and the second top cover 202 are aligned with the corresponding bases, and then pressure is applied manually or mechanically to make the top cover fit tightly with the base to achieve complete shielding of the non-powder-coated area.

[0035] S4: After the first base 101 and the first top cover 102 are attached, the seal 7 is fitted into the sealing groove 8, which can effectively block the semi-fluid resin powder from entering the installation channel 4; Specifically, during the process of fitting the top cover and the base, ensure that the seal 7 is accurately embedded in the sealing groove 8, for example, by slightly rotating or pressing, so that the seal 7 completely enters the groove to form an effective seal.

[0036] S5: The inner walls of the installation channel 4 and the installation chamber 6 are provided with a heat-insulating film to effectively prevent the heat conduction loss of the heated N-wire transfer copper bar. The N-wire transfer copper bar, the first fixture 1 and the second fixture 2 are subjected to powder dipping treatment. The powder is effectively coated on the surface of the N-wire transfer copper bar at 210°C. The N-wire transfer copper bar and the first fixture 1 or the second fixture 2 form a temperature difference, and the powder is not easy to adhere to the surface of the first fixture 1 or the second fixture 2. ; Specifically, before powder dipping, check the integrity of the thermal insulation film. Put the installed copper busbar and fixture into the powder dipping equipment as a whole, and control the powder dipping time to 5-8 minutes to ensure that the powder is effectively coated on the surface of the copper busbar at 210℃.

[0037] S6: After the powder layer of the powdered area of ​​the N-line copper busbar is solidified, the first base 101 and the first top cover 102 are detached from the N-line copper busbar, and the second base 201 and the second top cover 202 are detached from the N-line copper busbar; Specifically, wait for 20-30 minutes in the curing area until the powder layer is cured. Then, the operator uses a special tool, such as a wrench or a clamp, to carefully detach the first base 101 and the first top cover 102, the second base 201 and the second top cover 202 from the copper busbar.

[0038] S7: performing a cooling process on the first fixture 1 and the second fixture 2; Specifically, place the disassembled fixture in a well-ventilated area, or use a fan for forced air cooling to reduce the fixture temperature to room temperature within 15-20 minutes.

[0039] S8: Cleaning the surfaces of the first fixture 1 and the second fixture 2; Specifically, use a clean rag to dip in an appropriate amount of detergent and wipe the surface of the fixture to remove residual powder and stains. For areas that are difficult to clean, a small brush can be used for auxiliary cleaning.

[0040] Through the above method, efficient and high-quality insulation powder dipping treatment of the N-line transfer copper busbar can be achieved. The design of the fixture and the use method cooperate with each other to ensure the accuracy and efficiency of the powder dipping process.

[0041] The embodiments of this specific implementation method are all preferred embodiments of the present application, and are not intended to limit the protection scope of the present application. Therefore, all equivalent changes made based on the structure, shape, and principle of the present application should be included in the protection scope of the present application.

Claims

1. An insulation powder-impregnated shielding fixture for N-line copper busbar of electric vehicles. It is characterized in that The invention comprises a first fixture (1) and a second fixture (2), wherein the first fixture (1) comprises a first base (101) and a first top cover (102), the first base (101) is provided with a first installation groove (3), the groove wall of the first installation groove (3) and the first top cover (102) together form an installation channel (4) for the N-line transfer copper busbar to pass through; the second fixture (2) comprises a second base (201) and a second top cover (202), the second base (201) is provided with a second installation groove ( 5), the groove wall of the second installation groove (5) and the second top cover (202) are combined to form an installation chamber (6); a sealing member (7) is provided on the first base (101) along the direction of the groove walls on both sides of the first installation groove (3), and a sealing groove (8) is concavely provided on the first top cover (102) at a position corresponding to the sealing member (7), and the sealing member (7) can be embedded in the sealing groove (8), and the inner wall of the installation channel (4) and the inner wall of the installation chamber (6) are provided with a heat insulation film.

2. According to claim 1, an electric vehicle N line transfer copper bar insulation powder-impregnated shielding fixture, It is characterized in that The first base (101) is provided with a first guide pin (9), the first top cover (102) is provided with a first guide groove (10), and the first guide pin (9) can be embedded in the first guide groove (10).

3. According to claim 1, an electric vehicle N line transfer copper bar insulation powder-impregnated shielding fixture, It is characterized in that The second top cover (202) is provided with a second guide pin (11), and the second base (201) is provided with a second guide groove (12), and the second guide pin (11) can be embedded in the second guide groove (12).

4. According to claim 1, an electric vehicle N line transfer copper bar insulation powder-impregnated shielding fixture, It is characterized in that A plurality of first magnets (13) are provided on the first base (101), and a plurality of second magnets (14) are provided on the first top cover (102), and the first magnets (13) and the second magnets (14) cooperate to be adsorbed.

5. According to claim 1, an electric vehicle N line transfer copper bar insulation powder dipping shielding fixture, It is characterized in that A plurality of third magnets (15) are provided on the second base (201), and a plurality of fourth magnets (16) are provided on the second top cover (202), wherein the third magnets (15) and the fourth magnets (16) cooperate to be adsorbed.

6. According to claim 1, an electric vehicle N line transfer copper bar insulation powder dipping shielding fixture, It is characterized in that The first base (101), the first top cover (102), the second base (201) and the second top cover (202) are all made of aluminum alloy material.

7. A method for insulating and powder dipping a copper busbar for N-line transfer of an electric vehicle, using the insulating and powder dipping and shielding jig for N-line transfer of an electric vehicle according to claims 1-6, It is characterized in that include: S1: Heat the N line transfer copper busbar to 220℃~250℃; S2: installing the heated N-wire transfer copper busbar on the first base (101) and the second base (201), so that the first base (101) and the second base (201) receive the non-powdered area of ​​the N-wire transfer copper busbar; S3: The first top cover (102) and the second top cover (202) are aligned and attached to the first base (101) and the second base (201) respectively, so that the first fixture (1) and the second fixture (2) can complete shielding of the non-powdered area of ​​the N-line transfer copper busbar; S4: After the first base (101) and the first top cover (102) are attached, the sealing member (7) is fitted into the sealing groove (8), which can effectively prevent the semi-fluid resin powder from entering the installation channel (4); S5: The inner walls of the installation channel (4) and the installation chamber (6) are provided with a heat-insulating film to effectively prevent heat conduction loss of the heated N-wire transfer copper busbar. The N-wire transfer copper busbar, the first fixture (1) and the second fixture (2) are subjected to a powder dipping treatment, and the powder is effectively coated on the surface of the N-wire transfer copper busbar at 210° C. A temperature difference is formed between the N-wire transfer copper busbar and the first fixture (1) or the second fixture (2) body, and the powder is not easy to adhere to the surface of the first fixture (1) or the second fixture (2).

8. The method for insulating and powder dipping the N-line copper busbar of an electric vehicle according to claim 7, It is characterized in that Also includes: S6: After the powder layer in the powdered area of ​​the N-line copper busbar is solidified, the first base (101) and the first top cover (102) are detached from the N-line copper busbar, and the second base (201) and the second top cover (202) are detached from the N-line copper busbar; S7: performing a cooling process on the first fixture (1) and the second fixture (2); S8: Cleaning the surfaces of the first jig (1) and the second jig (2).

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