New energy automobile circuit board combining and splicing process

Abstract

The invention relates to the technical field of new energy automobile manufacturing, and discloses a new energy automobile circuit board combining and splicing process which comprises the steps of circuit board pretreatment, insulation board installation, circuit board installation, conductive connecting piece connection, wire harness connection, overall fixing, detection and the like. The circuit board is cleaned, checked and marked, the positioning columns and the positioning holes are used for achieving accurate installation of the insulating board, the circuit board is positioned through the limiting grooves and the limiting blocks, the circuit board is connected through the conductive connecting pieces, welding and insulating treatment are conducted, and finally the assembled circuit board combination is integrally fixed and detected. According to the process, the production efficiency and the assembly precision of the new energy automobile circuit board combination are improved, and the stability and the safety of the circuit board combination are ensured.

Description

Technical Field

[0001] The present invention relates to the technical field of new energy vehicle manufacturing, and in particular to a new energy vehicle circuit board assembly process. Background Art

[0002] With the rapid development of new energy vehicles, the performance and safety requirements for these vehicles are becoming increasingly stringent. As a crucial component of new energy vehicles, the quality of their assembly process directly impacts their performance and safety. Currently, existing assembly processes for new energy vehicle circuit boards present the following issues: Inaccurate installation and positioning of the circuit boards can easily lead to misaligned connections between them, impacting their proper operation; insufficiently secure connections for conductive connectors can easily lead to poor contact and other issues, posing a safety hazard; inadequate wiring harness connection and organization can easily lead to friction and collision with the circuit board or other components, damaging the wiring harness; and insufficiently secure overall mounting can easily cause the circuit board assembly to shake and vibrate during driving, impacting its service life. Furthermore, existing processes also have shortcomings in quality inspection, lacking inspection of the circuit board's microstructure and testing of the dynamic stability of the circuit board assembly, making it difficult to fully guarantee the quality of the circuit board assembly. Summary of the Invention

[0003] In view of the shortcomings of the existing technology, the present invention provides a new energy vehicle circuit board assembly process.

[0004] To achieve the above-mentioned purpose, the present invention provides the following technical solution: a new energy vehicle circuit board assembly process, comprising the following steps:

[0005] Circuit board pretreatment: Clean the circuit boards of new energy vehicles, remove dust, oil and other impurities on the surface, check whether the circuit boards are damaged or deformed, mark the qualified circuit boards, and mark the installation position and connection points of the circuit boards;

[0006] Insulation board installation: Place the insulation board on the assembly workbench, determine the installation position of the positioning columns on the insulation board according to the installation position of the circuit board, and fix the positioning columns on the insulation board. The number and position of the positioning columns must match the positioning holes on the circuit board.

[0007] Circuit board installation: Place the pre-processed circuit board on the insulating board, match the positioning holes on the circuit board with the positioning columns on the insulating board, perform preliminary positioning of the circuit board, and then further position the circuit board through the limit slots and limit blocks to ensure the accurate installation position of the circuit board;

[0008] Conductive connector connection: Select appropriate conductive connectors according to the connection points on the circuit board, connect the conductive connectors to the two circuit boards that need to be connected, weld the connecting parts of the conductive connectors and the circuit boards to ensure a firm connection, and insulate the welded parts to prevent short circuits;

[0009] Wire harness connection: Connect one end of the wire harness to the wiring terminal of the circuit board, and the other end to other components of the new energy vehicle. Arrange and fix the wire harness to avoid friction and collision between the wire harness and the circuit board or other components;

[0010] Overall fixation: Use fixings to fix the circuit board and insulation board to the body of the new energy vehicle. The fixings include bolts, nuts, washers, etc. to ensure that the circuit board assembly is firmly installed;

[0011] Testing: Power on the assembled new energy vehicle circuit board combination for testing to check whether the circuit board is working normally, whether there are problems such as short circuit and open circuit, and repair the circuit board combination that fails the test.

[0012] Preferably, the height of the positioning post matches the thickness of the circuit board, and the diameter of the positioning post matches the diameter of the positioning hole, ensuring that the circuit board can be accurately fitted onto the positioning post.

[0013] Preferably, the limiting groove and limiting block are respectively provided on the insulating plate and the circuit board, and the shape and size of the limiting groove match those of the limiting block, ensuring that the circuit board can be stably placed in the limiting groove.

[0014] Preferably, the conductive connecting parts include conductive sheets, conductive columns, etc. The conductive connecting parts are made of copper or copper alloy, which has good conductivity and wear resistance.

[0015] Preferably, the insulation treatment uses materials such as insulating tape and insulating paint to wrap or paint the welding parts to ensure good insulation performance of the welding parts.

[0016] Preferably, in the circuit board pretreatment step, cleaning is performed by wiping with a dust-free cloth and a special cleaning agent, and during inspection, a microscope is used to perform microscopic inspection of the electronic components and circuits on the circuit board.

[0017] Preferably, in the wiring harness connection step, the wiring harness is tested for conductivity before connection, and after connection, a heat shrink tube is used to protect the terminal connection portion.

[0018] Preferably, in the detection step, in addition to the power-on detection, a vibration simulation test is also required to simulate the vibration environment during the driving of the new energy vehicle and detect the stability of the circuit board assembly.

[0019] Compared with the prior art, the present invention provides a new energy vehicle circuit board assembly process, which has the following beneficial effects:

[0020] 1. The new energy vehicle circuit board assembly process uses refined circuit board pretreatment, special cleaning agents and microscope inspection to ensure that the circuit board surface is clean and free of microscopic defects, providing a good foundation for subsequent installation and connection, and improving the overall performance of the circuit board assembly.

[0021] 2. The new energy vehicle circuit board assembly process uses the precise coordination of positioning columns and positioning holes, and limiting grooves and limiting blocks to achieve high-precision positioning of the circuit boards, ensuring accurate and reliable connections between circuit boards and reducing faults caused by installation deviations.

[0022] 3. The new energy vehicle circuit board assembly process uses high-quality conductive connectors and standardizes welding and insulation treatment to enhance the firmness and insulation of the conductive connection, improve the conductivity of the circuit board, and reduce safety hazards such as short circuits.

[0023] 4. The new energy vehicle circuit board combined assembly process performs conductivity testing and protective treatment on the wiring harness, while standardizing the wiring harness arrangement and fixation, effectively avoiding friction and collision between the wiring harness and other components, and extending the service life of the wiring harness.

[0024] 5. The new energy vehicle circuit board assembly process adds vibration simulation testing and combines power-on testing to comprehensively test the stability and electrical performance of the circuit board assembly in actual use environments to ensure the reliable quality of the circuit board assembly. DETAILED DESCRIPTION

[0025] The following will be combined with the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the embodiments described are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0026] Circuit board pretreatment

[0027] Select a batch of new energy vehicle circuit boards and wipe the surface with a dust-free cloth dipped in a specialized circuit board cleaner (such as a certain brand of electronic cleaner). Apply a moderate amount of force to avoid scratching the surface. After cleaning, place the circuit boards on a microscope inspection table and use a 10-50x microscope to inspect each component solder joint, wiring, pad, and other areas. Boards with microscopic defects are identified and removed. For qualified circuit boards, use a heat-resistant, waterproof, oil-based marker to mark the installation locations and connection points. The markings should be clear and of moderate width to facilitate subsequent identification.

[0028] Insulation board installation

[0029] Place an appropriately sized insulating board on a high-precision assembly workbench. Using a laser locator, precisely mark the installation locations for the four locating posts on the insulating board according to the circuit board design. The four posts are arranged in a rectangular pattern. Use an electric screwdriver to secure the posts to the insulating board with screws. Once the posts are installed, use a caliper to measure their height and diameter, ensuring they align with the circuit board's locating holes within ±0.05mm.

[0030] Circuit board installation

[0031] Carefully place the pre-processed circuit board on the insulating plate, ensuring that the four positioning holes on the board accurately fit over the four positioning posts on the insulating plate. Check the initial positioning by visual inspection and by gently shaking the board. Next, carefully adjust the position of the circuit board, ensuring that the stoppers on the board are fully embedded in the stop slots on the insulating plate. Use a feeler gauge to check the gap between the stoppers and the slots, ensuring it does not exceed 0.1mm. This completes the further positioning of the circuit board.

[0032] Conductive connector connection

[0033] Based on the design requirements of the circuit board, a copper conductive sheet with a thickness of 0.5mm and a width of 3mm was selected as the conductive connector. Using a constant-temperature soldering iron (set to 350°C) and specialized solder wire, one end of the conductive sheet was soldered to a connection point on a circuit board. The soldering time was controlled within 2-3 seconds to ensure a full, smooth, and free of cold solder joints. The other end of the conductive sheet was soldered to a corresponding connection point on another circuit board, also ensuring soldering quality. After soldering, the welded area was wrapped with three layers of 5mm-wide insulating tape, with each layer overlapping by 50% to ensure complete insulation.

[0034] Wiring harness connection

[0035] Before connecting the wiring harness, use a digital multimeter to test its continuity. Set the multimeter to the resistance setting and measure the corresponding wires at each end of the harness. The resistance should be close to 0Ω. If the resistance is too large or infinite, the harness is considered to have a problem and should be replaced. After passing the test, crimp one end of the harness to the wiring terminal on the circuit board using a terminal crimping machine, maintaining a crimping force of 8-10kN to ensure a secure connection between the terminal and the wire. Connect the other end of the harness to the motor controller of the new energy vehicle. Use a heat gun to heat the heat shrink tubing around the terminal connection, setting the temperature to 120-150°C to tightly shrink the tubing around the terminal. Finally, use nylon harness clamps to secure the harness to the metal bracket of the vehicle body, placing one clamp every 15-20cm to ensure the harness is neatly arranged and does not interfere with surrounding components.

[0036] Overall fixation

[0037] Use M4 bolts, nuts, and washers to secure the circuit board and insulation board to the new energy vehicle's frame. Set up fixing points at each of the four corners and the center of the insulation board. Use a torque wrench to tighten the bolts to 8-10 N·m, ensuring the circuit board assembly is securely fastened and does not shake noticeably.

[0038] Detection

[0039] Connect the assembled circuit board assembly to the electrical system of a new energy vehicle for power-on testing. Use a multimeter to measure the voltage and resistance of key nodes on the circuit board. The voltage value should meet the design requirements, and the resistance value should be within the normal range, with no short circuit or open circuit. Next, place the circuit board assembly on a vibration test bench, set the vibration frequency to 10-50Hz, the amplitude to 2mm, and the vibration time to 30 minutes to simulate the vibration environment during vehicle driving. During the vibration process, use an oscilloscope to monitor the electrical signal of the circuit board to observe whether the signal is stable and whether there are any abnormal fluctuations. After the test is completed, conduct a comprehensive inspection of the circuit board assembly to ensure that all components are firmly connected and there are no loose or falling off problems. If any problems are found during the test, the circuit board assembly will be repaired in a targeted manner until it passes the test.

[0040] When using,

[0041] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A new energy vehicle circuit board assembly process, characterized in that: The following steps are involved: Circuit board pretreatment: Clean the circuit boards of new energy vehicles, remove dust, oil and other impurities on the surface, check whether the circuit boards are damaged or deformed, mark the qualified circuit boards, and mark the installation position and connection points of the circuit boards; Insulation board installation: Place the insulation board on the assembly workbench, determine the installation position of the positioning columns on the insulation board according to the installation position of the circuit board, and fix the positioning columns on the insulation board. The number and position of the positioning columns must match the positioning holes on the circuit board. Circuit board installation: Place the pre-processed circuit board on the insulating board, match the positioning holes on the circuit board with the positioning columns on the insulating board, perform preliminary positioning of the circuit board, and then further position the circuit board through the limit slots and limit blocks to ensure the accurate installation position of the circuit board; Conductive connector connection: Select appropriate conductive connectors according to the connection points on the circuit board, connect the conductive connectors to the two circuit boards that need to be connected, weld the connecting parts of the conductive connectors and the circuit boards to ensure a firm connection, and insulate the welding parts to prevent short circuits; Wire harness connection: Connect one end of the wire harness to the wiring terminal of the circuit board, and the other end to other components of the new energy vehicle. Arrange and fix the wire harness to avoid friction and collision between the wire harness and the circuit board or other components; Overall fixation: Use fixings to fix the circuit board and insulation board to the body of the new energy vehicle. The fixings include bolts, nuts, washers, etc. to ensure that the circuit board assembly is firmly installed; Testing: Power on the assembled new energy vehicle circuit board combination for testing to check whether the circuit board is working normally, whether there are problems such as short circuit and open circuit, and repair the circuit board combination that fails the test.

2. The new energy vehicle circuit board assembly process according to claim 1, characterized in that: The height of the positioning post matches the thickness of the circuit board, and the diameter of the positioning post matches the diameter of the positioning hole, ensuring that the circuit board can be accurately placed on the positioning post.

3. The new energy vehicle circuit board assembly process according to claim 1, characterized in that: The limiting groove and the limiting block are respectively arranged on the insulating plate and the circuit board. The shape and size of the limiting groove match those of the limiting block, ensuring that the circuit board can be stably placed in the limiting groove.

4. The new energy vehicle circuit board assembly process according to claim 1, characterized in that: The conductive connecting parts include conductive sheets, conductive columns, etc. The conductive connecting parts are made of copper or copper alloy and have good conductivity and wear resistance.

5. The new energy vehicle circuit board assembly process according to claim 1, characterized in that: The insulation treatment uses materials such as insulating tape and insulating paint to wrap or paint the welding parts to ensure good insulation performance of the welding parts.

6. The new energy vehicle circuit board assembly process according to claim 1, characterized in that: In the circuit board pretreatment step, cleaning is performed by wiping with a dust-free cloth and a special cleaning agent, and during inspection, a microscope is used to perform microscopic inspection of the electronic components and circuits on the circuit board.

7. The new energy vehicle circuit board assembly process according to claim 1, characterized in that: In the wiring harness connection step, the wiring harness is tested for conductivity before connection, and after connection, heat shrink tubing is used to protect the terminal connection parts.

8. The new energy vehicle circuit board assembly process according to claim 1, characterized in that: In the detection steps, in addition to the power-on test, a vibration simulation test is also required to simulate the vibration environment during the driving of the new energy vehicle and detect the stability of the circuit board assembly.