New energy automobile conducting bar wrapping floating device and method
By introducing a floating structure and an automated process with clear division of labor into the conductive busbar wrapping device for new energy vehicle batteries, the stability and efficiency issues during the wrapping process are resolved, stable transportation and precise wrapping of the busbars are achieved, the density and mechanical strength of the insulation layer are improved, and the failure rate and maintenance costs are reduced.
Patent Information
- Application Number
- CN202511006971.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-07-22
- Publication Date
- 2025-09-19
AI Technical Summary
The existing new energy vehicle battery conductive bar wrapping process has problems with poor wrapping stability and low efficiency. This is mainly due to the unstable tension and winding speed of the strip material, resulting in uneven winding, which affects the insulation performance and corrosion resistance.
A combined structure of a floating cavity in a fixed sleeve, a first floating seat, an elastic element, and a second floating seat is used to form a flexible floating structure, allowing the busbar to float radially during the wrapping process. The automated process with clear division of labor among the feeding, feeding, wrapping, and pressing mechanisms ensures stable transportation and precise wrapping of the busbar.
It improves the accuracy and quality of wrapping, reduces material waste, enhances the adaptability and robustness of the equipment, reduces the failure rate and maintenance costs in the production process, and improves production efficiency and the density and mechanical strength of the insulation layer.
Smart Images
Figure CN120674155A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the technical field of new energy conductive bar production, and in particular to a conductive bar wrapping floating device and method for new energy vehicles. Background Art
[0002] During the manufacturing process of conductive bars for new energy vehicle batteries, they are often wrapped with a protective strip to improve their insulation, protect them from environmental corrosion, and avoid short circuits with other components. This strip generally offers excellent insulation, corrosion resistance, and flexibility, effectively wrapping the bars and providing reliable protection.
[0003] However, the existing wrapping process has many problems, resulting in poor stability and low efficiency in the wrapping process. From a stability perspective, current wrapping equipment and processes make it difficult to accurately control the tension and winding speed of the strip material. During the wrapping process, unstable tension of the strip material will cause it to be wound unevenly on the surface of the conductive bar, resulting in uneven tightness. This will not only affect the appearance quality of the conductive bar, but may also greatly reduce the protective effect of local areas, reduce the insulation performance and corrosion resistance of the conductive bar, and thus affect the safety and reliability of the entire battery system. In addition, unstable wrapping speed will also lead to inconsistent number of winding layers and spacing, further undermining the stability and uniformity of the wrapping. Therefore, a new design is needed for the existing wrapping structure. Summary of the Invention
[0004] To address these issues, the present invention forms a flexible floating structure by combining a floating cavity within a fixed sleeve, a first floating seat, an elastic element, and a second floating seat. This allows the busbar to float radially during the wrapping process, effectively addressing the issue of busbar displacement during transport and wrapping. This device and method for floating busbar wrapping in new energy vehicles effectively addresses this issue.
[0005] The technical solution adopted by the present invention is: a floating device for wrapping a conductive bar of a new energy vehicle, comprising a frame, a feeding mechanism, a feeding mechanism, a wrapping mechanism and a pressing mechanism, the frame is provided with a workbench, the workbench is provided with a column, the feeding mechanism is provided on the column, the column is used to separate the frame into a feeding area and a wrapping area, the feeding mechanism is provided in the feeding area, the wrapping mechanism is provided in the wrapping area and is located on the periphery of the feeding mechanism, the feeding mechanism is used to transport the conductive bar toward the feeding mechanism, the feeding mechanism comprises a fixed sleeve, a first floating seat, an elastic element, a second floating seat and a fixed ring, the fixed sleeve is fixedly provided on the column, the fixed sleeve is provided with a floating cavity, the The first floating seat, the elastic element and the second floating seat are sequentially arranged in the floating cavity, the fixed ring is arranged at the port of the floating cavity to limit the second floating cavity to move in the floating cavity, and a gap is provided between the outer diameters of the first floating seat and the second floating seat and the inner diameter of the floating cavity to allow the first floating seat and the second floating seat to move in the floating cavity; a feeding trough for feeding the electric bus is concentrically provided with the axis of the floating cavity, the first floating seat and the second floating seat; the wrapping mechanism is used to wrap the strip material around the electric bus passing through the feeding mechanism, and the first floating seat and the second floating seat are used to allow the electric bus to float radially during wrapping; the pressing mechanism is located behind the wrapping mechanism to compact the strip material after wrapping.
[0006] A further improvement to the above solution is that the feeding mechanism includes a discharge module and a feed straightening module. The discharge module is used to discharge the rolled electric rods to the feed straightening module, and the feed straightening module is used to straighten the electric rods and feed them into the feeding mechanism.
[0007] A further improvement to the above scheme is that the feed straightening module includes a position adjustment module, a straightening support frame, a horizontal straightening module and a vertical straightening module. The position adjustment module is arranged in the feed area, and the straightening support frame is arranged on the position adjustment module. The horizontal straightening module and the vertical straightening module are arranged in sequence on the straightening support frame to perform horizontal straightening and vertical straightening on the electric bus in sequence.
[0008] A further improvement to the above scheme is that the position adjustment module is used to adjust the straightening support frame along the transmission direction of the electric busbar, the horizontal straightening module includes a horizontal adjustment component and a horizontal straightening roller, and the horizontal adjustment component is used to adjust the position of the horizontal straightening roller to perform roller straightening on the horizontal direction of the electric busbar; the vertical straightening module includes a vertical adjustment component and a vertical straightening roller, and the vertical adjustment component is used to adjust the position of the vertical straightening roller to perform roller straightening on the vertical direction of the electric busbar.
[0009] A further improvement to the above solution is that the fixed sleeve is provided with a fixed support frame, the fixed sleeve is fixed to the frame through the fixed support frame, the axial direction of the fixed sleeve passes through the column, and the wrapping mechanism is provided on the outer periphery of the fixed sleeve.
[0010] A further improvement to the above solution is that the first floating seat is provided with a first positioning step, the second floating seat is provided with a second positioning step, the elastic element is a spring, and both ends of the spring respectively abut against the first positioning step and the second positioning step.
[0011] A further improvement to the above solution is that both the first floating seat and the second floating seat are formed by Teflon.
[0012] A further improvement to the above scheme is that the wrapping mechanism includes a wrapping drive module, a wrapping turntable, a wrapping guide arm and a tape winding disk, the wrapping drive module is used to drive the wrapping turntable to rotate with the fixed sleeve as the axis, the wrapping turntable is provided with a accommodating cavity, the tape winding disk is arranged in the accommodating cavity and is fixedly connected to the fixed sleeve, the wrapping guide arm is arranged on one side of the wrapping turntable and rotates with the wrapping turntable; the wrapping guide arm is provided with a plurality of wrapping guide rollers for guiding the strip material toward the electric bus, and when the wrapping turntable rotates, the tape winding disk guides the material toward the electric bus through the guide rollers, and wraps the material around the outer periphery of the electric bus during rotation.
[0013] A further improvement to the above scheme is that the pressing mechanism includes an XY adjustment module, a pressing connection bracket, a horizontal pressing module and a vertical pressing module. The XY adjustment module is located on the rear side of the wrapping mechanism, and the pressing connection bracket is arranged on the XY adjustment module. The horizontal pressing module and the vertical pressing module are arranged on the XY adjustment module in sequence. The horizontal pressing module is provided with multiple horizontal pressing rollers, and the vertical pressing module is provided with multiple vertical pressing rollers, so as to press the strip material after wrapping tightly onto the electric bus.
[0014] A conductive bus wrapping method is implemented using a floating wrapping device for conductive bus wrapping of new energy vehicles. The feeding mechanism, wrapping mechanism, and pressing mechanism are each provided with two groups. The feeding mechanism, wrapping mechanism, and pressing mechanism at the front end constitute a forward wrapping system, and the feeding mechanism, wrapping mechanism, and pressing mechanism at the rear end constitute a reverse wrapping system. The method is used to wrap a strip material in both forward and reverse directions around the outer diameter of the conductive bus. The wrapping method comprises the following steps: Step S1: The coiled material is discharged through the feeding mechanism and bidirectionally straightened by the straightening module: Horizontal straightening: Apply 5~15MPa roller pressure in the width direction of the bar through the horizontal straightening roller to eliminate horizontal bending; Vertical straightening: Apply 3~10MPa roller pressure in the thickness direction of the strip through the vertical straightening roller to eliminate vertical bending; Step S2: The straightened electric busbar is transported to a feeding mechanism, and the feeding mechanism compensates for radial displacement during wrapping through a floating structure: The electric busbar passes through the feeding slot of the fixed sleeve. The first floating seat and the second floating seat supported by the spring elastic element allow the electric busbar to float radially by 0.5~2mm. Step S3, wrapping the mica tape in the forward direction: The forward wrapping system's wrapping turntable rotates clockwise at a speed of 200-600 r / min, driving the wrapping guide arm to wrap the mica tape to the outer diameter of the electrode at a wrap angle of 55°-65°. The overlap rate of mica tape is controlled at 0.1%~10% to form the first insulation layer; Step S4, reverse wrapping the mica tape: The reverse wrapping system's wrapping turntable rotates counterclockwise at the same speed, wrapping the mica tape at a reverse wrap angle of 55°~65°, with the overlap rate synchronously controlled at 0.1%~10%, forming a second insulation layer that intersects the first layer. Step S5, bidirectional pressing and curing: After each wrapping, the pressing mechanism compacts the mica tape in multiple directions: The horizontal lamination roller applies 8~12MPa pressure to eliminate bubbles between layers; The vertical pressing roller applies 6~10MPa pressure to ensure that the adhesion between the mica tape and the surface of the electrode is ≥95%; The pressing temperature is maintained at 80~120℃ to activate the viscosity of the mica tape resin; Step S6: The distance between the forward wrapping system and the reverse wrapping system is 1.2 to 1.5 times the width of the wiring board to ensure that there is no interference between the bidirectional wrapping layers.
[0015] The beneficial effects of the present invention are: Compared with the existing electric bus wrapping, the present invention forms a flexible floating structure through the combination of the floating cavity in the fixed sleeve, the first floating seat, the elastic element and the second floating seat. The electric bus is allowed to float radially during the wrapping process, which effectively solves the problem of the electric bus offset during transportation and wrapping. Specifically, when the electric bus passes through the feed trough, the first floating seat and the second floating seat can move freely in the floating cavity, thereby automatically adjusting the position of the electric bus, and can be quickly reset after being offset by force during the wrapping process. The wrapping accuracy is improved, and the uneven wrapping or material waste caused by the offset of the electric bus is avoided, thereby improving the wrapping quality. During the conveying process of the electric bus, the elastic element can absorb some vibration and impact, reduce mechanical wear, and extend the service life of the equipment. It can also provide appropriate elastic force when the electric bus floats radially, ensuring that the electric bus passes through the feed trough stably, avoiding the fluctuation of the electric bus position caused by vibration. The present invention forms an efficient workflow through the clear division of labor among the feeding mechanism, feeding mechanism, wrapping mechanism and pressing mechanism. The feeding mechanism accurately transports the electric strip to the feeding mechanism, which ensures stable transportation and wrapping of the electric strip through a floating structure. The wrapping mechanism then performs precise wrapping on this basis, and finally the pressing mechanism compacts the wrapped strip material. The entire process is highly automated and easy to operate, greatly reducing the need for manual intervention and improving production efficiency. The columns separate the workbench into the feeding area and the wrapping area. The separation of the feeding area and the wrapping area prevents the transportation and wrapping processes of the electric strip from interfering with each other, improving work safety. The coil wrapping method uses a feed mechanism to feed coiled coil material and uses a straightening module for bidirectional straightening. Horizontal straightening rollers apply a pressure of 5-15 MPa across the coil width to effectively eliminate horizontal bowing, while vertical straightening rollers apply a pressure of 3-10 MPa across the coil thickness to eliminate vertical bowing. This bidirectional straightening method fully corrects coil deformation, ensuring straightness and surface flatness, providing high-quality base material for subsequent wrapping processes. The straightened coil achieves high straightness, reducing material waste and uneven wrapping caused by coil bending during wrapping, thereby improving the stability and reliability of the finished product. The feed mechanism uses a floating structure to compensate for radial displacement during wrapping. The coil passes through the feed chute of a fixed sleeve. The first and second floating seats, supported by spring elements, allow the coil to float radially by 0.5-2 mm. This eliminates radial displacement caused by uneven force or mechanical vibration during wrapping, ensuring stability and consistency. The introduction of a floating structure not only improves wrapping accuracy but also enhances the adaptability and robustness of the equipment, reducing production failure rates and maintenance costs. The forward and reverse wrapping systems work together to achieve bidirectional winding of tape material around the outer diameter of the busbar. The forward wrapping system's wrapping turntable rotates clockwise at a speed of 200-600 rpm, driving the wrapping guide arm to wrap the mica tape around the outer diameter of the busbar at a 65° wrap angle, with a controlled overlap ratio of 0.1%-10%, forming the first insulation layer. Subsequently, the reverse wrapping system's wrapping turntable rotates counterclockwise at the same speed, wrapping the mica tape at a reverse 65° wrap angle, with a controlled overlap ratio of 0.1%-10%, forming the second insulation layer interlaced with the first. This bidirectional wrapping method not only improves the density and uniformity of the insulation layer, but also enhances its mechanical strength and electrical performance, effectively preventing partial discharge and insulation breakdown that can occur during busbar operation. The pressing mechanism compacts the mica tape in multiple directions, maintaining the pressing temperature at 80-120°C to activate the viscosity of the mica tape resin, further enhancing the bonding strength and integrity of the insulation layer. Multi-directional pressing and curing not only improves the density and stability of the insulation layer, but also effectively avoids the formation of bubbles and gaps between layers, thereby improving the voltage resistance and service life of the busbar. The spacing between the forward and reverse wrapping systems is designed to be 1.2-1.5 times the width of the busbar, ensuring no interference between the bidirectional wrapping layers. The busbar size and wrapping process requirements are fully considered to avoid mutual influence and interference between the forward and reverse wrapping layers, ensuring the independence and integrity of each layer of insulation material. BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Figure 1 This is a three-dimensional schematic diagram of the conductive bar wrapping floating device for new energy vehicles of the present invention; Figure 2 for Figure 1A side view of the floating device for the conductive bar wrapping of a new energy vehicle; Figure 3 for Figure 1 A three-dimensional schematic diagram of the floating device for the conductive bar wrapping of new energy vehicles from another perspective; Figure 4 for Figure 1 A three-dimensional schematic diagram of the floating device for the conductive bar wrapping of new energy vehicles from another perspective; Figure 5 for Figure 1 A three-dimensional schematic diagram of the wrapping mechanism of the conductive bar wrapping floating device for new energy vehicles; Figure 6 for Figure 1 Schematic diagram of the feeding mechanism of the conductive bar wrapping floating device for new energy vehicles.
[0017] Description of the accompanying drawings: frame 1, workbench 11, column 12, feeding mechanism 2, unloading module 21, feeding straightening module 22, position adjustment module 221, straightening support frame 222, horizontal straightening module 223, horizontal adjustment component 2231, horizontal straightening roller 2232, vertical straightening module 224, vertical adjustment component 2241, vertical straightening roller 2242, feeding mechanism 3, fixed sleeve 31, floating cavity 311, fixed support frame 312, The first floating seat 32, the first positioning step 321, the elastic element 33, the second floating seat 34, the second positioning step 341, the fixing ring 35, the wrapping mechanism 4, the wrapping drive module 41, the wrapping turntable 42, the wrapping guide arm 43, the wrapping guide roller 431, the winding disk 44, the pressing mechanism 5, the XY adjustment module 51, the pressing connection bracket 52, the horizontal pressing module 53, the horizontal pressing roller 531, the vertical pressing module 54, and the vertical pressing roller 541. DETAILED DESCRIPTION
[0018] To facilitate understanding of the present invention, the present invention will be described more fully below with reference to the accompanying drawings. Preferred embodiments of the present invention are shown in the accompanying drawings. However, the present invention may be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a more thorough and comprehensive understanding of the present disclosure.
[0019] It should be noted that when an element is referred to as being “fixed to” another element, it may be directly on the other element or there may be an intermediate element. When an element is referred to as being “connected to” another element, it may be directly connected to the other element or there may be an intermediate element.
[0020] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which the present invention pertains. The terms used in the specification of the present invention herein are only for the purpose of describing specific embodiments and are not intended to limit the present invention. Figures 1 to 6As shown, in one embodiment of the present invention, a floating device for wrapping a conductive bar of a new energy vehicle is involved, including a frame 1, a feeding mechanism 2, a feeding mechanism 3, a wrapping mechanism 4 and a pressing mechanism 5. The frame 1 is provided with a workbench 11, and a column 12 is provided on the workbench 11. The feeding mechanism 3 is provided on the column 12, and the column 12 is used to separate the frame 1 into a feeding area and a wrapping area. The feeding mechanism 2 is provided in the feeding area, and the wrapping mechanism 4 is provided in the wrapping area and is located on the periphery of the feeding mechanism 3. The feeding mechanism 2 is used to transport the conductive bar toward the feeding mechanism 3. The feeding mechanism 3 includes a fixed sleeve 31, a first floating seat 32, an elastic element 33, a second floating seat 34 and a fixed ring 35. The fixed sleeve 31 is fixedly provided on the column 12, and the fixed sleeve 31 is provided with a floating cavity 311. The first floating seat 32 is provided with an elastic element 33, a second floating seat 34 and a fixed ring 35. A floating seat 32, an elastic element 33 and a second floating seat 34 are sequentially arranged in the floating cavity 311, and the fixed ring 35 is arranged at the port of the floating cavity 311 to limit the second floating cavity 311 to move in the floating cavity 311. A gap is provided between the outer diameters of the first floating seat 32 and the second floating seat 34 and the inner diameter of the floating cavity 311 to allow the first floating seat 32 and the second floating seat 34 to move in the floating cavity 311; a feeding trough for feeding the electric bus is concentrically provided with the axis of the floating cavity 311, the first floating seat 32 and the second floating seat 34; the wrapping mechanism 4 is used to wrap the strip material around the electric bus passing through the feeding mechanism 3, and the first floating seat 32 and the second floating seat 34 are used to allow the electric bus to float radially during wrapping; the pressing mechanism 5 is located behind the wrapping mechanism 4 to compact the strip material after wrapping. The present invention forms a flexible floating structure through the combination of a floating cavity 311 within a fixed sleeve 31, a first floating seat 32, an elastic element 33, and a second floating seat 34. This allows the strip to float radially during the wrapping process, effectively resolving the problem of strip displacement during transport and wrapping. Specifically, as the strip passes through the feed chute, the first floating seat 32 and the second floating seat 34 are able to move freely within the floating cavity 311, automatically adjusting the strip's position and quickly resetting it after being offset by force during wrapping. This improves wrapping accuracy, avoids uneven wrapping or material waste caused by strip displacement, and enhances wrapping quality. During strip conveying, the elastic element 33 absorbs some vibration and impact, reducing mechanical wear and extending the service life of the equipment. It also provides appropriate elastic force when the strip floats radially, ensuring stable passage of the strip through the feed chute and preventing position fluctuations caused by vibration. The present invention utilizes a clearly defined division of labor among the feed mechanism 2, feed mechanism 3, wrapping mechanism 4, and pressing mechanism 5, creating an efficient workflow. The feeding mechanism 2 accurately transports the electric strip to the feeding mechanism 3, and the feeding mechanism 3 ensures the stable transportation and wrapping of the electric strip through the floating structure. The wrapping mechanism 4 performs precise wrapping on this basis, and finally the pressing mechanism 5 compacts the wrapped strip material.The entire process is highly automated and easy to operate, significantly reducing the need for manual intervention and improving production efficiency. The uprights 12 separate the workbench 11 into a feeding area and a wrapping area. The separation of the feeding and wrapping areas prevents interference between the conveying of the strips and the wrapping process, improving work safety.
[0021] The feeding mechanism 2 includes a discharge module 21 and a feed straightening module 22. The discharge module 21 is used to discharge coiled electric bars to the feed straightening module 22, and the feed straightening module 22 is used to straighten the electric bars and feed them to the feeding mechanism 3. The feed straightening module 22 includes a position adjustment module 221, a straightening support frame 222, a horizontal straightening module 223, and a vertical straightening module 224. The position adjustment module 221 is arranged in the feeding area, and the straightening support frame 222 is arranged on the position adjustment module 221. The horizontal straightening module 223 and the vertical straightening module 224 are arranged on the straightening support frame 222 in sequence to perform horizontal and vertical straightening on the electric bars in sequence. In this embodiment, the coordinated work of the discharge module 21 and the straightening module 22 ensures a smooth transition of the electric bars from a coiled state to a straight state. The unloading module 21 is responsible for feeding the rolled electric strips to the straightening module 22. This process requires a high degree of stability and accuracy to avoid distortion or damage to the electric strips in the initial stage. The straightening module 22 further accurately straightens the electric strips to ensure their straightness and surface flatness in subsequent processing steps. The position adjustment module 221 is set in the feeding area and can be flexibly adjusted according to actual production needs to adapt to electric strips of different specifications, thereby enhancing the versatility and flexibility of the equipment. The straightening support frame 222 serves as the basic structure and provides a stable installation platform for the horizontal straightening module 223 and the vertical straightening module 224, ensuring the stability of the straightening process. The sequential arrangement of the horizontal straightening module 223 and the vertical straightening module 224 realizes all-round straightening of the electric strips, effectively eliminates the bending deformation of the electric strips in the horizontal and vertical directions, improves the straightness of the electric strips, and thereby improves the tightness and uniformity of the wrapping. The stress concentration phenomenon of the electric busbar during the straightening process is reduced, the internal stress of the electric busbar material is reduced, the secondary deformation caused by stress release is avoided, and the stability and reliability of the electric busbar during the wrapping process are ensured.
[0022] The position adjustment module 221 is used to adjust the straightening support frame 222 along the transmission direction of the electric bar. The horizontal straightening module 223 includes a horizontal adjustment component 2231 and a horizontal straightening roller 2232. The horizontal adjustment component 2231 is used to adjust the position of the horizontal straightening roller 2232 to roll-straighten the electric bar in the horizontal direction. The vertical straightening module 224 includes a vertical adjustment component 2241 and a vertical straightening roller 2242. The vertical adjustment component 2241 is used to adjust the position of the vertical straightening roller 2242 to roll-straighten the electric bar in the vertical direction. In this embodiment, the position adjustment module 221 ensures the stability and positioning accuracy of the electric bar during transmission by precisely adjusting the straightening support frame 222 along the transmission direction of the electric bar, effectively avoiding processing errors caused by position offset. The horizontal adjustment component 2231 and the horizontal straightening roller 2232 in the horizontal straightening module 223 work together to achieve precise roll-straightening of the electric bar in the horizontal direction. It can correct the bending or twisting of the electric busbar on the horizontal plane, and can also ensure the flatness of the electric busbar surface, thereby improving the fit and aesthetics of the subsequent wrapping process. The position adjustment function of the horizontal straightening roller 2232 allows the operator to flexibly adjust according to actual needs to adapt to the processing requirements of electric buses of different specifications, thereby enhancing the versatility and flexibility of the equipment. The vertical straightening module 224 achieves precise straightening of the electric busbar in the vertical direction through the cooperation of the vertical adjustment component 2241 and the vertical straightening roller 2242. It helps to eliminate the deformation of the electric busbar in the vertical direction, and can also ensure the overall straightness of the electric busbar, providing a more stable substrate for the subsequent wrapping process. The position adjustment function of the vertical straightening roller 2242 also gives the equipment a high degree of adaptability and adjustability, meeting diversified production needs.
[0023] The fixed sleeve 31 is provided with a fixed support frame 312, and the fixed sleeve 31 is fixed to the frame 1 through the fixed support frame 312. The axial direction of the fixed sleeve 31 passes through the column 12, and the wrapping mechanism 4 is arranged on the outer periphery of the fixed sleeve 31. In this embodiment, the structure ensures the axial positioning accuracy of the fixed sleeve 31 during operation, and also effectively avoids displacement caused by vibration or external force, thereby ensuring the accuracy and consistency of the wrapping operation. The axial passage of the fixed sleeve 31 through the column 12 enhances the structural rigidity of the device. The column 12 acts as a supporting element and works together with the fixed sleeve 31 to form a stable frame system that can effectively resist various torques and stresses generated during the wrapping process, ensuring the normal operation of the device under high load conditions. The wrapping mechanism 4 is arranged on the outer periphery of the fixed sleeve 31, making the entire device structure more compact and reasonable. The close cooperation between the wrapping mechanism 4 and the fixed sleeve 31 facilitates the efficient wrapping of the electric bus.
[0024] The first floating seat 32 is provided with a first positioning step 321, and the second floating seat 34 is provided with a second positioning step 341. The elastic element 33 is a spring, with its ends abutting the first and second positioning steps 321 and 341, respectively. Specifically, both the first and second floating seats 32 and 34 are formed from Teflon. In this embodiment, the first and second positioning steps 321 and 341, respectively, ensure precise abutment between the ends of the springs, thereby achieving effective positioning and stable operation. The spring, as the elastic element 33, plays a key role in this structure, providing a buffering and regulating effect, effectively absorbing vibrations and shocks generated during the wiring harness wrapping process, ensuring smooth and precise wrapping. Both the first and second floating seats 32 and 34 are formed from Teflon, a choice that offers numerous advantages. Teflon (polytetrafluoroethylene) is known for its excellent wear resistance, corrosion resistance, and self-lubricating properties, ensuring excellent performance stability even during high-frequency reciprocating motion.
[0025] See Figure 6 As shown, the wrapping mechanism 4 includes a wrapping drive module 41, a wrapping turntable 42, a wrapping guide arm 43, and a tape reel 44. The wrapping drive module 41 is used to drive the wrapping turntable 42 to rotate with the fixed sleeve 31 as the axis. The wrapping turntable 42 is provided with a receiving cavity. The tape reel 44 is arranged in the receiving cavity and is fixedly connected to the fixed sleeve 31. The wrapping guide arm 43 is arranged on one side of the wrapping turntable 42 and rotates with the wrapping turntable 42. The wrapping guide arm 43 is provided with a plurality of wrapping guide rollers 431 for guiding the strip material toward the electric bar. When the wrapping turntable 42 rotates, the tape reel 44 guides the material toward the electric bar through the guide rollers and wraps the material around the outer periphery of the electric bar during rotation. In this embodiment, the precise control capability of the wrapping drive module 41 ensures that the wrapping turntable 42 rotates stably with the fixed sleeve 31 as the axis, improves the stability of the wrapping process, and effectively avoids the uneven winding of the material caused by uneven rotation. The accommodating cavity structure on the wrapping turntable 42 accommodates the tape reel 44 therein and is fixedly connected to the fixed sleeve 31, thereby realizing the orderly supply of materials and further improving the consistency and reliability of the wrapping operation. The setting of the wrapping guide arm 43 and its synchronous rotation with the wrapping turntable 42 ensure that the strip material always maintains the correct path and tension state during the guiding process. The configuration of multiple wrapping guide rollers 431 can not only effectively guide the strip material toward the strip, but also fine-tune it during the material transmission process to ensure its precise winding around the periphery of the strip. The possibility of material deviation or slippage is reduced, thereby ensuring the consistency and high standards of the wrapping quality. Since the material is continuously and stably guided during the winding process, its distribution around the periphery of the strip is more even, which enhances the mechanical and electrical properties of the strip and extends its service life.
[0026] The pressing mechanism 5 includes an XY adjustment module 51, a pressing connection bracket 52, a horizontal pressing module 53 and a vertical pressing module 54. The XY adjustment module 51 is located at the rear side of the wrapping mechanism 4, and the pressing connection bracket 52 is arranged on the XY adjustment module 51. The horizontal pressing module 53 and the vertical pressing module 54 are arranged on the XY adjustment module 51 in sequence. The horizontal pressing module 53 is provided with a plurality of horizontal pressing rollers 531, and the vertical pressing module 54 is provided with a plurality of vertical pressing rollers 541, so as to press the strip material after wrapping tightly onto the electric bus. In this embodiment, the XY adjustment module 51 is located at the rear side of the wrapping mechanism 4, providing a stable base for subsequent pressing operations. The XY adjustment module 51 enables the horizontal pressing module 53 and the vertical pressing module 54 to be precisely adjusted on a two-dimensional plane, thereby adapting to the requirements of electric bus bars of different specifications and shapes, greatly enhancing the flexibility and applicability of the device. The pressing connection bracket 52 serves as a connecting piece to firmly fix the horizontal pressing module 53 and the vertical pressing module 54 on the XY adjustment module 51 to form a whole. It ensures the coordinated work between the various parts, avoids displacement caused by vibration or external force, and ensures the stability and consistency of the pressing process. The horizontal pressing module 53 is equipped with a plurality of horizontal pressing rollers 531, which can apply uniform horizontal pressure to the strip material so that it fits tightly on the surface of the electric bus. The vertical pressing module 54 further strengthens the vertical pressure on the strip material through a plurality of vertical pressing rollers 541 to ensure its firm attachment to the electric bus. The double pressing mechanism not only increases the contact area between the strip material and the electric bus, but also effectively eliminates possible air gaps, thereby improving the overall electrical performance and mechanical strength.
[0027] A conductive bus wrapping method is implemented using a floating wrapping device for a conductive bus of a new energy vehicle. The feeding mechanism 3, the wrapping mechanism 4, and the pressing mechanism 5 are each provided with two groups. The feeding mechanism 3, the wrapping mechanism 4, and the pressing mechanism 5 at the front end constitute a forward wrapping system, and the feeding mechanism 3, the wrapping mechanism 4, and the pressing mechanism 5 at the rear end constitute a reverse wrapping system; the strip material is wound in both forward and reverse directions on the outer diameter of the conductive bus; The wrapping method comprises the following steps: Step S1: The rolled electroplating material is fed into the feeding mechanism 2 and bidirectionally straightened by the straightening module 22: horizontal straightening: a roller pressure of 5 to 15 MPa is applied in the width direction of the electroplating by the horizontal straightening roller 2232 to eliminate horizontal bending; vertical straightening: a roller pressure of 3 to 10 MPa is applied in the thickness direction of the electroplating by the vertical straightening roller 2242 to eliminate vertical bending; Step S2: The straightened electric busbar is conveyed to the feeding mechanism 3. The feeding mechanism 3 compensates for radial displacement during wrapping by means of a floating structure: the electric busbar passes through the feeding slot of the fixed sleeve 31. The first floating seat 32 and the second floating seat 34 supported by the spring elastic element 33 allow the electric busbar to float radially by 0.5 to 2 mm. Step S3, forward wrapping the mica tape: The wrapping turntable 42 of the forward wrapping system rotates clockwise at a speed of 200-600 r / min, driving the wrapping guide arm 43 to wrap the mica tape at a wrap angle of 55°-65° to the outer diameter of the busbar; the overlap rate of the mica tape is controlled at 0.1%-10% to form a first insulating layer; Step S4, reverse wrapping the mica tape: The wrapping turntable 42 of the reverse wrapping system rotates counterclockwise at the same speed, wrapping the mica tape at a reverse wrap angle of 55° to 65°, with the overlap rate synchronously controlled at 0.1% to 10%, to form a second insulation layer that intersects the first layer; Step S5, bidirectional pressing and curing: After each wrapping, the pressing mechanism 5 performs multi-directional compaction on the mica tape: the horizontal pressing roller 531 applies a pressure of 8-12 MPa to eliminate interlayer bubbles; the vertical pressing roller 541 applies a pressure of 6-10 MPa to ensure that the adhesion between the mica tape and the surface of the electrode is ≥95%; the pressing temperature is maintained at 80-120°C to activate the viscosity of the mica tape resin; Step S6, the distance between the forward wrapping system and the reverse wrapping system is 1.2 to 1.5 times the width of the strip, ensuring that there is no interference between the bidirectional wrapping layers. In this embodiment, the rolled strip is discharged through the feeding mechanism 2, and the straightening module 22 is used for bidirectional straightening. The horizontal straightening roller 2232 applies a roller pressure of 5 to 15 MPa in the width direction of the strip to effectively eliminate horizontal bending; the vertical straightening roller 2242 applies a roller pressure of 3 to 10 MPa in the thickness direction of the strip to eliminate vertical bending. The bidirectional straightening method can fully correct the deformation of the strip, ensure its straightness and surface flatness, and provide high-quality basic materials for subsequent wrapping processes. The straightened strip has high straightness, which reduces material waste and uneven wrapping caused by the bending of the strip itself during the wrapping process, and improves the stability and reliability of the finished product. The feed mechanism 3 uses a floating structure to compensate for radial displacement during wrapping. The strip passes through the feed slot of the fixed sleeve 31. The first floating seat 32 and second floating seat 34, supported by a spring element 33, allow the strip to float radially by 0.5 to 2 mm. This solves the problem of radial displacement of the strip caused by uneven force or mechanical vibration during wrapping, ensuring stability and consistency during the wrapping process. The introduction of the floating structure not only improves wrapping accuracy but also enhances the adaptability and robustness of the equipment, reducing production failure rates and maintenance costs. The forward and reverse wrapping systems work together to achieve bidirectional winding of the strip material around the outer diameter of the strip. The forward wrapping system's wrapping turntable 42 rotates clockwise at a speed of 200 to 600 rpm, driving the wrapping guide arm 43 to wrap the mica tape around the outer diameter of the strip at a 65° wrap angle. The overlap ratio of the mica tape is controlled at 0.1% to 10%, forming the first insulation layer. Subsequently, the reverse wrapping system's wrapping turntable 42 rotates counterclockwise at the same speed, wrapping the mica tape at a reverse 65° wrap angle, with the overlap rate simultaneously controlled between 0.1% and 10%, forming a second insulation layer that intersects the first layer. This bidirectional wrapping method not only improves the density and uniformity of the insulation layer, but also enhances its mechanical strength and electrical performance, effectively preventing partial discharge and insulation breakdown that may occur during the busbar's use. The pressing mechanism 5 compacts the mica tape in multiple directions, maintaining the pressing temperature between 80°C and 120°C to activate the viscosity of the mica tape resin, further enhancing the bonding strength and integrity of the insulation layer. This multidirectional pressing and curing not only improves the density and stability of the insulation layer, but also effectively prevents the formation of bubbles and voids between layers, thereby improving the busbar's voltage resistance and service life. The spacing between the forward and reverse wrapping systems is designed to be 1.2 to 1.5 times the busbar width, ensuring no interference between the bidirectional wrapping layers. The size of the busbar and the requirements of the winding process are fully considered to avoid mutual influence and interference between the positive and negative winding layers, and ensure the independence and integrity of each layer of insulation material.
[0028] The above embodiments merely illustrate several implementations of the present invention, and while their descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the present invention. It should be noted that a person skilled in the art would be able to make numerous modifications and improvements without departing from the spirit of the present invention, all of which fall within the scope of protection of the present invention. Therefore, the scope of protection of the present invention shall be determined by the appended claims.
Claims
1. A floating device for wrapping conductive bars of new energy vehicles, characterized by: The invention comprises a frame, a feeding mechanism, a feeding mechanism, a wrapping mechanism and a pressing mechanism, the frame is provided with a workbench, the workbench is provided with a column, the feeding mechanism is provided on the column, the column is used to separate the frame into a feeding area and a wrapping area, the feeding mechanism is provided in the feeding area, the wrapping mechanism is provided in the wrapping area and is located on the periphery of the feeding mechanism, the feeding mechanism is used to transport the electric bus toward the feeding mechanism, the feeding mechanism comprises a fixed sleeve, a first floating seat, an elastic element, a second floating seat and a fixed ring, the fixed sleeve is fixedly provided on the column, the fixed sleeve is provided with a floating cavity, the first floating seat, the elastic element and the second floating seat The movable seats are arranged in the floating cavity in sequence, and the fixed ring is arranged at the port of the floating cavity to limit the second floating cavity to move in the floating cavity. A gap is provided between the outer diameters of the first floating seat and the second floating seat and the inner diameter of the floating cavity to allow the first floating seat and the second floating seat to move in the floating cavity; a feeding trough for feeding the electric bus is concentrically provided with the axis of the floating cavity, the first floating seat and the second floating seat; the wrapping mechanism is used to wrap the strip material around the electric bus passing through the feeding mechanism, and the first floating seat and the second floating seat are used to allow the electric bus to float radially during wrapping; the pressing mechanism is located behind the wrapping mechanism to compact the strip material after wrapping.
2. The conductive bar wrapping floating device for new energy vehicles according to claim 1, characterized in that: The feeding mechanism includes a discharge module and a feed straightening module. The discharge module is used to discharge the rolled electric rod to the feed straightening module, and the feed straightening module is used to straighten the electric rod and then feed it to the feeding mechanism.
3. The conductive bar wrapping floating device for new energy vehicles according to claim 2, characterized in that: The feed straightening module includes a position adjustment module, a straightening support frame, a horizontal straightening module and a vertical straightening module. The position adjustment module is arranged in the feed area, and the straightening support frame is arranged on the position adjustment module. The horizontal straightening module and the vertical straightening module are arranged on the straightening support frame in sequence to perform horizontal straightening and vertical straightening on the electric bus in sequence.
4. The conductive bar wrapping floating device for new energy vehicles according to claim 3, characterized in that: The position adjustment module is used to adjust the straightening support frame along the transmission direction of the electric busbar. The horizontal straightening module includes a horizontal adjustment component and a horizontal straightening roller. The horizontal adjustment component is used to adjust the position of the horizontal straightening roller to perform roller straightening on the horizontal direction of the electric busbar; the vertical straightening module includes a vertical adjustment component and a vertical straightening roller. The vertical adjustment component is used to adjust the position of the vertical straightening roller to perform roller straightening on the vertical direction of the electric busbar.
5. The conductive bar wrapping floating device for new energy vehicles according to claim 1, characterized in that: The fixed sleeve is provided with a fixed support frame, and the fixed sleeve is fixed on the frame through the fixed support frame. The axial direction of the fixed sleeve passes through the column, and the wrapping mechanism is arranged on the outer periphery of the fixed sleeve.
6. The conductive bar wrapping floating device for new energy vehicles according to claim 1, characterized in that: The first floating seat is provided with a first positioning step, the second floating seat is provided with a second positioning step, the elastic element is a spring, and two ends of the spring respectively abut against the first positioning step and the second positioning step.
7. The conductive bar wrapping floating device for new energy vehicles according to claim 6, characterized in that: The first floating seat and the second floating seat are both formed by processing Teflon.
8. The conductive bar wrapping floating device for new energy vehicles according to claim 1, characterized in that: The wrapping mechanism includes a wrapping drive module, a wrapping turntable, a wrapping guide arm and a tape winding disk. The wrapping drive module is used to drive the wrapping turntable to rotate with the fixed sleeve as the axis. The wrapping turntable is provided with a accommodating cavity. The tape winding disk is arranged in the accommodating cavity and is fixedly connected to the fixed sleeve. The wrapping guide arm is arranged on one side of the wrapping turntable and rotates with the wrapping turntable; the wrapping guide arm is provided with a plurality of wrapping guide rollers for guiding the strip material toward the electric bus. When the wrapping turntable rotates, the tape winding disk guides the material toward the electric bus through the guide rollers, and wraps the material around the outer periphery of the electric bus during the rotation process.
9. The conductive bar wrapping floating device for new energy vehicles according to claim 1, characterized in that: The pressing mechanism includes an XY adjustment module, a pressing connection bracket, a horizontal pressing module and a vertical pressing module. The XY adjustment module is located on the rear side of the wrapping mechanism. The pressing connection bracket is arranged on the XY adjustment module. The horizontal pressing module and the vertical pressing module are arranged on the XY adjustment module in sequence. The horizontal pressing module is provided with multiple horizontal pressing rollers, and the vertical pressing module is provided with multiple vertical pressing rollers, so as to press the wrapped strip material tightly onto the electric bus.
10. A method for wrapping an electric busbar, characterized in that: The floating device for wrapping the conductive bar of a new energy vehicle according to any one of claims 1 to 9 is implemented, wherein the feeding mechanism, the wrapping mechanism and the pressing mechanism are each provided with two groups, the feeding mechanism, the wrapping mechanism and the pressing mechanism at the front end constitute a forward wrapping system, and the feeding mechanism, the wrapping mechanism and the pressing mechanism at the rear end constitute a reverse wrapping system; the strip material is wound in both forward and reverse directions on the outer diameter of the conductive bar; The wrapping method includes the following steps: Step S1: The coiled material is discharged through the feeding mechanism and bidirectionally straightened by the straightening module: Horizontal straightening: Apply 5~15MPa roller pressure in the width direction of the bar through the horizontal straightening roller to eliminate horizontal bending; Vertical straightening: Apply 3~10MPa roller pressure in the thickness direction of the strip through the vertical straightening roller to eliminate vertical bending; Step S2: The straightened electric busbar is transported to a feeding mechanism, and the feeding mechanism compensates for radial displacement during wrapping through a floating structure: The electric busbar passes through the feeding slot of the fixed sleeve. The first floating seat and the second floating seat supported by the spring elastic element allow the electric busbar to float radially by 0.5~2mm. Step S3, wrapping the mica tape in the forward direction: The forward wrapping system's wrapping turntable rotates clockwise at a speed of 200-600 r / min, driving the wrapping guide arm to wrap the mica tape to the outer diameter of the electrode at a wrap angle of 55°-65°. The overlap rate of mica tape is controlled at 0.1%~10% to form the first insulation layer; Step S4, reverse wrapping the mica tape: The reverse wrapping system's wrapping turntable rotates counterclockwise at the same speed, wrapping the mica tape at a reverse wrap angle of 55°~65°, with the overlap rate synchronously controlled at 0.1%~10%, forming a second insulation layer that intersects the first layer. Step S5, bidirectional pressing and curing: After each wrapping, the pressing mechanism compacts the mica tape in multiple directions: The horizontal lamination roller applies 8~12MPa pressure to eliminate bubbles between layers; The vertical pressing roller applies 6~10MPa pressure to ensure that the adhesion between the mica tape and the surface of the electrode is ≥95%; The pressing temperature is maintained at 80~120℃ to activate the viscosity of the mica tape resin; Step S6: The distance between the forward wrapping system and the reverse wrapping system is 1.2 to 1.5 times the width of the wiring board to ensure that there is no interference between the bidirectional wrapping layers.