Wiring harness power energy storage battery sampling assembly and method

Abstract

The invention discloses a wiring harness power energy storage battery sampling assembly and method, and the assembly is characterized in that a PPTC self-recovery fuse, an NTC, a nickel sheet welding end and a crimping end are integrated on a long-strip-shaped PCB, and the PPTC is fixedly sealed in a main current path through a solder mask windowing technology and a four-corner tin injection technology. The terminal is clamped with the notch of the aluminum bar through the U-shaped buckle at the welding end of the nickel sheet, and then stable connection and electrical conduction are realized through hot riveting and laser welding; and the NTC is directly contacted with the battery cell through the lower heat-conducting silica gel pad to measure the temperature. The invention further discloses a preparation method of the terminal and an assembly method of the assembly. The problems that a traditional wire harness scheme is complex in welding, free of overcurrent protection and inaccurate in temperature collection and an FPC scheme is high in cost, poor in overcurrent and difficult to maintain are solved, and the beneficial effects of high reliability, high precision, easy maintenance and easy automatic production are achieved.

Description

TECHNICAL FIELD

[0001] The present application relates to a kind of sampling assembly and method, in particular to a kind of harness power energy storage battery sampling assembly and method. BACKGROUND

[0002] With the rapid development of new energy vehicles and energy storage industry, the voltage and temperature sampling precision, reliability and cost of battery management system (BMS) to battery module also put forward higher requirements. The current mainstream sampling scheme mainly exists following technical bottleneck: The existing harness sampling scheme usually adopts single-core non-shielded wire and aluminum bar to be connected by ultrasonic direct welding. This process has significant defects. The ultrasonic welding parameter variable is as many as more than twenty. The hardness and purity of the material are extremely harsh. The existing standard aluminum material hardness range hardness interval is generally 14HV. The hardness of aluminum bar needs to be stable within 7HV. It needs pure copper and the temperature resistance is lower than 120 DEG C. This leads to poor welding consistency and low product yield. In addition, this scheme lacks built-in overcurrent protection function. Short circuit is easy to cause thermal runaway risk. At the same time, the temperature collection path is long. It is usually in turn battery, aluminum bar, terminal shell and NTC. The process transmission loss is large. The response is slow. The precision is insufficient.

[0003] Secondly, although the existing flexible circuit board (FPC) scheme has high integration, the process is complex and the manufacturing cost is high. Moreover, in order to maintain flexibility, the cross section of FPC is usually small, which leads to weak overcurrent capacity and no surge resistance. Once the integrated fuse is fused, the FPC module usually needs to be replaced as a whole. The maintenance cost is also very high. SUMMARY

[0004] In order to solve the above technical problems, the present application provides a kind of harness power energy storage battery sampling assembly and method.

[0005] In order to solve the above technical problems, the technical scheme adopted by the present application is: a kind of harness power energy storage battery sampling assembly, including PCB board, nickel sheet welding end and nickel sheet crimping end welded at both ends of etching circuit of PCB board;PPTC and NTC are connected in series in etching circuit;PPTC is electrically connected with NTC, nickel sheet welding end and nickel sheet crimping end through etching circuit.

[0006] Further, the position of NTC on the PCB board is coupled with the battery through the heat-conducting silica gel pad.

[0007] Further, the nickel sheet welding end has a U-shaped buckle structure that engages with the notch of the aluminum bar. The size of the U-shaped buckle structure is 1.7mm*8mm. The groove of the U-shaped buckle structure is sunken by 1.0mm. The size of the notch of the aluminum bar is 1.8mm*8.5mm.

[0008] Further, the PCB board is in a long strip structure, the nickel sheet welding end and the nickel sheet crimping end are welded at two ends of the PCB board along the length direction of the PCB board respectively, the wire of the nickel sheet crimping end and the nickel sheet welding end are electrically connected with the etching circuit on the PCB board, the PPTC and the NTC are both in the planar projection of the PCB board, the PPTC, the nickel sheet welding end and the nickel sheet crimping end are arranged in a straight line along the length direction of the PCB board.

[0009] Further, the etching circuit of the PCB board is provided with a solder resist layer opening window in the area corresponding to the welded PPTC to form a welding site; the PPTC is arranged on the welding site, and the PPTC is surrounded by the tin liquid solidification structure injected from the four corners of the welding site to form a conduction structure body meeting the electrical connection of the nickel sheet welding end and the PPTC.

[0010] Further, the wire diameter specification of the wire is 0.22mm2~0.35mm2, and is determined according to the model of the nickel sheet crimping end (6).

[0011] A preparation method of a wiring harness power energy storage battery sampling assembly: A preparation method of a wiring harness power energy storage battery sampling assembly:

[0012] A preparation method of a wiring harness power energy storage battery sampling assembly: S1, wire pretreatment, opening, branching and stripping of the wire are performed to expose the copper core, and one end of the wire is crimped with the nickel sheet crimping end; S2, carrier and connecting piece are placed, the isolation plate is placed on the flow plate, and then the aluminum bar is placed in the limiting structure of the isolation plate; S3, terminal positioning, the U-shaped buckle of the nickel sheet welding end is clamped with the notch on the aluminum bar, and the rivet hole on the PCB board is aligned with the rivet column on the isolation plate; S4, hot riveting fixation, the rivet column on the aluminum bar and the PCB board is treated by hot riveting to form a mushroom head at the end of the rivet column, so as to be mechanically fixed on the isolation plate; S5, laser welding step: the nickel sheet welding end and the aluminum bar are laser welded to realize electrical conduction.

[0013] Further, the limiting hole of the aluminum bar in step S2 is an upper and lower misaligned rivet hole, and the misaligned distance is greater than the radius of the corresponding rivet column.

[0014] Further, in step S5, the welding power of the laser welding is 155±10 W, the welding frequency is 300 KHz, and the welding speed is 120±10 mm / s.

[0015] The application discloses a kind of harness power energy storage battery sampling components and method, adopt laser welding instead of traditional ultrasonic welding, more than 20 kinds of difficult to control process parameters are simplified into power, frequency, speed three core variables, greatly reduce the process difficulty and dependence on operator. Meanwhile, this process eliminates the harsh requirements for aluminum bar hardness, without being stabilized within 7HV and strict restriction to wire temperature resistance, expand the material selection range, fundamentally solve the poor welding consistency, low product yield technical bottleneck.

[0016] Integrated recoverable overcurrent protection, significantly improve system safety and maintenance convenience, innovatively integrate self-recovery fuse in sampling circuit, when abnormal large current appears in circuit, it can act quickly, cut off circuit, effectively prevent wire and peripheral components from burning due to overcurrent, avoid the risk of thermal runaway. After troubleshooting, PPTC can automatically recover, overcome the drawbacks of traditional one-time fuse blown and FPC scheme damaged, realize the reuse of components, greatly reduce the maintenance cost and time. In addition, PPTC can be controlled to power off after blowing, and power on after troubleshooting.

[0017] Create an efficient and direct temperature transfer path to achieve accurate and rapid temperature sampling. By introducing a heat-conducting silicone pad, a short-path, low-thermal-resistance heat conduction channel is established between the battery cell, the heat-conducting silicone pad, and the NTC. This design eliminates the long transfer path in traditional schemes, significantly reducing thermal loss and thermal delay in intermediate links, allowing the NTC to quickly and accurately sense the true temperature of the battery cell, providing more timely and reliable data support for the battery management system.

[0018] Through the double positioning structure of U-shaped buckle mechanical pre-positioning and hot rivet final locking, combined with the assembly process of fixing rigid components first and then processing flexible wires, the industry problem of traditional harness unable to realize automation due to wire interference is completely solved. This innovation enables high-precision laser welding to be completed by robots, not only simplifying the assembly process and saving labor costs, but also improving production efficiency and product consistency, providing the possibility for large-scale, low-cost manufacturing.

[0019] Finally, the standardized PCB layout, strong overcurrent capability of low-cost wires, and easy maintenance of modular terminals are combined, which surpasses the traditional harness direct welding scheme and FPC in performance, and is much lower than FPC in cost. BRIEF DESCRIPTION OF DRAWINGS

[0020] Figure 1 It is a top view of the application.

[0021] Figure 2 This is a side view of the present invention.

[0022] Figure 3 This is a schematic diagram of the sampling component assembly.

[0023] In the diagram: 1. PCB board; 2. PPTC; 3. NTC; 4. Etched circuit; 5. Nickel sheet soldering end; 6. Nickel sheet crimping end; 7. Thermal conductive silicone pad; 8. Wire. Detailed Implementation

[0024] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0025] Example 1: Wiring Harness Power Storage Battery Sampling Component like Figure 1 and Figure 2 As shown, the core of this invention lies in the aforementioned wire harness power storage battery sampling component. This terminal, as a modular functional unit, is manufactured as follows: A long strip of PCB board 1 is etched to form the required etched circuit 4. A solder mask window is created in the area where PPTC2 is to be soldered, forming an exposed soldering position. Component integration and soldering are then performed. A surface-mount PPTC (resetting fuse) of the appropriate specification is selected and placed in the aforementioned soldering position. Between the four corners of the PPTC2 electrode and the PCB window, solder is melted by heating and seeps into and fills the gap at the connection point, then solidified, forming a stable structure that encapsulates and electrically connects the PPTC2 to the etched circuit 4. This ensures the reliability of the overcurrent protection function and facilitates future maintenance and replacement. Simultaneously, the nickel sheet soldering end 5 and the nickel sheet crimping end 6 are fixed to both ends of the PCB board 1 along its length. Thus, the nickel sheet soldering end 5, PPTC2, etched circuit 4, and nickel sheet crimping end 6 are connected in series, forming a cross-shaped integrated structure on the PCB board 1. This compact layout facilitates automated assembly. The NTC3 is fixed to a predetermined position on the PCB board 1 by soldering. A thermally conductive silicone pad 7 is attached to the underside of the NTC3 on the PCB board 1. This design establishes a direct, short-path heat conduction channel between the battery cell, the thermally conductive silicone pad, and the NTC. Finally, the insulation layer of the end of the conductor 8 (single-core unshielded wire) is stripped, and a secure electrical and mechanical connection is achieved with the nickel sheet crimping end 6 using a crimping tool. The conductor diameter is preferably 0.22mm²~0.35mm², which has a significantly better current-carrying capacity than traditional FPC circuits.

[0026] This embodiment solves the problem of lack of overcurrent protection for conductors in traditional CCS ultrasonic direct soldering of wire harnesses. By integrating PPTC2, recoverable overcurrent protection is achieved, avoiding the risk of component burnout or thermal runaway during short circuits, thus improving safety. It also addresses the issue of poor temperature acquisition accuracy by directly connecting the battery cell to the thermally conductive silicone pad 7, eliminating the lengthy path of traditional battery cell → aluminum bus → terminal housing → NTC, reducing heat loss, and achieving rapid temperature response and high-precision acquisition. Furthermore, it solves the problems of poor overcurrent capacity and high cost of FPCs: by using standard conductors combined with the PCB, it ensures strong overcurrent capacity while leveraging the cost advantages of standardized PCB production. The conductors are also easy to recycle, making it more environmentally friendly.

[0027] Example 2: Assembly method of sampling component like Figure 3 As shown, this embodiment provides a complete assembly method for a battery sampling assembly based on the aforementioned terminals. Process optimization is key to achieving automation. The method includes the following steps: S1, Conductor Pre-treatment: The conductors are opened, separated, and stripped. Depending on whether the terminal has its own wire, there are two treatment methods. If the NTC terminal has its own wire, the two parallel wire ends of the NTC terminal are separated, stripped, and then crimped to the connecting terminal. For the PPTC terminal, the insulation layer is stripped from both ends of the conductor, one end is fixed to the nickel sheet crimping end 6 of the terminal, and the other end is simultaneously crimped to the connecting terminal. If the NTC terminal does not have its own wire, the customer-specified type of conductor with three wires is selected, the insulation layer is stripped from both ends, one end of the three wires is simultaneously connected to the connecting terminal, the other end of the single wire is crimped to the terminal, and the remaining two wires are soldered to the etched circuit 4 on PCB board 1.

[0028] S2, Carrier and Connecting Piece Insertion: The isolation plate is placed on the transfer plate as a carrier and insulating carrier. Then, the aluminum bar is individually inserted into the limiting structure of the isolation plate. Here, the limiting hole of the aluminum bar is designed with a foolproof structure, specifically a staggered rivet hole, and the stagger distance is greater than the rivet radius (e.g., rivet φ5mm, rivet hole φ5.4mm, stagger distance > 2.5mm), ensuring that the aluminum bar can only be inserted in one correct orientation.

[0029] S3, Terminal Positioning: Place the prepared wire harness power storage battery sampling assembly into the slot. The U-shaped clips (1.7mm*8mm, 1.0mm recessed groove) at the nickel sheet welding end engage with the pre-made cutouts (1.8mm*8.5mm) on the aluminum foil, achieving horizontal pre-fixation. Simultaneously, the riveting holes on the PCB board align with the riveting posts on the isolation plate. This dual positioning design ensures the accuracy of subsequent welding.

[0030] S4, Hot riveting fixation: The rivets at the positions of the aluminum bar and PCB board are hot riveted to form mushroom heads at the ends of the rivets, thereby mechanically locking the aluminum bar and terminals securely to the isolation plate.

[0031] S5, Laser Welding: After the components are fully mechanically fixed, the nickel sheet welding ends are laser welded to the aluminum bar. Example welding parameters: welding power 155±10W, welding frequency 300KHz, welding speed 120±10mm / s. By selecting appropriate nickel sheet specifications (e.g., 8mm wide, 0.3mm thick) and welding point patterns (e.g., six-point staggered weld or four-point weld), the welded joint can achieve excellent performance: peel force ≥60N, tensile force ≥300N, and welding internal resistance ≤60μΩ.

[0032] This embodiment solves the problems of complex and unstable welding processes by replacing ultrasonic welding with laser welding. It simplifies over twenty control variables into three core parameters: power, frequency, and speed, significantly reducing process difficulty and improving consistency and yield. Simultaneously, it addresses the challenges of automated production. By first individually inserting the aluminum bar, then securing the terminal, and finally performing laser welding, it achieves a process of rigid positioning followed by flexible wiring. This completely solves the problem in traditional solutions where welding the wire first prevents the aluminum bar from being placed independently, making fully automated production lines possible. Furthermore, it improves connection reliability and performance. The dual positioning of the U-shaped clip and hot riveting ensures no weld point shift during laser welding. Precisely controlled laser welding parameters result in high mechanical strength and low connection resistance, enhancing the overall reliability of the product.

[0033] In summary, through structural and methodological innovation, this invention systematically solves the pain points of existing technologies, such as high-difficulty welding, lack of safety protection, inaccurate sampling, hindered automation, and high cost, and provides a high-performance, high-reliability, low-cost battery sampling solution that is easy to automate.

[0034] The above embodiments are not intended to limit the present invention, and the present invention is not limited to the examples given above. Any changes, modifications, additions or substitutions made by those skilled in the art within the scope of the technical solution of the present invention are also within the protection scope of the present invention.

Claims

1. A wire harness power storage battery sampling assembly, characterized in that, It includes a PCB board (1), nickel sheet soldering ends (5) and nickel sheet crimping ends (6) soldered to both ends of the etched lines on the PCB board (1); PPTC (2) and NTC (3) are connected in series in the etched lines; PPTC (2) is electrically connected to NTC (3), the nickel sheet soldering ends (5) and the nickel sheet crimping ends (6) through the etching circuit (4) and the wires (8).

2. The wire harness power storage battery sampling assembly according to claim 1, characterized in that: The NTC (3) is located on the PCB board (1) and is thermally coupled to the battery cell via a thermally conductive silicone pad (7).

3. The wire harness power storage battery sampling assembly according to claim 1, characterized in that: The nickel sheet welding end (5) has a U-shaped buckle structure that engages with the cut of the aluminum bar. The U-shaped buckle structure has a size of 1.7mm*8mm and a groove that is recessed by 1.0mm. The cut of the aluminum bar has a size of 1.8mm*8.5mm.

4. The wire harness power storage battery sampling assembly according to claim 1, characterized in that: The PCB board (1) is a long strip structure. The nickel sheet welding end (5) and the nickel sheet pressing end (6) are respectively welded to both ends of the PCB board (1) along its length direction. The wire (8) of the nickel sheet pressing end (6) and the nickel sheet welding end (5) are electrically connected to the etched lines (4) on the PCB board (1). The PPTC (2) and NTC (3) are both on the plane projection of the PCB board (1). The PPTC (2), the nickel sheet welding end (5) and the nickel sheet pressing end (6) are arranged in a straight line along the length direction of the PCB board (1).

5. The wire harness power storage battery sampling assembly according to claim 1 or 4, characterized in that: The etched lines (4) of the PCB board (1) have solder mask openings in the area corresponding to the soldering of the PPTC (2) to form a soldering position; the PPTC (2) is set on the soldering position, and the PPTC is surrounded by a solidified structure by the molten tin injected from the four corners of the soldering position to form a conductive structure that satisfies the electrical connection between the nickel sheet soldering end (5) and the PPTC (2).

6. The wire harness power storage battery sampling assembly according to claim 1 or 4, characterized in that: The wire diameter of the conductor (8) is 0.22mm²~0.35mm², and depends on the model of the nickel sheet crimping end (6).

7. A method for preparing a wire harness power storage battery sampling assembly, characterized in that: An etched circuit PCB board is prepared, and windows are made on the PCB board corresponding to the positions where nickel sheets are soldered. A PPTC is selected, and both ends of the soldering position are placed into the holes of the window. Molten solder is injected into the window holes at the four corners of the PPTC. The soldering end and the crimping end of the nickel sheet are soldered to the PCB board through the molten solder, so that the nickel sheet, PCB board and PPTC form an integrated conductive structure after the molten solder solidifies. The NTC is soldered to the PCB board, and then the whole is sealed and protected with epoxy resin.

8. An assembly method for a wire harness power storage battery sampling assembly, characterized in that: Includes the following steps: S1, Wire pretreatment: The wires are opened, split, and stripped to expose the copper core, and one end is crimped to the nickel sheet crimping end; S2, Carrier and connecting piece placement: The isolation plate is placed on the transfer plate, and then the aluminum bar is placed separately into the limiting structure of the isolation plate; S3, Terminal positioning: The U-shaped buckle of the nickel sheet welding end is engaged with the cut on the aluminum bar, and the riveting holes on the PCB board are aligned with the rivets on the isolation plate; S4, Hot riveting fixation: The aluminum bar and the rivets on the PCB board are hot riveted to form mushroom heads at the ends of the rivets, thereby mechanically fixing them to the isolation plate; S5, Laser welding step: The nickel sheet welding end and the aluminum bar are laser welded to achieve electrical conductivity.

9. The assembly method of the wire harness power storage battery sampling assembly according to claim 8, characterized in that: In step S2, the limiting hole of the aluminum bar is a rivet post hole that is staggered vertically, and the stagger distance is greater than the radius of the corresponding rivet post.

10. The assembly method of the wire harness power storage battery sampling assembly according to claim 8, characterized in that: In step S5, the laser welding power is 155±10W, the welding frequency is 300KHz, and the welding speed is 120±10mm / s.

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