Aluminum power wire harness applied to unmanned aerial vehicle field

Abstract

The invention discloses an aluminum power wire harness applied to the field of unmanned aerial vehicles, the aluminum power wire harness comprises a connecting port, and a positive wire and a negative wire which are connected with the connecting port, the connecting port comprises two connecting terminals and an injection molding shell, the connecting terminals are subjected to semi-gold plating treatment and are divided into gold plating parts for plugging and exposed parts for welding, and the exposed parts are connected with the connecting port. The gold plating part is a composite coating with a nickel-plated bottom layer and a gold-plated surface layer; and the exposed part is a copper substrate which is not subjected to any electroplating treatment. The exposed part and the wire are subjected to ultrasonic welding treatment to form a solid-phase welding point, the exposed part of the connecting terminal and the solid-phase welding point are coated with an injection molding shell formed through injection molding, and the injection molding shell is further provided with a sealing ring in a sleeved mode. According to the invention, a power wire harness in which a copper wire is replaced by an aluminum wire in the field of new energy automobiles is applied to the field of unmanned aerial vehicles, and except for the advantages of light weight and low cost, the connection terminal subjected to partition treatment gives consideration to corrosion / oxidation resistance and welding strength, and has relatively good reliability and durability.

Description

TECHNICAL FIELD

[0001] The application relates to the field of unmanned aerial vehicle parts, in particular to an aluminum power wire harness applied to the field of unmanned aerial vehicles. BACKGROUND

[0002] Low-altitude economy is an emerging industry, and one of the core fields of the unmanned aerial vehicle industry gradually moves from the exploration period to the mature period, and the strategy direction of the related enterprises is adjusted from "paying attention to performance" to "cost control". Among them, the unmanned aerial vehicle power wire harness is an important part of the transportation of electric energy, and the unmanned aerial vehicle power wire harness in the prior art is generally copper wire. However, the price of copper wire is high, which does not meet the development focus of the unmanned aerial vehicle today. At the same time, the density of copper is large, and the unmanned aerial vehicle power wire harness using copper wire will lead to a large overall mass of the unmanned aerial vehicle, affecting the endurance of the unmanned aerial vehicle.

[0003] There is a power cable using aluminum wire in the field of new energy vehicles, which has the advantages of small weight and low cost, and is directly applied to the field of unmanned aerial vehicles, but there is a key defect: The connection of the copper base material connecting terminal and the aluminum wire needs ultrasonic welding treatment, however, the unmanned aerial vehicle exists in the scene of long-term strong acid / alkali environment, the silver-plated or bare copper connecting terminal is easy to be corroded and oxidized, thereby affecting the electrical performance of the wire harness, and the durability is poor. The industry will use all-gold-plated connecting terminals to cope with environmental erosion, but the all-gold-plated terminals will seriously weaken the welding strength of ultrasonic welding, and the connecting terminals are easy to fall off under external force, resulting in that the wire harness loses its function, and the reliability is poor.

[0004] Therefore, there is an urgent need for an aluminum wire unmanned aerial vehicle power wire harness which can realize "acid / alkali / oxidation corrosion resistance" and "high ultrasonic welding strength" of the connecting terminal. SUMMARY

[0005] In order to solve the above technical problems, the application provides an aluminum power wire harness applied to the field of unmanned aerial vehicles.

[0006] In order to solve the above technical problems, the application adopts the technical scheme of: an aluminum power wire harness applied to the field of unmanned aerial vehicles, comprising a connecting port and positive and negative wires connected thereto; The connecting port comprises a connecting terminal and an injection shell processed in sections, the connecting terminal is provided with a gold-plated part and a bare part for ultrasonic welding connected in sections; The injection shell is arranged on the bare part of the connecting terminal; The conductor material of the positive and negative wires is aluminum.

[0007] Further, the gold-plated part is a composite plating layer of a bottom layer of nickel plating and a surface layer of gold plating, and the bare part is a copper base without any treatment.

[0008] Further, the positive and negative conductive wires are copper-based welded with the exposed part of the connecting terminal with solid phase welding points.

[0009] Further, the injection molding shell is covered on the solid phase welding points welded by the connecting terminal and the aluminum conductive wire through injection molding treatment.

[0010] Further, the injection molding shell is provided with a sealing groove, and the sealing groove is sleeved with a sealing ring for ensuring the connection sealing.

[0011] An aluminum brake power harness preparation process applied in the field of unmanned aerial vehicles, the aluminum wire of any one of claims 1-5 is used to replace the copper wire of the power harness, and the preparation process comprises the following steps: Step one: electroplating, the copper base of the connecting terminal is divided into a gold-plated part and an exposed part, the gold-plated part is treated with nickel plating and gold plating, and the exposed part is not treated with any electroplating; Step two: ultrasonic welding, one end of the positive / negative conductive wire is stripped of the protective layer to expose the wire, the wire is arranged on the exposed part of the connecting terminal, the side needle of the ultrasonic welding equipment is lowered and fixed together with the anvil to fix the connecting terminal, the ultrasonic welding head is lowered to contact the wire, the high-frequency vibration and a certain pressure force the wire to form a solid phase welding point, so that the ultrasonic welding is completed; Step three: injection molding, the connecting terminal and the conductive wire after ultrasonic welding are arranged in the mold of the injection molding equipment, the mold is closed and the injection material is filled in the cavity of the mold, the equipment keeps the pressure of the filled mold and cools, and the connecting terminal and the solid phase welding point after demolding are covered with an injection molding shell.

[0012] Further, in step two, the vibration frequency of the ultrasonic welding head is 19.70KHz-20.30KHz, and the welding time is 1810ms.

[0013] Further, in step three, the injection material is PA66, the injection time is 18s, and the injection temperature is 260℃-275℃.

[0014] The aluminum power harness of the application replaces the copper wire in the field of new energy vehicles, based on the advantages of small weight and low cost, and is applied in the field of unmanned aerial vehicles, the problems of the silver / copper-plated connecting terminal exposed in the environment for a long time and easily corroded to affect the performance, and the problem of the gold-plated connecting terminal with low ultrasonic welding strength and easily falling off under external force to cause failure, in order to realize the aluminum brake power harness with high corrosion resistance and high welding strength, the connecting terminal is divided into a gold-plated part and an exposed part, the gold-plated part guarantees the electrical performance and high corrosion resistance, and the exposed part guarantees the ultrasonic welding strength, the problem of the reliability and durability of the aluminum power harness replacing the copper wire in the field of unmanned aerial vehicles is solved, and the application of the aluminum brake power harness in the field of unmanned aerial vehicles is realized. Attached Figure Description

[0015] Figure 1 This is an exploded view of the present invention.

[0016] Figure 2 This is a schematic diagram of the overall structure of the present invention.

[0017] Figure 3 This is a schematic diagram of the structure of the connection terminal of the present invention.

[0018] Figure 4 This is a schematic diagram illustrating the welding effect of the present invention.

[0019] Figure 5 This is a schematic diagram illustrating the injection molding effect of the present invention.

[0020] Figure 6 This is a schematic diagram of the device connection of the present invention.

[0021] In the diagram: 1. Connecting terminal; 2. Positive wire; 3. Negative wire; 4. Injection molded shell; 5. Sealing ring; 10. Connecting port; 11. Gold-plated part; 12. Exposed part; 20. Other components. Detailed Implementation

[0022] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0023] This invention discloses a drone power harness in which aluminum wires replace copper wires, such as... Figure 1 and Figure 2 As shown, it includes a connection port 10, a positive wire 2, and a negative wire 3. The connection port 10 includes two connection terminals 1. The positive wire 2 and the negative wire 3 are fixedly connected to their respective connection terminals via ultrasonic welding. An injection-molded shell 4 is used to cover the welded joints between the positive wire 2, the negative wire 3, and the connection terminals 1. The injection-molded shell 4 has mounting bolt holes and is fitted with a sealing ring 5. Detailed explanation follows: Connection terminal 1 as follows Figure 3As shown, the connection terminal 1 is processed by a traditional connection terminal half-gold plating process, i.e. a partial gold plating process. After the process, the connection terminal 1 can be simply divided into a gold-plated part 11 for connection and a bare part 12 for welding. The gold-plated part 11 is the plug-in part of the wire harness and other devices 20 (such as motors), which is processed by a mature electroplating process to form a composite plating layer with a nickel bottom layer and a gold surface layer. The nickel bottom layer of the composite plating layer acts as a barrier layer to effectively prevent the atomic diffusion between the copper matrix and the gold surface layer. The nickel bottom layer can also isolate the copper matrix from the environment, weaken the corrosion of oxygen, water and other substances in the environment, and thus prolong the service life of the connection terminal. In addition, the nickel bottom layer has a certain hardness, which can protect the copper matrix from accidental damage and thus enhance the mechanical strength of the gold-plated part of the connection terminal. The gold surface layer of the composite plating layer has good corrosion resistance and oxidation resistance, which can avoid the problems of oxidation, sulfuration and corrosion of the gold-plated part of the connection terminal, thereby prolonging the service life of the connection terminal. At the same time, the gold surface layer is an excellent conductor with good electrical contact performance, which can ensure the stability of electrical connection.

[0024] The bare part 12 is used as the area for ultrasonic welding with aluminum wires. The bare part 12 has no electroplating treatment, and the exposed copper matrix is directly welded with aluminum wires, which has better welding strength and connection stability than the combination of gold plating layer and aluminum wires, and can effectively avoid the problem of connection terminal falling off, thus ensuring the reliability of the connection.

[0025] Traditional unmanned aerial vehicle power harnesses often use full-gold plating process to deal with the corrosion and oxidation of substances in the environment, especially for strong acid / strong alkaline drugs of spraying robots (pesticide robots). However, the setting of the gold plating layer weakens the welding strength of the connection terminal and the aluminum wire ultrasonic welding, and the tensile strength of the welded part is weak, which is prone to the problem of connection terminal falling off. To solve this problem, the application creatively adopts a "zoned processing" scheme, the setting of the gold-plated part 11 ensures the corrosion resistance, oxidation resistance and good electrical connection performance of the connection terminal 1, and the setting of the bare part 12 ensures the welding strength and connection stability of the connection terminal 1 and the aluminum wire.

[0026] The positive and negative lead wires 2 and 3 are the carriers of electric energy transmission. Compared with the traditional unmanned aerial vehicle power harness, the application uses aluminum material instead of copper material for the positive and negative lead wires in the field of new energy vehicles. The density of aluminum is 2.7 g / cm³, which is much smaller than the density of copper, which is 8.9 g / cm³. Therefore, when achieving the same basic electrical performance, the aluminum lead wire is lighter in weight, which is conducive to reducing the endurance pressure of the unmanned aerial vehicle. In addition, the aluminum lead wire has economic advantages compared with the copper lead wire. It is estimated that the power harness using aluminum material can save 30% of the cost compared with the power harness using copper material, which is more in line with the strategy direction of "cost control" in the field of unmanned aerial vehicles today.

[0027] The injection-molded housing 4 is a protective component for the connecting terminal. Through injection molding, it completely encapsulates the exposed portion 12 of the connecting terminal 1 and the welded joint of the aluminum wire, forming a closed protective shell to isolate the copper substrate of the exposed portion 12 from contact with oxygen, moisture, and other elements in the environment, reducing the risk of corrosion of the copper substrate by water and oxygen. Furthermore, the injection-molded housing 4 is provided with mounting bolt holes for positioning and fixing the connecting port 10 to other devices 20, further ensuring the stability of the electrical connection between the power harness and other devices (motor).

[0028] In addition, a sealing groove is provided on the outside of the injection molded shell 4, and a sealing ring 5 is fitted in the sealing groove. The sealing ring 5 is designed to seal the connection port 10 and other components 20 at the insertion point. Specifically, when the connection port 10 is inserted into other components 20, the sealing ring 5 fits into the interface of other components 20 to ensure its sealing performance, preventing moisture and corrosive liquids from seeping into the interface from the gaps at the insertion point, thus ensuring the safety of the electrical connection between the injection molded shell and other components.

[0029] This invention applies the use of aluminum wires instead of copper wires in power harnesses, a technology previously used in the new energy vehicle industry, to the field of unmanned aerial vehicles (UAVs). The specific process flow is as follows: Electroplating treatment: The present invention performs a semi-gold plating treatment on the connecting terminals of the copper substrate. The exposed part of the connecting terminal is protected and does not undergo any electroplating treatment to maintain its exposed copper substrate. The gold-plated part is treated with nickel plating and gold plating to form a composite plating layer with a nickel underlayer and a gold surface layer.

[0030] Welding process: This invention involves ultrasonic welding of the connecting terminals and aluminum wires, such as... Figure 4 As shown, with 16mm 2 Take aluminum conductors with a cross-sectional area as an example.

[0031] The ultrasonic welding equipment is in standby mode, with the ultrasonic probe positioned above the welding area of ​​the anvil, and the two side pins on either side of the probe. The operator places the connector terminal in the welding area of ​​the anvil, exposing one end of the aluminum wire and placing it on the exposed portion of the connector terminal. The operator runs the equipment, which has a maximum output power of 1310W. The two pins of the equipment descend until they contact the connection terminal, and the two pins apply a force of 60-100N to fix the connection terminal to the welding area of ​​the anvil. At the same time, the gap between the two pins limits the weld width of the solid-state weld joint, ensuring that the weld width meets the requirements of USCAR 38 standard. The ultrasonic welding head of the device is lowered to the welding work area, the ultrasonic welding head reciprocates at a frequency of 19.70 KHz-20.30 KHz, and the ultrasonic welding head applies a downward force to the exposed wire of the aluminum wire. Within 1.8 s of welding time, the heat generated by the vibration friction between the exposed wire and the exposed part of the connecting terminal causes the instantaneous temperature between the two to reach 1300℃ (the vibration frequency of the ultrasonic welding head and the welding time of the workpiece are suitable for 2mm 2 -120mm 2 cross-sectional area of the aluminum wire), which is higher than the melting temperature of the connecting terminal and the wire (the melting temperature of copper is 1083℃, and the melting temperature of aluminum is 660℃), and the exposed wire is subjected to the ultrasonic welding head and the exposed part of the connecting terminal to form a rectangular solid-phase welding point with a welding width of 8mm and a welding height of 2mm (this welding height and welding width are only suitable for 2mm 2 cross-sectional area of the aluminum wire). After ultrasonic welding, the tensile strength of the solid-phase welding point meets the standard requirements of USCAR 38.

[0032] Injection molding process: The present application performs injection molding on the aluminum wire after welding, as shown in Figure 5 .

[0033] The workers prepare a set of positive and negative wires after ultrasonic welding, place them in the mold of the injection molding machine, close the mold, and fill the mold cavity with the corresponding material. Then, the filled mold is subjected to pressure holding and cooling, and finally, the cooled mold is removed to take out the injection-molded workpiece (related parameters of the injection molding process: the injection molding material is PA66, the injection molding temperature is 260℃-275℃, the injection molding time is 18s, the injection molding machine's discharge pressure is 100Pa, the injection molding pressure is 34Pa, and the pressure holding pressure is 15Pa). The injection-molded shell covers the solid-phase welding point and the entire exposed part of the connecting terminal, ensuring the corrosion resistance of the connecting terminal and preventing accidental shedding of the wire and the connecting terminal.

[0034] In summary, the present application applies the power harness with aluminum wire instead of copper wire in the field of new energy vehicles to the field of unmanned aerial vehicles to obtain the advantages of small weight and low cost. On this basis, the present application creatively sets a partitioned connecting terminal, the gold-plated part for connection ensures the electrical connection performance and corrosion resistance, and the exposed part for welding ensures the welding strength of the ultrasonic welding process. At the same time, the exposed part of the connecting terminal is covered with an injection-molded shell to ensure the corrosion resistance of the connecting terminal, and the sealing ring of the injection-molded shell ensures the safety of the power harness and other devices. The present application solves the problem of mutual restraint of reliability and durability when applying the power harness with aluminum wire instead of copper wire to the field of unmanned aerial vehicles.

[0035] The above embodiments are not a limitation of the present application, and the present application is not limited to the above examples. Changes, modifications, additions or replacements made by those skilled in the art within the technical scheme of the present application shall also fall within the protection scope of the present application.

Claims

1. A power harness in which aluminum wire is used in place of copper wire, characterized by: It includes a connection port (10) and its connected positive lead wire (2) and negative lead wire (3); The connection port (10) includes a connection terminal (1) and an injection shell (4), the connection terminal (1) is provided with a gold-plated part (11) for electrical connection and a bare part (12) for ultrasonic welding; The injection shell (4) is arranged on the bare part (12) of the connection terminal (1); The conductor material of the positive lead wire (2) and the negative lead wire (3) is aluminum.

2. The power harness of claim 1, wherein: The gold-plated part (11) is a composite plating layer with a bottom layer of nickel plating and a surface layer of gold plating, and the bare part (12) is a copper base without any treatment.

3. The power harness of claim 2, wherein: The positive lead wire (2) and the negative lead wire (3) are welded with solid-phase welding points on the copper base of the bare part of the connection terminal (1).

4. The power harness of claim 3, wherein: The injection shell (4) covers the solid-phase welding points and the bare part of the connection terminal (1).

5. The power harness of claim 4, wherein: The injection shell (4) is provided with a sealing groove, and a sealing ring (5) for ensuring connection sealing is sleeved in the sealing groove.

6. An aluminum brake harness manufacturing process applied in the field of unmanned aerial vehicles, using the power harness of any one of claims 1-5 to replace the copper wire with the aluminum wire. The preparation process comprises: Step one: electroplating, the copper base of the connection terminal (1) is divided into a gold-plated part and a bare part, the gold-plated part (11) is treated by nickel plating and gold plating, and the bare part (12) is not treated by electroplating; Step two: ultrasonic welding, one end of the positive / negative lead wire is stripped of the protective layer to expose the wire, the wire is arranged on the bare part of the connection terminal, the side needle of the ultrasonic welding equipment is lowered and fixed together with the anvil to connect the connection terminal, the ultrasonic welding head is lowered to contact the wire, the high-frequency vibration and a certain pressure force the wire to form a solid-phase welding point to complete the ultrasonic welding; Step three: injection, the connection terminal and the lead wire after ultrasonic welding are arranged in the mold of the injection equipment, the mold is closed and the injection material is filled in the cavity of the mold, the equipment keeps the filled mold pressure and cools, and the bare part and the solid-phase welding point of the connection terminal after demolding are covered with the injection shell.

7. The process for manufacturing an aluminum brake force line bundle for use in the field of unmanned aerial vehicles as claimed in claim 6, wherein: In step two, the vibration frequency of the ultrasonic welding head is 19.70KHz-20.30KHz, and the welding time is 1810ms.

8. The process for manufacturing an aluminum brake force line bundle for use in the field of unmanned aerial vehicles according to claim 6, characterized in that: In step three, the injection material is PA66, the injection time is 18s, and the injection temperature is 260℃-275℃.

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