Insulation and voltage resistance testing device for copper bar injection molding part of new energy automobile

Abstract

The invention relates to the field of detection equipment, and discloses an insulation and voltage resistance testing device for a new energy automobile copper bar injection molding part, which comprises a parallel transmission mechanism positioned on an in-line rack and used for forming a driving structure for bidirectional linear displacement of the automobile copper bar injection molding part; the longitudinal shaft transfer mechanism is located on the in-line rack and used for forming a traction structure for lifting the automobile copper bar injection molding part up and down and forming a reciprocating traction line in a closed-loop state in cooperation with the parallel transmission mechanism. The copper bar parallel bearing mechanism is located on the parallel transmission mechanism and the longitudinal shaft transfer mechanism. By taking the in-line rack as a core, the structural integration of the closed-loop type test production line is realized, and the design of the upper parallel transmission mechanism and the lower reverse conveying mechanism is realized, so that materials can efficiently and accurately flow among different working procedures, the material retention phenomenon of a traditional test line is reduced, and the production efficiency is improved. The side rack achieves efficient distribution of finished products and inferior-quality products through the conveying belt, the follow-up logistics path is optimized, and the overall operation efficiency of a production line is improved.

Description

Technical Field

[0001] This invention relates to the field of testing equipment technology, specifically to an insulation withstand voltage testing device for copper busbar injection molded parts for new energy vehicles. Background Technology

[0002] In pure electric vehicles equipped only with batteries, the battery serves as the sole power source for the vehicle's drive system. In hybrid electric vehicles, which combine a traditional engine (or fuel cell) with a battery, the battery can act as both the primary and auxiliary power source for the drive system. New energy vehicle batteries require copper busbars for wiring connections, and these busbars also provide structural support.

[0003] Traditional automotive copper busbar testing equipment suffers from problems such as low efficiency, insufficient automation, poor testing accuracy, numerous safety hazards, limited adaptability, waste of production resources, and lagging data processing. This results in long testing cycles, high labor costs, unstable test results, and poor equipment flexibility, making it difficult to meet the requirements of modern production for high efficiency, precision, safety, and intelligence. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides an insulation withstand voltage testing device for injection-molded copper busbars in new energy vehicles. This device solves the problems of low efficiency, poor automation, and low testing accuracy in traditional automotive copper busbar testing equipment, which result in long testing cycles, high costs, and unstable results.

[0005] To achieve the above objectives, the present invention provides the following technical solution: an insulation withstand voltage testing device for copper busbar injection molded parts in new energy vehicles, comprising: An inline frame is used to fix the structure of an insulation withstand voltage test device for copper busbar injection molded parts in new energy vehicles; The side-mounted rack is located in the inline rack and is used to support the output structure after the automotive copper busbar injection molding parts have been tested; The parallel transmission mechanism is located in the in-line frame and is used as a drive structure to form a bidirectional linear displacement of automotive copper busbar injection molded parts; The longitudinal axis transfer mechanism is located on the inline frame and is used to form a traction structure for lifting the automotive copper busbar injection molded parts up and down, and works with the parallel transmission mechanism to form a closed-loop reciprocating traction line; The parallel copper busbar support mechanism is located on the parallel transmission mechanism and the longitudinal axis transfer mechanism. It works with the chain transmission component and the support platform to support the automotive copper busbar injection molded parts to be tested in a parallel manner. The quantity positioning mechanism is located on the inline frame and works with the material linkage table to pre-measure and position the interval distance and quantity of multiple sets of parallel automotive copper busbar injection molded parts. The high-voltage access mechanism is located on the inline frame and works with the material linkage table to provide high-voltage power for the simultaneous input of multiple sets of parallel automotive copper busbar injection molded parts for testing. The pressure resistance testing unit is located on the inline frame and works with the material linkage table to supply power for the pressure resistance test of the parallel automotive copper busbar injection molded parts; The insulation resistance testing mechanism is located on the inline frame and is used in conjunction with the material linkage table to test the insulation resistance status of automotive copper busbar injection molded parts after high voltage testing. The shifting output mechanism is located on the inline frame, and works with the suspension frame and material linkage table to output the automotive copper busbar injection molded parts that have been inspected and the defective products that are not up to standard.

[0006] Preferably, the side-mounted frame is fixed to one side of the output direction of the inline frame, and the bottom of the side-mounted frame is provided with two sets of parallel output belts for outputting finished products and defective products respectively. The parallel transmission mechanism consists of two sets, arranged in a staggered manner within the inline frame to form an output structure in both vertical and horizontal directions. The longitudinal axis transfer mechanism is distributed on both sides of the inline frame and forms a closed-loop conveying cycle drive structure with the parallel transmission mechanism. Multiple sets of copper busbar parallel bearing mechanisms are distributed and displaced on the parallel transmission mechanism and the longitudinal axis transfer mechanism. The quantity positioning mechanism is fixed to the top of the inline frame near... On the side near the input direction, the high-voltage access mechanism consists of multiple sets, arranged at equal intervals on the top of the inline frame, and is immediately connected to the output direction of the quantity positioning mechanism. It can simultaneously connect to the copper busbar injection molded parts carried by multiple sets of copper busbar parallel bearing mechanisms. The withstand voltage test mechanism is located on the top of the inline frame and in the output direction of the last set of high-voltage access mechanisms. The insulation resistance test mechanism is located on the top of the inline frame and in the output direction of the withstand voltage test mechanism. The transposition output mechanism is located on the top of the longitudinal axis transfer mechanism in the output direction and is positioned between the output direction of the insulation resistance test mechanism and the side frame.

[0007] Preferably, the parallel transmission mechanism includes opposing frames, which are distributed vertically and horizontally within the straight frame in a bidirectional staggered manner, and a chain-type transmission component is disposed within the opposing frames. The chain of the chain-type transmission component is provided with a guide wheel structure, and positioning sensing elements are equidistantly distributed within the opposing frames.

[0008] Preferably, the longitudinal axis transfer mechanism includes a suspension frame, which is fixed on both sides of the inline frame, and the bearing platform moves up and down inside the suspension frame. The top surface of the bearing platform is supported by a wheeled receiving member arranged opposite to it. A wheeled transmission member is provided on the side of the suspension frame, and the bearing platform is fixed to the transmission end of the wheeled transmission member.

[0009] Preferably, the parallel copper busbar support mechanism includes a material linkage table, which can be placed on a chain-type transmission component and a support platform. The top of the material linkage table is fixed with equidistant limiting seats to support the copper busbar itself, and fastening pins are distributed on both sides of the limiting seats to fix the copper busbar on the limiting seats.

[0010] Preferably, the quantity positioning mechanism includes a linear displacement component and a suspended linkage beam. The linear displacement component is fixed to the top of the inline frame and positioned at the end of the suspension frame in the input direction. The linear displacement component is equipped with a belt conveyor. The suspended linkage beam slides along the top of the linear displacement component and is pulled by the belt conveyor. The top of the suspended linkage beam is a hydraulic cylinder structure, and a horizontal positioning beam is fixed at the top telescopic end. The horizontal positioning beam is suspended above the parallel transmission mechanism, and a distance measuring element is provided at its end.

[0011] Preferably, the high-voltage access mechanism includes a gantry suspension, which is fixedly distributed on the top of the inline frame. The parallel copper busbar bearing mechanism can be driven by the parallel transmission mechanism to pass through the gantry suspension. The gantry suspension has equidistantly distributed hydraulic lifting components, and the bottom telescopic end of the hydraulic lifting component is fixed with a counter-wedge. Copper tube output ends are distributed on the counter-wedge to correspond to each interface of a single copper busbar injection molding part.

[0012] Preferably, the pressure resistance testing mechanism includes a second gantry suspension and a second hydraulic lifting component. The second gantry suspension is fixed to the top of the inline frame, and the parallel copper busbar bearing mechanism can be driven by the parallel transmission mechanism to pass through the second gantry suspension. A second linear displacement component is provided on the top of the second gantry suspension, and a belt traction component is provided on the second linear displacement component. The second hydraulic lifting component slides along the top of the second gantry suspension and is simultaneously pulled by the belt traction component. A power connection mold is fixed to the bottom telescopic end of the second hydraulic lifting component, and an access end pipe corresponding to the copper busbar interface is provided on the power connection mold.

[0013] Preferably, the insulation resistance testing mechanism includes a gantry suspension three and a hydraulic lifting component three. The gantry suspension three is fixed to the top of the inline frame, and the copper busbar parallel bearing mechanism can be driven by the parallel transmission mechanism to pass through the gantry suspension three. A linear displacement component three is provided on the top of the gantry suspension three, and a belt traction component is provided on the linear displacement component three. The hydraulic lifting component three slides along the top of the gantry suspension three and is simultaneously pulled by the belt traction component. A resistance detection element is fixed at the bottom telescopic end of the hydraulic lifting component three.

[0014] Preferably, the shifting output mechanism includes a gantry suspension four, a longitudinal axis displacement component, and a rotary cylinder component. The gantry suspension four is fixed on the suspension frame in the output direction, and the copper busbar parallel bearing mechanism can be driven into the gantry suspension four through the parallel transmission mechanism. A transverse axis displacement component is fixed at the top of the gantry suspension four, and a belt traction component is provided on the transverse axis displacement component. The longitudinal axis displacement component slides along the transverse axis displacement component and is fixed at the output end of the belt traction component. A belt traction component is also provided on the longitudinal axis displacement component. The rotary cylinder component slides along the longitudinal axis displacement component and can be driven by the belt traction component. A clamping cylinder component is fixed at the bottom output end of the rotary cylinder component.

[0015] This invention provides an insulation withstand voltage testing device for injection-molded copper busbar parts in new energy vehicles. It has the following beneficial effects: 1. This invention features overall integration and efficient flow: The equipment uses a straight frame as its core, realizing the structural integration of a closed-loop testing production line. The design of the upper parallel transmission mechanism and the lower reverse conveying mechanism enables materials to flow efficiently and accurately between different processes, reducing material retention in traditional testing lines and improving production efficiency. In addition, the side-mounted frame achieves efficient separation of finished and defective products through the conveyor belt, optimizing the subsequent logistics path and improving the overall operational efficiency of the production line.

[0016] 2. This invention provides precise electrical testing and inspection results: The integrated design of the high-voltage power supply access mechanism, withstand voltage testing mechanism, and insulation resistance testing mechanism ensures seamless connection and efficient operation of multiple testing stations, enabling efficient electrical performance testing of copper busbar injection molded parts. The precise positioning of the hydraulic lifting components and the power connection mold frame greatly improves the accuracy and stability of each testing stage, effectively reducing testing errors caused by positional deviations.

[0017] 3. This invention features closed-loop circulation and resource optimization: Through the upper and lower layer transfer configuration of the longitudinal axis transfer mechanism, the equipment forms an effective closed-loop circulation system. The unloaded copper busbar parallel bearing mechanism quickly returns from the output end to the input end, thereby ensuring the continuous operation of the production line and the efficient utilization of materials, reducing resource waste, shortening equipment idle time, and improving equipment utilization.

[0018] 4. This invention possesses highly flexible process adaptability: the equipment design considers the parallel testing of multiple sets of copper busbar injection molded parts, and through the arrangement of parallel bearing mechanisms, it can flexibly adapt to copper busbars of different specifications and types. This process adaptability improves the application range of the equipment under different production needs, enabling it to serve diversified production tasks. Attached Figure Description

[0019] Figure 1 This is a three-dimensional schematic diagram of the main structure of the present invention; Figure 2 This is a schematic diagram of the automotive copper busbar injection molded part to be tested in this invention. Figure 3 This is a schematic diagram of the main structure of the present invention. Figure 1 ; Figure 4 This is a schematic diagram of the main structure of the present invention. Figure 2 ; Figure 5 This is a schematic diagram of the internal structure of the main body of the present invention; Figure 6 This is a schematic diagram of the parallel transmission mechanism of the present invention; Figure 7 This is a schematic diagram of the longitudinal axis transport mechanism of the present invention; Figure 8 This is a schematic diagram of the parallel copper busbar support mechanism of the present invention; Figure 9 This is a schematic diagram of the quantity positioning mechanism of the present invention; Figure 10 This is a schematic diagram of the high-voltage access mechanism of the present invention. Figure 1 ; Figure 11 This is a schematic diagram of the high-voltage access mechanism of the present invention. Figure 2 ; Figure 12 This is a schematic diagram of the combined structure of the withstand voltage testing mechanism and the insulation resistance testing mechanism of the present invention; Figure 13 This is a schematic diagram of the pressure resistance testing mechanism of the present invention; Figure 14 This is a schematic diagram of the insulation resistance testing mechanism of the present invention; Figure 15 This is a schematic diagram of the transposition output mechanism of the present invention.

[0020] The components include: 1. Inline frame; 2. Side-mounted frame; 3. Parallel transmission mechanism; 4. Longitudinal axis transport mechanism; 5. Copper busbar parallel bearing mechanism; 6. Quantity positioning mechanism; 7. High voltage access mechanism; 8. Withstand voltage testing mechanism; 9. Insulation resistance testing mechanism; 10. Transposition output mechanism; 31. Opposing frame; 32. Chain-type transmission component; 33. Positioning sensing element; 41. Suspension frame; 42. Bearing platform; 43. Wheeled receiving component; 44. Wheeled transmission component; 51. Material linkage table; 52. Limiting bracket; 53. Fastening pin; 61. Linear positioner. 62. Shifting component 1; 63. Suspension linkage beam; 64. Horizontal positioning beam; 71. Distance measuring element; 72. Gantry suspension 1; 73. Hydraulic lifting component 1; 84. Opposing wedge frame; 85. Gantry suspension 2; 86. Linear displacement component 2; 87. Hydraulic lifting component 2; 88. Electrical connection mold frame; 99. Gantry suspension 3; 90. Linear displacement component 3; 91. Hydraulic lifting component 3; 92. Resistance detection element; 101. Gantry suspension 4; 102. Horizontal axis displacement component; 103. Vertical axis displacement component; 104. Rotary cylinder component; 105. Clamping cylinder component. Detailed Implementation

[0021] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] Please see the appendix Figure 1 This invention provides an insulation withstand voltage testing device for copper busbar injection molded parts of new energy vehicles, including: a linear frame 1, used to fix the structure of the insulation withstand voltage testing device for copper busbar injection molded parts of new energy vehicles. The linear frame 1 serves as the core support structure of the equipment, bearing the installation and operation of all testing mechanisms. Its interior adopts a double-layer frame design, with a forward transmission track laid on the upper layer and a reverse return track set on the lower layer. Multiple sets of positioning bases are preset on the top of the frame for fixing key components such as the high-voltage access mechanism 7 and the withstand voltage testing mechanism 8. Vertical sliding grooves are opened on both sides of the frame to form a mechanical docking surface with the suspension frame 41 of the longitudinal axis transfer mechanism 4, ensuring the lifting and guiding accuracy of the bearing platform 42. The bottom of the frame is equipped with anti-vibration pads to eliminate mechanical vibration interference during the transmission process.

[0023] Please see the appendix Figure 2 The copper busbar injection molded part to be tested is the physical copper busbar injection molded part of the present invention, which is an insulation withstand voltage test device for copper busbar injection molded parts of new energy vehicles.

[0024] Please see the appendix Figure 1 -Appendix Figure 4The side frame 2 is located on the inline frame 1 and is used to support the output structure after the automotive copper busbar injection molding parts have been tested. The side frame 2 is fixed on one side of the output direction of the inline frame 1, and the bottom of the side frame 2 is equipped with two sets of parallel output belts for the output of finished products and defective products, respectively. The side frame 2 is fixed to the output end side of the inline frame 1 by rigid connectors. The top of the side frame 2 is welded with a dual-channel output frame, on which finished product output belts and defective product output belts are installed respectively. Each belt is equipped with an independent drive motor and speed controller to realize dual-track asynchronous conveying after sorting.

[0025] Please see the appendix Figure 5 -Appendix Figure 6 The parallel transmission mechanism 3 is located in the straight frame 1 and is used to form a drive structure for bidirectional linear displacement of automotive copper busbar injection molding parts. There are two sets of parallel transmission mechanisms 3, which are distributed in parallel in the straight frame 1 in a staggered manner to form an output structure in both the upper and lower directions. The parallel transmission mechanism 3 consists of two sets of chain transmission systems, which are embedded in the upper and lower spaces of the straight frame 1 respectively. Each system includes an opposing frame 31, a chain transmission component 32 and a positioning sensing element 33. The chain transmission component 32 adopts a double-row roller chain structure, and the guide wheels between the chain links realize low-friction transmission. The positioning sensing element 33 is a photoelectric encoder array, which is equidistantly distributed along the longitudinal direction of the opposing frame 31 to monitor the displacement coordinates of the material linkage table 51 in real time. The upper and lower transmission systems are driven independently by variable frequency motors, and the output directions are opposite to each other. Please see the appendix Figure 6 The parallel transmission mechanism 3 includes opposing frames 31, which are distributed vertically and horizontally within the straight frame 1 in a bidirectional staggered manner. A chain-type transmission component 32 is installed within the opposing frames 31. A guide wheel structure is provided on the chain of the chain-type transmission component 32. Positioning sensing elements 33 are equidistantly distributed within the opposing frames 31. The opposing frames 31 of the chain-type transmission component 32 are fixed to the internal beam frame of the straight frame 1 by high-strength bolts. The guide wheel structure uses nylon-coated bearings, which are nested at both ends of the chain link pin to form a rolling contact surface. The positioning sensing element 33 is a slotted photoelectric switch. A pair of transmitting and receiving modules are set every 150mm. When the trigger baffle at the bottom of the material linkage table 51 passes through the detection slot, a position pulse signal is generated. A gap is reserved between the guide wheel and the track, and a constant contact pressure is maintained by a spring pre-tightening mechanism.

[0026] Please see the appendix Figure 5 -Appendix Figure 7 The longitudinal axis transfer mechanism 4 is located on the inline frame 1 and is used to form a traction structure for lifting the automotive copper busbar injection molded parts up and down. It also works with the parallel transmission mechanism 3 to form a closed-loop reciprocating traction line. The longitudinal axis transfer mechanism 4 is distributed on both sides of the inline frame 1 and forms a closed-loop conveying cycle drive structure with the parallel transmission mechanism 3. Please see the appendix Figure 6 -Appendix Figure 7The longitudinal axis transfer mechanism 4 includes a suspension frame 41, which is fixed on both sides of the inline frame 1. The support platform 42 is vertically displaced inside the suspension frame 41, and the top surface of the support platform 42 is supported by the oppositely arranged wheeled receiving components 43. The suspension frame 41 is provided with a wheeled transmission component 44 on its side, and the support platform 42 is fixed to the transmission end of the wheeled transmission component 44. The suspension frame 41 of the longitudinal axis transfer mechanism 4 is welded to the columns on both sides of the inline frame 1. The support platform 42 is slidably engaged with the chrome-plated guide rod of the suspension frame 41 through four sets of linear bearings. The wheeled receiving component 43 is a double V-shaped roller set with a polyurethane adhesive layer on its surface, used to support the guide edge of the material linkage table 51. The wheeled transmission component 44 adopts synchronous belt drive, and the servo motor drives the active wheel to pull the support platform 42 to move vertically along the guide rod. The stroke range covers the height difference between the upper and lower transmission tracks.

[0027] Please see the appendix Figure 6 -Appendix Figure 8 The parallel copper busbar support mechanism 5 is located on the parallel transmission mechanism 3 and the longitudinal axis transfer mechanism 4. It works with the chain transmission component 32 and the support platform 42 to support the automotive copper busbar injection molded parts to be tested in a parallel manner. There are multiple sets of the parallel copper busbar support mechanism 5, which are distributed on the parallel transmission mechanism 3 and the longitudinal axis transfer mechanism 4 for displacement. Please see the appendix Figure 8 The parallel copper busbar support mechanism 5 includes a material linkage table 51, which can be placed on the chain conveyor 32 and the support table 42. The top of the material linkage table 51 is fixed with equidistant limiting seats 52 to support the copper busbars themselves. Fastening pins 53 are distributed on both sides of the limiting seats 52 to fix the copper busbars onto them. The material linkage table 51 of the parallel copper busbar support mechanism 5 is a rectangular alloy substrate with a guide groove machined at the bottom to mesh with the guide wheel of the chain conveyor 32. The limiting seats 52 are made of insulating nylon material. The top of the plate has a U-shaped slot to support the copper busbar body. The fastening pin 53 adopts a quick-release eccentric wheel structure, which can press the edge of the copper busbar by rotating 90°. Anti-tipping guards are set on both sides of the plate to ensure the stability of the posture during the transfer process of the longitudinal axis transfer mechanism 4. The end of the fastening pin 53 is equipped with a silicone buffer pad. The clamping force is adjusted by a butterfly spring. A wiring groove is opened on the back of the plate to centrally lay the high voltage test wires to the bottom terminal block. The spacing between adjacent plates is set to a fixed value according to the standard specifications of the copper busbar to form an equidistant bearing array.

[0028] Please see the appendix Figure 5 -Appendix Figure 9 The quantity positioning mechanism 6 is located on the inline frame 1 and works with the material linkage table 51 to measure and position the interval distance and quantity of multiple sets of parallel automotive copper busbar injection molded parts in advance. The quantity positioning mechanism 6 is fixed on the top of the inline frame 1 on the side close to the input direction. Please see the appendix Figure 8 -Appendix Figure 9The quantity positioning mechanism 6 includes a linear displacement component 61 and a suspended linkage beam 62. The linear displacement component 61 is fixed to the top of the inline frame 1 and is located at the end of the suspension frame 41 in the input direction. The linear displacement component 61 is equipped with a belt conveyor. The suspended linkage beam 62 slides along the top of the linear displacement component 61 and is pulled by the belt conveyor. The top of the suspended linkage beam 62 is a hydraulic cylinder structure, and a horizontal positioning beam 63 is fixed at the top telescopic end. The horizontal positioning beam 63 is suspended above the parallel transmission mechanism 3, and a distance measuring element 64 is provided at its end. The horizontal positioning beam 63 uses a honeycomb aluminum profile to reduce weight, and a sensor mounting hole array is opened at the bottom. The distance measuring element 64 is a laser probe that emits a detection beam vertically downward. During measurement, the hydraulic cylinder pushes the horizontal positioning beam 63 down to the surface of the copper busbar. The laser beam scans the edge contour of the copper busbar and calculates the distance between adjacent card holders. The linear displacement component 61 drives the entire measuring assembly to pass through the copper busbar area at a constant speed to complete continuous sampling along the entire length.

[0029] Please see the appendix Figure 8 -Appendix Figure 10 The high-voltage access mechanism 7 is located on the inline frame 1. It works with the material linkage table 51 to provide high-voltage power for the simultaneous input of multiple sets of parallel automotive copper busbar injection molded parts for testing. The high-voltage access mechanism 7 consists of multiple sets, which are arranged at equal intervals on the top of the inline frame 1 and are also connected to the output direction of the quantity positioning mechanism 6. It can simultaneously connect multiple sets of copper busbar injection molded parts carried by the parallel copper busbar bearing mechanism 5. Please see the appendix Figure 10 -Appendix Figure 11 The high-voltage access mechanism 7 includes a gantry suspension 71, which is fixed on the top of the inline frame 1. The parallel copper busbar bearing mechanism 5 can be driven by the parallel transmission mechanism 3 to pass through the gantry suspension 71. The gantry suspension 71 has equidistantly distributed hydraulic lifting components 72, and the bottom telescopic end of the hydraulic lifting component 72 is fixed with a counter-wedge 73. The counter-wedge 73 is provided with copper tube output ends to correspond to the various interfaces of the individual copper busbar injection molded parts. The gantry suspension 71 of the high-voltage access mechanism 7 is connected across the top guide rail of the inline frame 1. The hydraulic lifting component 72 is a double-acting hydraulic cylinder with the cylinder body fixed to the suspension crossbeam. The counter-wedge 73 is connected to the piston rod through an insulating ceramic column. The bottom of the counter-wedge 73 is inlaid with a split copper electrode. The front end of the electrode is a spring pin structure with a high-voltage wire inside. The wedge 73 is provided with a guide pin on the inclined surface. When pressed down, it is inserted into the positioning hole of the copper busbar to ensure the electrode alignment accuracy.

[0030] Please see the appendix Figure 11 -Appendix Figure 13 The pressure resistance testing mechanism 8 is located on the inline frame 1. It works with the material linkage table 51 to input the power supply for the pressure resistance test of the parallel automotive copper busbar injection molded parts. The pressure resistance testing mechanism 8 is set on the top of the inline frame 1 and is positioned in the output direction of the last set of high voltage access mechanisms 7. Please see the appendix Figure 12 -Appendix Figure 13 The pressure resistance testing mechanism 8 includes a gantry suspension 81 and a hydraulic lifting component 83. The gantry suspension 81 is fixed to the top of the inline frame 1, and the parallel copper busbar bearing mechanism 5 can be driven by the parallel transmission mechanism 3 to pass through the gantry suspension 81. A linear displacement component 82 is provided on the top of the gantry suspension 81, and a belt traction component is provided on the linear displacement component 82. The hydraulic lifting component 83 slides along the top of the gantry suspension 81 and is simultaneously pulled by the belt traction component. The bottom telescopic end of the hydraulic lifting component 83 is fixed with a connector. The electrical test frame 84 is equipped with an access pipe with a corresponding copper busbar interface. The gantry suspension 81 of the withstand voltage test mechanism 8 is fixed by anchor bolts. The linear displacement component 82 adopts a linear motor module. The mover is directly connected to the mounting plate of the hydraulic lifting component 83. The hydraulic lifting component 83 is a compact hydraulic cylinder. The flange at the end of the piston rod is fixed to the electrical test frame 84. The electrical test frame 84 adopts a layered design: the upper layer is the high voltage input terminal area, and the lower layer is arranged with a spring probe array. The probe tips are gold-plated to reduce contact resistance.

[0031] Please see the appendix Figure 11 -Appendix Figure 14 The insulation resistance testing mechanism 9 is located on the inline frame 1 and works with the material linkage table 51 to test the insulation resistance status of automotive copper busbar injection molded parts after high voltage testing. The insulation resistance testing mechanism 9 is set on the top of the inline frame 1 and is positioned in the output direction of the withstand voltage testing mechanism 8. The gantry suspension three 91 of the insulation resistance testing mechanism 9 has the same structure as the previous testing mechanism. The linear displacement component three 92 uses ball screw drive, and the nut seat is connected to the hydraulic lifting component three 93. The resistance detection element 94 is a four-terminal measurement module, which includes a dual probe group with current and voltage electrodes. The probe is made of tungsten carbide alloy material with nickel plating on the surface to prevent oxidation. The measurement circuit integrates a constant current source and a high-precision ADC, and is connected to the control cabinet through a shielded cable. Please see the appendix Figure 12 -Appendix Figure 14 The insulation resistance testing mechanism 9 includes a gantry suspension 3 91 and a hydraulic lifting component 3 93. The gantry suspension 3 91 is fixed on the top of the inline frame 1, and the copper busbar parallel bearing mechanism 5 can be driven by the parallel transmission mechanism 3 to pass through the gantry suspension 3 91. A linear displacement component 3 92 is provided on the top of the gantry suspension 3 91, and a belt traction component is provided on the linear displacement component 3 92. The hydraulic lifting component 3 93 slides along the top of the gantry suspension 3 91 and is simultaneously pulled by the belt traction component. A resistance detection element 94 is fixed at the bottom telescopic end of the hydraulic lifting component 3 93. When the resistance detection element 94 descends, the current electrode contacts the surface of the copper busbar first and applies a constant test current. The voltage electrode then contacts and collects a voltage drop signal in the mV range. The resistance value is calculated by Ohm's law. The probe pressure is maintained at a constant value by the hydraulic system. The linear displacement component 3 92 drives the probe group to move stepwise along the length of the copper busbar to generate a resistance distribution curve.

[0032] Please see the appendix Figure 13 -Appendix Figure 15 The shifting output mechanism 10 is located on the inline frame 1, and works with the suspension frame 41 and the material linkage table 51 to turn the output of the tested automotive copper busbar injection molded parts and unqualified defective products. The shifting output mechanism 10 is set on the top of the longitudinal axis transfer mechanism 4 in the output direction, and is placed between the output direction of the insulation resistance test mechanism 9 and the side frame 2. Please see the appendix Figure 14 -Appendix Figure 15 The shifting output mechanism 10 includes a gantry suspension four 101, a longitudinal axis displacement member 103, and a rotary cylinder member 104. The gantry suspension four 101 is fixed on the suspension frame 41 in the output direction, and the copper busbar parallel bearing mechanism 5 can be driven into the gantry suspension four 101 by the parallel transmission mechanism 3. A transverse axis displacement member 102 is fixed on the top of the gantry suspension four 101, and a belt traction member is provided on the transverse axis displacement member 102. The longitudinal axis displacement member 103 slides along the transverse axis displacement member 102 and is fixed to the output end of the belt traction member. A belt traction member is also provided on the longitudinal axis displacement member 103. The rotary cylinder member 104... The longitudinal axis displacement component 103 slides and can be driven by the belt traction component. The bottom output end of the rotary cylinder component 104 is fixed with the clamping cylinder component 105. The gantry suspension 4101 of the shift output mechanism 10 is welded to the top of the output end suspension frame 41. The transverse axis displacement component 102 adopts gear and rack transmission. The servo motor drives the pinion to move along the crossbeam rack. The longitudinal axis displacement component 103 is installed on the transverse axis slide through the linear guide pair and moves vertically by the synchronous belt traction. The rotary cylinder component 104 adopts the 180° swing model. The output shaft flange connects to the clamping cylinder component 105. The pneumatic manual index is equipped with a self-locking three-jaw chuck.

[0033] Based on the above technical content, this invention also provides a working principle for an insulation withstand voltage testing device for copper busbar injection molded parts in new energy vehicles, including the following: Overall structure and operating framework of the equipment The equipment uses the inline frame 1 as the core carrier to form a linear closed-loop testing production line. The side frame 2 realizes the separation of finished products and defective products through two sets of output belts at the bottom. The parallel transmission mechanism 3 is arranged in layers inside the inline frame 1. The upper transmission mechanism performs forward conveying in the testing direction, and the lower mechanism performs reverse conveying in the empty return direction. The two output directions are opposite. The longitudinal axis transfer mechanism 4 is distributed on both sides of the inline frame 1. It works with the parallel transmission mechanism 3 to realize the vertical transfer of materials between the upper and lower layers, forming a closed-loop conveying system. The copper busbar parallel bearing mechanism 5 serves as the core carrier. It carries the copper busbar injection molded parts to be tested through multiple sets of parallel arrangement and circulates in the closed-loop system. Copper busbar injection molding part loading and initial positioning The copper busbar injection molded parts to be tested are loaded at the longitudinal axis transfer mechanism 4 at the input end of the straight frame 1. This mechanism drives the bearing platform 42 to rise and fall through the pulley transmission component 44 in the suspension frame 41, so that the pulley receiving component 43 at the top of the bearing platform 42 is raised to the same height as the upper parallel transmission mechanism 3. The operator fixes the copper busbar injection molded parts in the limiting card seat 52 of the copper busbar parallel bearing mechanism 5 in a parallel manner, and locks them through the fastening pin 53. The loaded copper busbar parallel bearing mechanism 5 is transferred from the bearing platform 42 to the chain transmission component 32 of the upper parallel transmission mechanism 3. The chain transmission component 32 drives the guide wheel structure through the sprocket, which drives the material linkage table 51 to move in a straight line. As loading continues, multiple sets of copper busbar parallel bearing mechanisms 5 are distributed at equal intervals on the upper transmission line. Quantity positioning and spacing measurement When the copper busbar parallel bearing mechanism 5 enters the number positioning mechanism 6 station, the positioning sensor element 33 detects the position of the carrier and triggers the positioning program. The linear displacement component 61 drives the suspended linkage beam 62 to move laterally along the top of the straight frame 1 through the belt transmission component. The hydraulic cylinder at the top of the suspended linkage beam 62 pushes the horizontal positioning beam 63 down to above the copper busbar parallel bearing mechanism 5. The distance measuring element 64 measures the parallel spacing, number of arrangements and horizontal position of multiple sets of copper busbar injection molded parts in real time. The measurement data is used to calibrate the electrode positioning accuracy of the subsequent high voltage access station. High-voltage power supply connection and synchronization test The copper busbar parallel bearing mechanism 5, after completing its positioning, enters the workstation array composed of multiple high-voltage access mechanisms 7. The gantry suspension 71 of each high-voltage access mechanism 7 spans above the transmission line and is equipped with a hydraulic lifting component 72 inside. The hydraulic lifting component 72 drives the opposing wedge frame 73 to descend. The copper tube output end on its surface is pressed into contact with the interface of the copper busbar injection molded part. Multiple high-voltage access mechanisms 7 operate synchronously and inject a preset high-voltage current into all the copper busbar parallel bearing mechanisms 5 in the workstation. The wedge-shaped structure of the opposing wedge frame 73 ensures that the electrode achieves self-alignment during the vertical pressing process. Pressure resistance test The charged copper busbar injection molded part enters the withstand voltage test mechanism 8 along with the chain conduction component 32. The linear displacement component 82 at the top of the gantry suspension 81 drives the hydraulic lifting component 83 to move laterally through the belt traction component, tracking the displacement trajectory of the copper busbar parallel bearing mechanism 5. The hydraulic lifting component 83 descends to make the access end pipe of the power connection mold frame 84 contact the copper busbar interface. The withstand voltage performance of the insulation layer is continuously measured under high voltage. The linear displacement component 82 ensures that the test probe maintains stable contact during the displacement process. Insulation resistance test After the withstand voltage test is completed, the vehicle enters the insulation resistance test mechanism 9. The linear displacement component 92 at the top of the gantry suspension 3 91 drives the hydraulic lifting component 3 93 to move laterally synchronously. The resistance detection element 94 at its bottom descends to the surface of the copper busbar. The resistance detection element 94 measures the resistance value of the copper busbar body and the injection-molded insulation layer in a multi-point contact manner to detect whether there is a risk of breakdown or leakage after the high voltage test. The data is transmitted to the control system in real time for qualification judgment. Sorting output and empty load return After the test is completed, the parallel copper busbar carrying mechanism 5 enters the switching output mechanism 10. The horizontal axis displacement component 102 at the top of the gantry suspension 4 101 drives the vertical axis displacement component 103 to move laterally. The vertical axis displacement component 103 controls the vertical lifting of the rotating cylinder component 104 through the belt traction component. The clamping cylinder component 105 classifies and grabs finished products or defective products according to the test results. The rotating cylinder component 104 rotates 90° to transfer the finished products to the finished product output belt at the top of the side frame 2, and the defective products are transferred to the defective product output belt. After sorting, the empty material linkage table 51 remains in the original position. The empty copper busbar carrying mechanism 5 descends to the height of the lower parallel transmission mechanism 3 via the carrying platform 42 of the output end vertical axis transfer mechanism 4. The lower chain transmission component 32 transports the empty carrier to the input end in a reverse drive manner. The input end vertical axis transfer mechanism 4 raises the carrying platform 42 again to reset the empty carrier to the upper transmission line, completing the closed loop cycle. Closed-loop control system logic The positioning sensor 33 built into the chain-type transmission component 32 monitors the displacement coordinates of the parallel copper busbar bearing mechanism 5 in real time. The start and stop sequence of the actuators at each station is controlled by the PLC. The measurement data of the quantity positioning mechanism 6 dynamically calibrates the electrode position of the high voltage access mechanism 7. The upper and lower parallel transmission mechanism 3 is driven synchronously by a servo motor to ensure that the displacement speed of the carrier is precisely matched with the action cycle of the test station. The pulley transmission component 44 of the longitudinal axis transfer mechanism 4 controls the lifting stroke through an encoder to achieve zero error in inter-layer transfer. Security protection mechanism The opposing wedge frame 73 of the high-voltage access mechanism 7 uses copper electrodes coated with insulating ceramic to prevent high-voltage breakdown. The power connection mold frame 84 of the withstand voltage test mechanism 8 is equipped with an overcurrent protection module, which automatically cuts off the power supply when an abnormal current is detected. The clamping action of the shift output mechanism 10 is electrically interlocked with the start and stop of the transmission line. When sorting is not completed, the parallel transmission mechanism 3 remains stationary. The lifting process of the bearing platform 42 triggers the position sensor to ensure precise alignment with the plane of the transmission belt.

[0034] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An insulation voltage test device for a new energy vehicle copper bar injection molding part, characterized in that, The application relates to a new energy automobile copper bar injection molding piece insulation voltage resistance testing device structure. The side rack (2) is located in the straight-line rack (1) and is used for bearing the output structure of the automobile copper bar injection molding piece after testing. The parallel transmission mechanism (3) is located in the straight-line rack (1) and is used for forming a bidirectional linear displacement driving structure of the automobile copper bar injection molding piece. The longitudinal axis transfer mechanism (4) is located in the straight-line rack (1) and is used for forming a traction structure of lifting up and down of the automobile copper bar injection molding piece and cooperating with the parallel transmission mechanism (3) to form a reciprocating traction line in a closed loop state. The copper bar parallel bearing mechanism (5) is located on the parallel transmission mechanism (3) and the longitudinal axis transfer mechanism (4) and is used for bearing the automobile copper bar injection molding piece to be tested in a parallel form in cooperation with the chain type conducting element (32) and the bearing table (42). The quantity positioning mechanism (6) is located in the straight-line rack (1) and is used for measuring and positioning interval distances and quantities of multiple groups of parallel automobile copper bar injection molding pieces in advance in cooperation with the material linkage table (51). The high-voltage access mechanism (7) is located in the straight-line rack (1) and is used for inputting the high-voltage power supply for testing of multiple groups of parallel automobile copper bar injection molding pieces in cooperation with the material linkage table (51). The insulation resistance testing mechanism (9) is located in the straight-line rack (1) and is used for testing the insulation resistance state of the automobile copper bar injection molding piece after high-voltage testing in cooperation with the material linkage table (51). The transposition output mechanism (10) is located in the straight-line rack (1) and is used for outputting the automobile copper bar injection molding piece after testing and unqualified defective products in cooperation with the suspension frame (41) and the material linkage table (51). ​ ​ 2.The insulation voltage test device for a new energy vehicle copper bar injection molding part of claim 1, wherein The side rack (2) is fixed on the output side of the straight rack (1), and the bottom of the side rack (2) is provided with two groups of parallel output belt parts for output of finished products and defective products respectively, the parallel transmission mechanism (3) is two groups and is distributed in the straight rack (1) in front and back staggered form to form an output structure in two directions, the longitudinal axis transfer mechanism (4) is distributed on both sides of the straight rack (1) and forms a closed loop conveying circulating driving structure with the parallel transmission mechanism (3), the copper bar parallel carrying mechanism (5) is a plurality of groups and is distributed on the displacement of the parallel transmission mechanism (3) and the longitudinal axis transfer mechanism (4), the quantity positioning mechanism (6) is fixed on the top of the straight rack (1) near the input side, the high-voltage access mechanism (7) is a plurality of groups and is arranged in equal distance distribution form on the top of the straight rack (1), and is arranged in the output direction of the quantity positioning mechanism (6) and can simultaneously access a plurality of copper bar injection molded parts carried by the copper bar parallel carrying mechanism (5), the withstand voltage test mechanism (8) is arranged on the top of the straight rack (1) and is arranged in the output direction of the last group of high-voltage access mechanism (7), the insulation resistance test mechanism (9) is arranged on the top of the straight rack (1) and is arranged in the output direction of the withstand voltage test mechanism (8), and the transposition output mechanism (10) is arranged on the top of the longitudinal axis transfer mechanism (4) in the output direction and is arranged between the insulation resistance test mechanism (9) and the side rack (2). 3.The insulation voltage test device for a new energy vehicle copper bar injection molding part of claim 1, wherein The parallel transmission mechanism (3) comprises an opposite rack (31), the opposite rack (31) is distributed in the straight rack (1) in a two-way staggered form, and a chain type conducting part (32) is arranged in the opposite rack (31), the chain part of the chain type conducting part (32) is provided with a guide wheel structure, and the opposite rack (31) is provided with a positioning sensor element (33) at equal intervals.

4. The insulation voltage test device for a new energy vehicle copper bar injection molding part according to claim 1, characterized in that, The longitudinal axis transfer mechanism (4) comprises a suspension rack (41), the suspension rack (41) is fixed on both sides of the straight rack (1), and a carrying table (42) is displaced in the suspension rack (41), and the top surface of the carrying table (42) is supported by oppositely arranged belt type receiving parts (43), the suspension rack (41) is provided with a belt type conducting part (44) on the side, and the carrying table (42) is fixed on the conducting end of the belt type conducting part (44). 5.The insulation voltage test device for a new energy vehicle copper bar injection molding part of claim 1, wherein, The copper bar parallel carrying mechanism (5) comprises a material linkage table (51), the material linkage table (51) can be placed on the chain type conducting part (32) and the carrying table (42), and the top of the material linkage table (51) is fixed with equidistant limiting clamping bases (52) respectively to carry the copper bar itself, and the limiting clamping bases (52) are provided with fastening pins (53) on both sides to fix the copper bar on the limiting clamping bases (52). 6.The insulation voltage test device for a new energy vehicle copper bar injection molding part of claim 1, wherein The quantity positioning mechanism (6) includes a linear displacement piece one (61) and a suspended linkage beam (62), the linear displacement piece one (61) is fixed on the top of the in-line rack (1), and is arranged at the end of the suspended frame (41) in the input direction, and the linear displacement piece one (61) is provided with a belt transmission element, the suspended linkage beam (62) slides along the top of the linear displacement piece one (61), and is pulled through the belt transmission element, the top of the suspended linkage beam (62) is a hydraulic cylinder structure, and the top telescopic end is fixed with a transverse positioning beam (63), and the transverse positioning beam (63) is suspended above the parallel transmission mechanism (3), and the end is provided with a distance measuring element (64). 7.The insulation voltage testing device for a new energy vehicle copper bar injection molding part of claim 1, wherein, The high-voltage access mechanism (7) includes a portal suspension one (71), the portal suspension one (71) is fixed on the top of the in-line rack (1), and the copper bar parallel bearing mechanism (5) can pass through the portal suspension one (71) driven by the parallel transmission mechanism (3), the portal suspension one (71) is fixed with equidistantly distributed hydraulic lifting piece one (72) inside, and the bottom telescopic end of the hydraulic lifting piece one (72) is fixed with the opposite wedge (73), and the opposite wedge (73) is provided with copper pipe output end in distribution, to correspond to each interface of single copper bar injection molding part. 8.The insulation voltage test device of a new energy vehicle copper bar injection molding part of claim 1, wherein, The pressure resistance test mechanism (8) includes a portal suspension two (81) and a hydraulic lifting piece two (83), the portal suspension two (81) is fixed on the top of the in-line rack (1), and the copper bar parallel bearing mechanism (5) can pass through the portal suspension two (81) driven by the parallel transmission mechanism (3), the top of the portal suspension two (81) is provided with a linear displacement piece two (82), and the linear displacement piece two (82) is provided with a belt traction element, the hydraulic lifting piece two (83) slides along the top of the portal suspension two (81), while being pulled through the belt traction element, the bottom telescopic end of the hydraulic lifting piece two (83) is fixed with an electrical connection mold frame (84), and the electrical connection mold frame (84) is provided with an access end pipe corresponding to the copper bar interface. 9.The insulation voltage testing device for a new energy vehicle copper bar injection molding part of claim 1, wherein, The insulation resistance test mechanism (9) includes a portal suspension three (91) and a hydraulic lifting piece three (93), the portal suspension three (91) is fixed on the top of the in-line rack (1), and the copper bar parallel bearing mechanism (5) can pass through the portal suspension three (91) driven by the parallel transmission mechanism (3), the top of the portal suspension three (91) is provided with a linear displacement piece three (92), and the linear displacement piece three (92) is provided with a belt traction element, the hydraulic lifting piece three (93) slides along the top of the portal suspension three (91), while being pulled through the belt traction element, the bottom telescopic end of the hydraulic lifting piece three (93) is fixed with a resistance detection element (94). 10.The insulation voltage test device for a new energy vehicle copper bar injection molding part of claim 1, wherein, The transposition output mechanism (10) includes gantry suspension four (101), longitudinal axis displacement piece (103) and rotating cylinder piece (104), the gantry suspension four (101) is fixed on the suspension frame (41) in the output direction, and copper row parallel bearing mechanism (5) can be driven into gantry suspension four (101) through parallel transmission mechanism (3), the top of gantry suspension four (101) is fixed with horizontal axis displacement piece (102), and horizontal axis displacement piece (102) is provided with belt traction piece, longitudinal axis displacement piece (103) slides along horizontal axis displacement piece (102) and is fixed at the output end of belt traction piece, longitudinal axis displacement piece (103) is also provided with belt traction piece, rotating cylinder piece (104) slides along longitudinal axis displacement piece (103) and can be driven by belt traction piece, and the bottom output end of rotating cylinder piece (104) is fixed with clamping cylinder piece (105).

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