Aluminum wire harness structure for new energy charging base and processing method of aluminum wire harness structure

Abstract

The invention relates to the technical field of automobile connecting wire harnesses, and discloses an aluminum wire harness structure for a new energy charging seat and a processing method thereof.The aluminum wire harness structure comprises an aluminum wire core and a copper terminal, the aluminum wire core comprises a core main body part and a core connecting part, and the copper terminal comprises an end main body part and an end connecting part; the core connecting part and the end connecting part are respectively formed by stamping of a wire core press molding machine and a terminal press molding machine, the surface of the core main body part is sleeved with an insulating sleeve, and two corresponding side surfaces of the core connecting part are integrally connected with side tooth blocks; according to the aluminum wire harness structure, tight interference fit between the aluminum wire core and the copper terminal is achieved through clamping fit between the side tooth blocks and the side tooth grooves in combination with a temperature difference assembly process and by means of the thermal expansion and cold contraction characteristic of metal, secondary fixing of the insertion blocks and the insertion barrels is assisted, a dual mechanical locking structure is formed, and the problems of loosening and falling of the connecting parts are effectively avoided.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of automobile connection wire harness, and particularly relates to an aluminum wire harness structure for a new energy charging seat and a processing method thereof. BACKGROUND

[0002] With the rapid development of the new energy automobile industry, as a key component of electric energy transmission, the performance stability and durability of the charging seat directly affect the charging efficiency and use safety of the vehicle. As the core carrier of electric energy transmission inside the charging seat, the wire harness must have good electrical conductivity, corrosion resistance and mechanical strength to adapt to the complex use environment and high frequency charging requirements of new energy vehicles.

[0003] At present, the new energy charging seat wire harness mostly uses copper wire as the conductor material. Although copper wire has excellent electrical conductivity, it has high cost and is prone to oxidation and corrosion in long-term use. Especially in harsh working conditions such as humidity and high temperature, the corrosion problem will aggravate the aging of the wire harness and shorten its service life. If copper wire is directly replaced by aluminum wire with lower cost and better corrosion resistance in the prior art, many technical problems will be encountered. Specifically, the material difference between aluminum wire and copper terminal is large, and their physical properties and chemical properties are different. The conventional connection methods such as direct welding and bolt fixing are difficult to achieve stable and low-resistance connection, and are prone to problems such as poor contact and serious heating, which affect the electric energy transmission efficiency. Therefore, the application provides an aluminum wire harness structure to solve the problem. SUMMARY

[0004] The purpose of the application is to provide an aluminum wire harness structure with simple structure and reasonable design to solve the above problems.

[0005] The application achieves the above-mentioned purposes through the following technical solutions: The application provides an aluminum wire harness structure for a new energy charging seat, comprising an aluminum wire core and a copper terminal. The aluminum wire core comprises a core main body part and a core connecting part. The copper terminal comprises a terminal main body part and a terminal connecting part. The core connecting part and the terminal connecting part are respectively formed by stamping with a wire core die and a terminal die. The surface of the core main body part is provided with an insulating sleeve. The two side surfaces of the core connecting part are integrally connected with side tooth blocks. The surface of the terminal connecting part is provided with a connecting groove. The two side inner walls of the connecting groove are provided with side tooth grooves corresponding to the side tooth blocks. The terminal connecting part is heated to expand, and the core connecting part is cooled to shrink. The shrunk core connecting part is placed in the connecting groove. After the terminal connecting part and the core connecting part return to normal temperature, the core connecting part is clamped in the connecting groove.

[0006] As a further optimization scheme of the present application, the surface of the core connecting part is provided with a round hole, and the inner wall of the connecting groove is integrally connected with the position corresponding to the round hole. When the core connecting part is clamped in the connecting groove, the plug-in sleeve is located in the round hole, and the plug-in block is inserted into the plug-in sleeve.

[0007] As a further optimization scheme of the present application, the surface of the core connecting part is provided with a first anti-skid groove, and the surface of the end connecting part is provided with a second anti-skid groove corresponding to the first anti-skid groove.

[0008] As a further optimization scheme of the present application, the wire core pressing machine comprises a rack one, an upper die and a lower die are arranged in a one-to-one correspondence on the rack one, a driving member one is connected to the rack one, the upper die is connected to the driving end of the driving member one, and a heater is also connected to the rack one. The heater heats the aluminum wire core to be processed. The aluminum wire core to be processed is placed in the placement groove one of the lower die. The driving member one drives the upper die to move downward to cooperate with the lower die to press the aluminum wire core, so that the heated aluminum wire core forms a core connecting part.

[0009] As a further optimization scheme of the present application, a clamp is connected to the rack one, the clamping end of the clamp is connected with two symmetrical water cooling jackets, and clamping grooves are formed on the corresponding two side surfaces of the two water cooling jackets. The core main part outside the insulating sleeve is placed in the clamping groove.

[0010] As a further optimization scheme of the present application, the terminal pressing machine comprises a rack two, a lower pressing die, an upper pressing die and an upper pressing die assembly are connected to the rack two, a copper bar to be processed is placed in the lower pressing die, the upper pressing die cooperates with the lower pressing die to press the copper bar to form a connecting groove and a plug-in sleeve, and the upper pressing die assembly cooperates with the lower pressing die to press the inner walls of the two sides corresponding to the connecting groove to form a side tooth groove.

[0011] As a further optimization scheme of the present application, a driving member two and a driving assembly are installed on the rack two, a fixed frame is fixedly connected to the driving end of the driving member two, a sliding plate is slidably connected in the fixed frame, the driving assembly is connected to the surface of the fixed frame, and the driving assembly drives the sliding plate to slide along the inner wall of the fixed frame. The upper pressing die and the upper pressing die assembly are connected to the lower side surface of the sliding plate.

[0012] As a further optimization scheme of the present application, the upper pressing die assembly comprises a mounting frame, the mounting frame is fixedly connected to the lower surface of the sliding plate, two symmetrical moving blocks are slidably connected in the mounting frame, and a die plate is connected to the side surface of each moving block close to each other. The die plate extends out of the mounting frame.

[0013] As a further optimization of the present invention, a pushing component is connected to the sliding plate. The pushing component drives two sets of moving blocks to move closer or further apart from each other. The pushing component includes a driving component three, a connecting rod and a diagonal rod. The two sets of moving blocks extend from the inner walls of the corresponding sides of the mounting frame to the outside of the mounting frame. The surfaces of the two sets of moving blocks outside the mounting frame are provided with inclined grooves. The connecting rod is connected to the driving end of the driving component three. The diagonal rods are symmetrically arranged. Both sets of diagonal rods are connected to the surface of the connecting rod and slide along the inner wall of the inclined groove on the corresponding side.

[0014] A second aspect of this invention provides a method for processing aluminum wire harnesses for new energy charging bases, thereby fabricating the aforementioned aluminum wire harness structure for new energy charging bases, comprising the following steps: Step 1, Aluminum wire pretreatment: Peel off the ends of the aluminum wire to expose the aluminum wire core, and place the core body of the aluminum wire core in a water-cooling jacket; Step 2, Aluminum wire core forming: The aluminum wire core is heated to a state of easy plastic deformation using a heater, the upper mold is driven to move down and cooperate with the lower mold to stamp the aluminum wire core to obtain an integrally formed core connection part; Step 3, Copper Terminal Manufacturing: The copper rod is heated to a red-hot state by resistance heating, and then stamped to obtain an integrally formed copper terminal with the cooperation of the lower die, the upper die and the upper die assembly. Step 4, Temperature Difference Assembly: The copper terminals are heated a second time to an expanded state, while the aluminum wire core is cooled to a contracted state to create an assembly gap. Then, the connection is made under temperature difference conditions. Step 5, Welding Reinforcement: Use an ultrasonic welding head to weld the inserted aluminum wire core and copper terminal; Step 6, Sealing and Protection: Apply sealant to the connection between the aluminum wire core and the copper terminal. After the sealant has cured, cover it with heat shrink film and shrink it under hot air to form insulation protection.

[0015] The beneficial effects of this invention are as follows: The aluminum wire harness structure of this invention achieves a tight interference fit between the aluminum wire core and the copper terminal by using the snap-fit ​​of the side tooth block and the side tooth groove, combined with the temperature difference assembly process, and utilizing the thermal expansion and contraction characteristics of metal. It is further supplemented by the secondary fixation of the plug block and the plug cylinder to form a double mechanical locking structure, which effectively avoids the problem of loosening and falling off of the connection parts. At the same time, the ultrasonic welding process achieves atomic-level fusion of the connection surface between the aluminum wire core and the copper terminal, reduces contact resistance, reduces heat generation, and significantly improves the conductivity and connection stability of the wire harness. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a schematic diagram of the core connector structure of the present invention; Figure 3 This is a schematic diagram of the wire core laminating machine structure of the present invention; Figure 4 This is a schematic diagram of the lower mold structure of the present invention; Figure 5 This is a schematic diagram of the upper mold structure of the present invention; Figure 6 This is a schematic diagram of the terminal molding machine structure of the present invention; Figure 7 This is a schematic diagram of the drive component structure of the present invention; Figure 8 This is a schematic diagram of the pushing component structure of the present invention; Figure 9 This is a schematic diagram of the internal structure of the mounting frame of the present invention.

[0017] In the diagram: 1. Heat shrink film; 2. Insulating sleeve; 3. Core body; 4. Core connecting part; 41. First anti-slip groove; 42. Round hole; 43. Side tooth block; 5. End body; 6. End connecting part; 61. Second anti-slip groove; 62. Insert; 63. Side tooth groove; 64. Connecting groove; 7. Insert block; 8. Frame one; 9. Upper mold; 10. Lower mold; 11. Heater; 12. Fixture; 13. Water cooling jacket; 14. Drive component three; 15. Frame two; 16. Lower pressing mold; 17. Upper pressing mold; 18. Upper pressing mold assembly; 181. Mounting frame; 182. Moving block; 183. Mold plate; 19. Drive component two; 20. Drive assembly; 21. Fixed frame; 22. Sliding plate; 23. Pushing assembly; 231. Drive component three; 232. Connecting rod; 233. Diagonal rod; 234. Diagonal groove. Detailed Implementation

[0018] The present application will now be described in further detail with reference to the accompanying drawings. It should be noted that the following specific embodiments are only used to further illustrate the present application and should not be construed as limiting the scope of protection of the present application. Those skilled in the art can make some non-essential improvements and adjustments to the present application based on the above application content.

[0019] Example 1; refer to Figure 1 and Figure 2 The structure shown is an aluminum wire harness structure for a new energy charging base, including an aluminum wire core and copper terminals. The aluminum wire core includes a core body 3 and a core connecting part 4. The copper terminal includes an end body 5 and an end connecting part 6. The core connecting part 4 and the end connecting part 6 are formed by stamping by a wire core molding machine and a terminal molding machine, respectively. An insulating sleeve 2 is sleeved on the surface of the core body 3. Side tooth blocks 43 are integrally connected to the corresponding two sides of the core connecting part 4. A connecting groove 64 is opened on the surface of the end connecting part 6. Side tooth grooves 63 corresponding to the side tooth blocks 43 are opened on the inner walls of the corresponding two sides of the connecting groove 64. The heating end connection 6 expands, and the cooling core connection 4 contracts. The contracted core connection 4 is placed in the connection groove 64. After the end connection 6 and the core connection 4 return to normal temperature, the core connection 4 is snapped into the connection groove 64.

[0020] It should be noted that, at room temperature, since the side tooth block 43 is integrally connected to the side of the core connecting part 4, the core connecting part 4 cannot be directly snapped into the connecting groove 64 of the end connecting part 6. Therefore, it is necessary to heat the end connecting part 6 to make it expand and cool the core connecting part 4 to make it contract so that the side tooth block 43 on the core connecting part 4 can be snapped into the side tooth groove 63. This setting makes it impossible for the core connecting part 4 to be easily removed from the connecting groove 64 after the end connecting part 6 and the core connecting part 4 return to room temperature.

[0021] This invention replaces the copper wire harness commonly used in new energy charging docks with an aluminum wire harness, thereby solving the corrosion problem.

[0022] Furthermore, it also includes a plug 7. A round hole 42 is provided on the surface of the core connecting part 4. A plug tube 62 is integrally connected to the inner wall of the connecting groove 64 at the position corresponding to the round hole 42. When the core connecting part 4 is engaged in the connecting groove 64, the plug tube 62 is located in the round hole 42, and the plug 7 is inserted into the plug tube 62.

[0023] The insert 7 is made of copper or aluminum.

[0024] It should be noted that the outer diameter of the insert 62 after heating and expansion is less than or equal to the diameter of the round hole 42 after cooling and contraction of the core connection part 4.

[0025] It should be further explained that at room temperature, the diameter of the insert 7 is slightly larger than the inner diameter of the insert 62. Therefore, in actual use, it is necessary to first use the hammer and the conical part to enlarge the opening of the insert 62, and then hammer the insert 7 into the insert 62. Specifically, insert the sharp end of the conical part into the insert 62, and then use the hammer to strike the other end of the conical part to enlarge the opening of the insert 62.

[0026] Furthermore, the surface of the core connecting part 4 is provided with a first anti-slip groove 41, and the surface of the end connecting part 6 is provided with a second anti-slip groove 61 corresponding to the first anti-slip groove 41.

[0027] It should be noted that after the end connection part 6 and the core connection part 4 are fully connected (i.e., after the plug 7 is inserted into the plug tube 62), the end connection part 6 and the core connection part 4 need to be copper-aluminum fusion welded by an ultrasonic welding head. After welding, waterproof sealant is applied to the connection between the end connection part 6 and the core connection part 4, and finally the heat shrink film 1 is put on to form a complete aluminum wire bundle.

[0028] refer to Figure 3The structure shown includes a wire core pressing machine, which includes a frame 8. An upper mold 9 and a lower mold 10 are installed on the frame 8. A drive unit 14 is connected to the frame 8. The upper mold 9 is connected to the drive end of the drive unit 14. A heater 11 is also connected to the frame 8. The heater 11 heats the aluminum wire core to be processed. The aluminum wire core to be processed is placed in the placement groove of the lower mold 10. The drive unit 14 drives the upper mold 9 to move down and cooperate with the lower mold 10 to press the aluminum wire core, so that the heated aluminum wire core forms the core connection part 4.

[0029] For details, please refer to Figure 4 and Figure 5 The structure shown has a lower mold groove on the bottom surface of the placement groove 1, and an upper mold groove on the side surface of the upper mold 9 near the lower mold 10. The upper mold and the lower mold are set in correspondence. The inner walls of the upper mold and the lower mold are in contact with the surface of the core connecting part 4. Through the cooperation of the upper mold 9 and the lower mold 10, the first anti-slip groove 41, the round hole 42 and the side tooth block 43 of the core connecting part 4 are formed as a single unit.

[0030] refer to Figure 3 As shown in the partial structure, a clamp 12 is connected to the frame 8. The clamping end of the clamp 12 is connected to a symmetrically arranged water-cooling sleeve 13. Clamping grooves are opened on the corresponding two side surfaces of the two sets of water-cooling sleeves 13. The core body 3 located outside the insulating sleeve 2 is placed in the clamping groove.

[0031] It should be noted that the clamp 12 can be an electrically controlled clamp or a manually controlled clamp. In actual use, the core body 3 is first placed between the two sets of water cooling jackets 13. When the clamp 12 is activated, the two sets of water cooling jackets 13 move closer to each other, so that the clamping groove clamps the core body 3. The water cooling jacket 13 is an existing device, so it will not be described in detail in this embodiment.

[0032] When the heater 11 heats the core connection part 4, the temperature of the core body part 3 is reduced by circulating cooling water into the water-cooled jacket 13 to prevent the heated core connection part 4 from passing heat through the core body part 3 and causing the insulating jacket 2 to melt.

[0033] refer to Figure 6 and Figure 7 The terminal molding machine shown includes a frame 15, on which a lower pressing die 16, an upper pressing die 17, and an upper pressing die assembly 18 are connected. The copper rod to be processed is placed in the lower pressing die 16. The upper pressing die 17 works with the lower pressing die 16 to press the copper rod to form a connecting groove 64 and a insert 62. The upper pressing die assembly 18 works with the lower pressing die 16 to press the inner walls of the corresponding two sides of the connecting groove 64 to form side tooth grooves 63.

[0034] It should be noted that after the lower pressing die 16, together with the upper pressing die 17 and the upper pressing die assembly 18, stamps the copper rod, a complete copper terminal is obtained.

[0035] Furthermore, a second drive component 19 and a drive assembly 20 are installed on the frame 2 15. The drive end of the second drive component 19 is fixedly connected to a fixed frame 21. A sliding plate 22 is slidably connected inside the fixed frame 21. The drive assembly 20 is connected to the surface of the fixed frame 21. The drive assembly 20 drives the sliding plate 22 to slide along the inner wall of the fixed frame 21. The upper pressure mold 17 and the upper pressure mold assembly 18 are connected to the lower surface of the sliding plate 22.

[0036] In this embodiment, both drive component 14 and drive component 2 19 are hydraulic cylinders.

[0037] It should be noted that the drive assembly 20 can be any mechanical structure capable of driving the sliding plate 22 to move linearly, specifically, it can be an electric push rod, a hydraulic cylinder, a pneumatic cylinder, etc.

[0038] In this embodiment, a specific structure of the drive component 20 is provided. Specifically, the drive component 20 includes a motor, a drive gear, and a rack. The rack is connected to the side of the sliding plate 22, the motor is connected to the surface of the fixed frame 21, the drive gear is fixedly connected to the drive end of the motor, and the drive gear extends into the fixed frame 21 to mesh with the rack.

[0039] In actual use, the drive assembly 20 needs to be started first to drive the sliding plate 22 to move, so that the upper pressing die 17 and the upper pressing die assembly 18 are aligned with the lower pressing die 16. Then, the drive component 29 is used to drive the fixed frame 21 to move, so that the lower pressing die 16 cooperates with the upper pressing die 17 and the upper pressing die assembly 18 to press the copper terminal.

[0040] refer to Figure 8 and Figure 9 The structure shown includes an upper molding assembly 18, which includes a mounting frame 181. The mounting frame 181 is fixedly connected to the lower surface of the sliding plate 22. Symmetrically arranged moving blocks 182 are slidably connected inside the mounting frame 181. A mold plate 183 is connected to the side surface of the two sets of moving blocks 182 that are close to each other. The mold plate 183 extends outside the mounting frame 181.

[0041] Furthermore, a pushing component 23 is connected to the sliding plate 22. The pushing component 23 drives the two sets of moving blocks 182 to move closer or further apart. The pushing component 23 includes a driving component 231, a connecting rod 232, and a diagonal rod 233. The two sets of moving blocks 182 extend from the inner walls of the corresponding two sides of the mounting frame 181 to the outside of the mounting frame 181. The surfaces of the two sets of moving blocks 182 located outside the mounting frame 181 are provided with inclined grooves 234. The connecting rod 232 is connected to the driving end of the driving component 231. The diagonal rods 233 are symmetrically arranged. Both sets of diagonal rods 233 are connected to the surface of the connecting rod 232 and slide along the inner wall of the inclined groove 234 on the corresponding side.

[0042] In actual use, after the lower die 16 and the upper die 17 perform stamping operations, the drive assembly 20 is activated to drive the sliding plate 22 to move, so that the upper die assembly 18 and the lower die 16 are aligned. Then, the drive component 29 is activated to move the die plate 183 into the connecting groove 64. Next, the drive component 3 231 is activated to drive the connecting rod 232 to move. With the cooperation of the inclined rod 233 and the inclined groove 234, the two sets of die plates 183 are driven to move away from each other, thereby stamping the corresponding side wall of the connecting groove 64.

[0043] Example 2; This embodiment provides a method for processing aluminum wire harnesses for new energy charging bases, producing the aluminum wire harness structure for new energy charging bases as shown in Embodiment 1, including the following steps: Step 1, Aluminum wire pretreatment: Peel off the ends of the aluminum wire to expose the aluminum wire core, and place the core body of the aluminum wire core in a water-cooling jacket; Step 2, Aluminum wire core forming: The aluminum wire core is heated to a state of easy plastic deformation using a heater, the upper mold is driven to move down and cooperate with the lower mold to stamp the aluminum wire core to obtain an integrally formed core connection part; Step 3, Copper Terminal Manufacturing: The copper rod is heated to a red-hot state by resistance heating, and then stamped to obtain an integrally formed copper terminal with the cooperation of the lower die, the upper die and the upper die assembly. Step 4, Temperature Difference Assembly: The copper terminals are heated a second time to an expanded state, while the aluminum wire core is cooled to a contracted state to create an assembly gap. Then, the connection is made under temperature difference conditions. Step 5, Welding Reinforcement: Use an ultrasonic welding head to weld the inserted aluminum wire core and copper terminal; Step 6, Sealing and Protection: Apply sealant to the connection between the aluminum wire core and the copper terminal. After the sealant has cured, cover it with heat shrink film and shrink it under hot air to form insulation protection.

[0044] Specifically, in step 1: Peeling parameters: The peeling length is usually 12mm ± 0.5mm to ensure sufficient operating space.

[0045] Water cooling protection: The water cooling jacket uses circulating cooling water at a temperature of 15-25℃ to ensure that the temperature of the insulation layer (i.e., the insulation jacket layer) is below 70℃, preventing the PE / PVC insulation layer from softening or melting.

[0046] In step 2: Heating parameters: Use a high-frequency heater to heat the multi-strand or single-strand aluminum wire core to 280℃±20℃, so that the aluminum wire core reaches a semi-solid, easily deformable state.

[0047] Stamping parameters: Under a pressure of 2-4 tons, the aluminum wire core is stamped into an integrated structure (i.e., a side tooth block) with a 60° sawtooth angle and a tooth depth of about 0.3mm using the lower and upper dies.

[0048] In step 3: Heating parameters: Heat the T2 copper rod to 800℃-900℃ (red hot state) by resistance heating.

[0049] Stamping: Under pressure of 3-5 tons, a precision inner cavity (i.e., side tooth groove) with a tolerance of -0.05mm is stamped out, which is complementary to the shape of the tooth block on the upper side of the aluminum wire core.

[0050] In step 4: Temperature difference control: The copper terminals are heated to 250°C to expand, while the aluminum wire core is cooled to -50°C with liquid nitrogen to shrink, creating an assembly gap of about 0.3mm.

[0051] Mechanical connection: The two parts are quickly inserted under temperature difference conditions to achieve an interference fit by utilizing the thermal expansion and contraction characteristics of metals.

[0052] In step 5: Ultrasonic welding: Using an ultrasonic welding head with a frequency of 20kHz, an amplitude of 30μm, and a pressure of 300N, the welding time is 0.5 seconds, ensuring atomic-level fusion of the joint surfaces.

[0053] In step 6: Waterproofing treatment: Apply silicone-modified waterproof sealant with a thickness of 1mm. After curing, the waterproof rating reaches IP67.

[0054] Insulation protection: Apply a double layer of heat-shrink film (with hot melt adhesive on the inner layer), which shrinks under 120°C hot air to form final insulation protection.

[0055] The above-mentioned parameterized process, through mechanical interlocking and metallurgical integration, effectively solves the problems of conductivity, tensile strength and corrosion resistance in aluminum wire connections.

[0056] The embodiments described above are merely examples of several implementations of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention.

Claims

1. An aluminum wire harness structure for a new energy charging base, characterized in that, The device includes an aluminum wire core and copper terminals. The aluminum wire core includes a core body and a core connecting part. The copper terminal includes an end body and an end connecting part. The core connecting part and the end connecting part are formed by stamping by a wire core molding machine and a terminal molding machine, respectively. An insulating sleeve is fitted on the surface of the core body. Side tooth blocks are integrally connected to the corresponding two sides of the core connecting part. A connecting groove is opened on the surface of the end connecting part. Side tooth grooves corresponding to the side tooth blocks are opened on the inner walls of the corresponding two sides of the connecting groove. Heating the end connection part causes it to expand, cooling the core connection part causes it to shrink, placing the shrunken core connection part into the connection groove, and after the end connection part and the core connection part return to normal temperature, the core connection part snaps into the connection groove.

2. The aluminum wire harness structure for a new energy charging base according to claim 1, characterized in that: It also includes a plug, and the surface of the core connector has a circular hole. The inner wall of the connecting groove is integrally connected with a plug tube at the position corresponding to the circular hole. When the core connector is snapped into the connecting groove, the plug tube is located in the circular hole, and the plug is inserted into the plug tube.

3. The aluminum wire harness structure for a new energy charging base according to claim 1, characterized in that: The surface of the core connector is provided with a first anti-slip groove, and the surface of the end connector is provided with a second anti-slip groove corresponding to the first anti-slip groove.

4. The aluminum wire harness structure for a new energy charging base according to claim 1, characterized in that: The wire core pressing machine includes a frame, on which an upper mold and a lower mold are installed, corresponding to each other. A drive unit is connected to the frame, and the upper mold is connected to the drive end of the drive unit. A heater is also connected to the frame, which heats the aluminum wire core to be processed. The aluminum wire core to be processed is placed in the placement groove of the lower mold. The drive unit drives the upper mold to move down and cooperate with the lower mold to press the aluminum wire core, so that the heated aluminum wire core forms a core connection part.

5. The aluminum wire harness structure for a new energy charging base according to claim 4, characterized in that: A clamp is connected to the frame, and the clamping end of the clamp is connected to a symmetrically arranged water-cooling jacket. Clamping grooves are opened on the corresponding two side surfaces of the two sets of water-cooling jackets, and the core body located outside the insulating jacket is placed in the clamping groove.

6. The aluminum wire harness structure for a new energy charging base according to claim 1, characterized in that: The terminal molding machine includes a frame two, on which a lower pressing mold, an upper pressing mold, and an upper pressing mold assembly are connected. The copper rod to be processed is placed in the lower pressing mold. The upper pressing mold works with the lower pressing mold to press the copper rod to form a connecting groove and a insert. The upper pressing mold assembly works with the lower pressing mold to press the inner walls of the corresponding two sides of the connecting groove to form side tooth grooves.

7. The aluminum wire harness structure for a new energy charging base according to claim 6, characterized in that: The second frame is equipped with a second drive component and a drive assembly. The drive end of the second drive component is fixedly connected to a fixed frame. A sliding plate is slidably connected inside the fixed frame. The drive assembly is connected to the surface of the fixed frame. The drive assembly drives the sliding plate to slide along the inner wall of the fixed frame. The upper pressing mold and the upper pressing mold assembly are connected to the lower surface of the sliding plate.

8. The aluminum wire harness structure for a new energy charging base according to claim 7, characterized in that: The upper molding assembly includes a mounting frame, which is fixedly connected to the lower surface of the sliding plate. Symmetrically arranged movable blocks are slidably connected inside the mounting frame. Mold plates are connected to the side surfaces of the two sets of movable blocks that are close to each other. The mold plates extend outside the mounting frame.

9. The aluminum wire harness structure for a new energy charging base according to claim 7, characterized in that: A pushing assembly is connected to the sliding plate. The pushing assembly drives two sets of moving blocks to move closer to or further away from each other. The pushing assembly includes a driving component three, a connecting rod, and a diagonal rod. The two sets of moving blocks extend from the inner walls of the corresponding sides of the mounting frame to the outside of the mounting frame. The surfaces of the two sets of moving blocks outside the mounting frame are provided with inclined grooves. The connecting rod is connected to the driving end of the driving component three. The diagonal rods are symmetrically arranged. Both sets of diagonal rods are connected to the surface of the connecting rod and slide along the inner wall of the inclined groove on the corresponding side.

10. A method for processing aluminum wire harnesses for new energy charging bases, used to manufacture the aluminum wire harness structure for new energy charging bases as described in any one of claims 1-9, characterized in that, Includes the following steps: Step 1, Aluminum wire pretreatment: Peel off the ends of the aluminum wire to expose the aluminum wire core, and place the core body of the aluminum wire core in a water-cooling jacket; Step 2, Aluminum wire core forming: The aluminum wire core is heated to a state of easy plastic deformation using a heater, the upper mold is driven to move down and cooperate with the lower mold to stamp the aluminum wire core to obtain an integrally formed core connection part; Step 3, Copper Terminal Manufacturing: The copper rod is heated to a red-hot state by resistance heating, and then stamped to obtain an integrally formed copper terminal with the cooperation of the lower die, the upper die and the upper die assembly. Step 4, Temperature Difference Assembly: The copper terminals are heated a second time to an expanded state, while the aluminum wire core is cooled to a contracted state to create an assembly gap. Then, the connection is made under temperature difference conditions. Step 5, Welding Reinforcement: Use an ultrasonic welding head to weld the inserted aluminum wire core and copper terminal; Step 6, Sealing and Protection: Apply sealant to the connection between the aluminum wire core and the copper terminal. After the sealant has cured, cover it with heat shrink film and shrink it under hot air to form insulation protection.

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