A new energy automobile battery box, an integrated forming equipment and a forming process thereof

Abstract

The application relates to the technical field of new energy automobile battery box manufacturing, and particularly discloses a new energy automobile battery box, which comprises front side beams, rear side beams and two groups of side beams which are sequentially connected in head and tail and surround a rectangular frame, the front side beams and the rear side beams are both provided as an integrated structure manufactured through an integrated forming process, and the front side beams have consistent cross-sectional shapes along the length direction of the front side beams; beams and longitudinal beams are arranged on the rectangular frame, the beams and the longitudinal beams are arranged in a perpendicular intersecting mode, one end of the beams is fixedly connected with one group of side beams, one end of the longitudinal beams is fixedly connected with the front side beams, the other end of the longitudinal beams is fixedly connected with the rear side beams, and the beams and the longitudinal beams separate the rectangular frame to form multiple groups of containing cavities for containing battery modules. The application has the effects of improving the uniformity of structural stress and reducing the manufacturing difficulty.

Description

Technical Field

[0001] This application relates to the field of new energy vehicle battery box manufacturing technology, and in particular to a new energy vehicle battery box, an integrated molding equipment and its molding process. Background Technology

[0002] With the rapid development of the new energy vehicle industry, the power battery system has become one of the most critical core components in the overall vehicle structure. Its structural safety, lightweight level, and manufacturing consistency directly affect the vehicle's range and operational safety. In the power battery system structure, the battery box is usually composed of an upper box and a lower box to form a sealed shell. The lower box, as the main structural component that carries key components such as the cell module, battery management system, and cooling system, not only needs to have high structural strength and overall rigidity, but also needs to meet multiple performance requirements such as impact resistance, waterproofing and dustproofing, electromagnetic shielding, and long-term service reliability.

[0003] In existing technologies, the lower battery box of new energy vehicles is generally an integrated load-bearing cavity structure composed of a base plate, frame, reinforcing rib structure, mounting bracket, and sealing connection flange. The frame includes a front beam, a rear beam, and left and right side beams. The front beam, as a lateral load-bearing component located at the front of the box, not only participates in constructing the overall frame of the box but also bears the forward impact load from the vehicle's movement and connects with the vehicle's chassis structure. Furthermore, its upper surface or edge area typically serves as part of the sealing interface, significantly impacting the sealing performance of the battery box. The front beam is usually made of aluminum alloy or high-strength steel. Due to the large overall length and arc-shaped or multi-folded structure of the front beam, it is usually difficult to achieve integral forming through a single process due to limitations in stamping equipment stroke and mold size. Therefore, in actual manufacturing, it is often produced in sections and then welded together.

[0004] However, there are significant shortcomings in practical applications. The front beam, manufactured using a segmented welding method, has long weld seams. The welding heat input causes changes in material structure and the accumulation of local residual stress in the weld seam and its heat-affected zone, which can easily lead to warping or dimensional deviations in the component. This affects the assembly accuracy between the front and side beams and the overall geometric consistency of the housing. Simultaneously, fluctuations in welding process parameters (such as current, voltage, and welding speed) and unstable control of assembly gaps can easily lead to problems such as incomplete fusion and poor weld formation. This not only weakens the mechanical properties of the welded joint, making the front beam more susceptible to local failure under impact or vibration loads, but also creates leakage channels in the weld area, resulting in a lower pass rate during airtightness testing and potential leakage hazards, making it difficult to meet the high sealing safety requirements of power battery systems. Furthermore, welding deformation can cause unevenness or misalignment of the sealing flange surface. Therefore, to ensure the manufacturing quality of the entire battery lower housing, additional straightening and correction processes are required, further increasing process complexity and manufacturing costs. Summary of the Invention

[0005] This application provides a new energy vehicle battery box, an integrated molding equipment and its molding process. The new energy vehicle battery box improves the uniformity of structural stress and reduces manufacturing difficulty. At the same time, the integrated molding equipment for the new energy vehicle battery box can not only realize the active control of the material flow direction during the tube forming process, but also improve the forming stability and wall thickness uniformity of the curved complex structure, ensuring the overall quality and production stability of the new energy vehicle battery box.

[0006] Firstly, the battery box for a new energy vehicle provided in this application adopts the following technical solution: A battery box for a new energy vehicle includes a front beam, a rear beam, and two sets of side beams connected end to end to form a rectangular frame. The front beam and the rear beam are both integral structures made by an integral molding process, and the front beam has a consistent cross-sectional shape along its own length. A rectangular frame is provided with horizontal beams and vertical beams, which are arranged perpendicularly to each other. One end of the horizontal beam is fixedly connected to a group of side beams, one end of the vertical beam is fixedly connected to the front beam, and the other end of the vertical beam is fixedly connected to the rear beam. The horizontal beams and vertical beams divide the rectangular frame into multiple sets of cavities for accommodating battery modules.

[0007] By adopting the above technical solution, the front and rear beams are designed as an integral molding structure, which reduces the number of welding joints in traditional segmented welding structures. This reduces the probability of defects such as porosity, lack of fusion, and slag inclusions during welding, thereby improving the overall airtightness and structural reliability of the battery box structure. At the same time, by using a continuous molding process, the front beam has a consistent cross-sectional shape along its length, which helps to improve the uniformity of structural stress and reduce manufacturing difficulty. The intersecting horizontal and vertical beams within the rectangular frame divide the internal space of the box into multiple cavities for accommodating battery modules. This not only improves the overall structural rigidity of the box but also enables the stable arrangement of battery modules, improving the structural safety and layout rationality of the battery system.

[0008] Secondly, the integrated molding equipment for a new energy vehicle battery box provided in this application adopts the following technical solution: An integrated molding equipment for a new energy vehicle battery box includes: A frame is provided with a controller on one side. A lower template and an upper template are provided on the frame. The lower template is fixed on the frame, and the upper template is slidably mounted on the frame. A hydraulic drive is provided on the frame. The output end of the hydraulic drive is connected to the upper template. The hydraulic drive can drive the upper template to reciprocate on the frame. A molding die, comprising a fixed die and a movable die, wherein the fixed die is fixed on the lower template and the movable die is fixed on the upper template; the fixed die has a first mold cavity and the movable die has a second mold cavity; when the fixed die and the movable die are closed, the first mold cavity and the second mold cavity combine to form a complete cavity; one end of the cavity is provided with a first injection port and the other end of the cavity is provided with a second injection port. The feeding assembly includes a plugging component, an injection head, and a first injection pump. Both the plugging component and the first injection pump are mounted on the frame. The injection head is mounted on the plugging component and is drively connected to the first injection pump. Two sets of plugging components are provided, and the two sets of plugging components are symmetrically arranged along the length of the frame. The two sets of plugging components can respectively perform movable sealing of the first injection port and the second injection port.

[0009] By adopting the above technical solution, a molding die consisting of a fixed mold and a moving mold is provided, with a first injection port and a second injection port respectively set at both ends of the mold cavity. This allows liquid medium to be injected into the pipe during the pipe forming process to form internal pressure support, so that the pipe is subjected to uniform internal pressure during the forming process, thereby improving the pipe's expansion forming ability and forming stability. At the same time, the injection port is dynamically sealed by the sealing component in the feeding assembly, which not only ensures the stable establishment of internal pressure in the pipe, but also enables rapid injection and sealing of liquid medium, improving the automation level and forming efficiency of the equipment.

[0010] Optionally, the plugging component includes a mounting base, a punch, and a plugging drive. The mounting base is fixed on the frame, the plugging drive is fixed on the mounting base, and the punch is fixed on the output end of the plugging drive. The plugging drive is electrically connected to the controller. The end of the punch facing away from the plugging drive is adapted to the shape of the first injection port. The plugging drive is used to drive the punch to reciprocate.

[0011] By adopting the above technical solution, a sealing drive component is set to drive the punch to reciprocate axially, enabling the punch to form a shape-fitting sealing connection with the injection port. This not only achieves reliable sealing of the injection port and prevents leakage of liquid media, but also applies axial extrusion force to the end of the pipe during the advancement process. This provides necessary axial material feeding during pipe forming, improves the material flowability in the forming area, reduces pipe wall thinning or cracking, and improves forming quality.

[0012] Optionally, the feeding assembly further includes an abutment member, which includes an abutment seat, a first abutment bladder, a second abutment bladder, and an abutment plate. The abutment seat is fixedly disposed on the side of the punch facing away from the mounting base. A liquid storage tank is formed on the abutment seat, and a partition plate is fixedly disposed in the liquid storage tank. The partition plate divides the liquid storage tank into two equal chambers, which are respectively designated as a third chamber and a fourth chamber. A communication port is provided on the side of the partition plate near the punch, and the third chamber and the fourth chamber are interconnected through the communication port. A first sliding plate is slidably disposed in the third chamber, and a second sliding plate is slidably disposed in the fourth chamber. A first flow-limiting plate is fixedly disposed in the third chamber, located on the side of the first sliding plate facing away from the communication port. The plate is evenly provided with several sets of first flow limiting holes. A second flow limiting plate is fixedly installed in the fourth chamber. The second flow limiting plate is located on the side of the second sliding plate away from the communication port. The second flow limiting plate is evenly provided with several sets of second flow limiting holes. The diameter of the first flow limiting hole is larger than the diameter of the second flow limiting hole. The first abutting bladder and the second abutting bladder are both fixedly installed on the punch. The first abutting bladder is connected to the third chamber through the first flow limiting hole. The second abutting bladder is connected to the fourth chamber through the second flow limiting hole. The first abutting bladder and the second abutting bladder are filled with hydraulic oil. A certain amount of hydraulic oil is filled in the abutting seat. The abutting plate is fixed on the side of the first abutting bladder and the second abutting bladder away from the abutting seat. The abutting plate is movably abutting against the outer wall of the pipe.

[0013] By adopting the above technical solution, an abutment is provided on the punch, and a third and fourth chamber are formed within the abutment seat. A first flow-limiting plate and a second flow-limiting plate are respectively installed in the two chambers, with the diameter of the first flow-limiting orifice being larger than that of the second flow-limiting orifice. This creates different flow resistances during the hydraulic oil flow. When the punch advances towards the pipe, hydraulic oil flows within the first and second abutment bladders. Due to the different diameters of the flow-limiting orifices on both sides, the first and second abutment bladders undergo different deformations under pressure. This results in different clamping forces on both sides of the pipe, thus creating an asymmetrical clamping state in the pipe's bending area. The design applies greater constraint to the outer side of the bend and relatively less constraint to the inner side, guiding the material to preferentially gather towards the outer side of the bend and form a controllable folded structure. This folded structure can be gradually stretched and unfolded as a material reserve during the subsequent internal high-pressure bulging process, effectively compensating for the material thinning problem that occurs on the outer side of the bend during the forming process. This avoids local wall thickness being too thin or cracking. It not only enables active control of the material flow direction during the tube forming process, but also improves the forming stability and wall thickness uniformity of complex bent structural parts, providing sufficient material reserves for subsequent cross-section shaping, thereby further improving the structural strength and forming quality of the final integrally formed edge beam.

[0014] Optionally, the fixed mold is provided with a separator, which includes a separator block and an air pump. A sliding groove is formed on the bottom wall of the first mold cavity. The separator block is slidably disposed in the sliding groove. The side of the separator block opposite to the sliding groove is movably abutting against the outer wall of the pipe. The air pump is disposed on the frame and is electrically connected to the controller. The output end of the air pump is drivenly connected to the sliding groove. The air pump can inject compressed air into the sliding groove, thereby driving the separator block to lift or retract.

[0015] By adopting the above technical solution, a partition block that can move up and down along the sliding groove is set on the fixed mold. Compressed air is injected into the sliding groove using an air pump to drive the partition block to rise or retract. This allows the partition block to abut against the outer wall of the tube in the early stage of tube forming. Furthermore, in conjunction with the punch, the internal space of the cavity is divided into two independent chambers. This creates a liquid-supported environment on one side of the tube's bending area, while the other side remains relatively free. The material on the inner side of the bend remains stable under liquid support, while the material on the outer side of the bend is more likely to migrate to the outer region under axial extrusion pressure and form a more stable structure. The controlled fold structure enables active control over the material flow direction and material accumulation position. Simultaneously, after axial feeding, the air pump is controlled to retract the partition block to release the cavity partition, restoring the cavity to a whole cavity. This provides a complete forming space for the subsequent internal high-pressure bulging stage, allowing the previously formed folds to be uniformly stretched and unfolded under internal pressure to conform to the cavity contour. This effectively improves the rationality of material distribution in the preforming stage of complex curved side beam structures and reduces the risk of wall thinning or cracking in the bending area of ​​the pipe, thereby significantly improving the forming quality and dimensional accuracy of the side beam structure.

[0016] Optionally, the fixed mold is further provided with a liquid filling component, which includes a liquid filling pipe, a plug, a second liquid injection pump, and a displacement drive. The liquid filling pipe is slidably inserted into the fixed mold. A receiving groove is formed on the inner side wall of the first mold cavity. One end of the liquid filling pipe extends into the receiving groove. The plug is fixed to the end of the liquid filling pipe near the first mold cavity. The plug is adapted to the shape of the receiving groove and is tightly sealed to the receiving groove. An outlet is formed on the end of the liquid filling pipe away from the first mold cavity. The second liquid injection pump is fixed to the frame and electrically connected to the controller. The second liquid injection pump is drively connected to the end of the liquid filling pipe away from the plug. A support frame is fixed to the outer side wall of the fixed mold. The displacement drive is fixed to the support frame and electrically connected to the controller. The output end of the displacement drive is connected to the end of the liquid filling pipe away from the plug. The displacement drive can drive the liquid filling pipe to reciprocate on the fixed mold.

[0017] By adopting the above technical solution, a liquid filling component is set on the fixed mold, and a slidable liquid filling tube and a plug structure adapted to its shape are used to allow the liquid filling tube to reciprocate along the fixed mold under the drive of the displacement drive component. This enables selective injection or discharge of liquid medium in a specific area of ​​the first mold cavity. During the tube forming process, the hydraulic state of a local area in the cavity is dynamically controlled, so that the inner curved area receives stable liquid support in the preforming stage, while the other side remains relatively free. The material on the inner curved side remains stable under the liquid support, while the material on the outer curved side is more likely to migrate to the outer area under axial extrusion force and form a controllable fold structure. This achieves active control of the material flow direction and material accumulation position, further improving the dimensional consistency and overall forming stability of the side beam structure. Optionally, a liquid storage tank is provided on one side of the frame, the liquid storage tank is filled with emulsion, the input end of the first injection pump is drivenly connected to the liquid storage tank, and the input end of the second injection pump is drivenly connected to the liquid storage tank.

[0018] By adopting the above technical solution, setting up a storage tank to provide a unified source of liquid medium for the first and second injection pumps can not only ensure the stability of liquid supply during the molding process, but also simplify the structure of the liquid supply system and improve the overall reliability and continuous working capability of the equipment.

[0019] Optionally, a lubrication assembly is also included. The lubrication assembly includes a support platform, a lubrication seat, an oil supply pipe, and an oil storage box. The support platform is located on one side of the frame. The lubrication seat is fixed on the support platform and has an oil covering groove. The oil storage box is fixed on the support platform and contains lubricating oil. The lubrication seat has an oil drain hole. One end of the oil supply pipe is connected to the oil storage box, and the end of the oil supply pipe away from the oil storage box is located in the oil drain hole. The oil supply pipe is connected to the oil covering groove through the oil drain hole. A sealing bead is slidably disposed in the oil drain hole, and the sealing bead can dynamically seal the oil drain hole.

[0020] By adopting the above technical solution, a lubricating oil layer can be formed on the outer surface of the pipe before it enters the mold, thereby reducing the frictional resistance between the pipe and the mold, reducing surface scratches and local stress concentration during the forming process, and facilitating the smooth flow of material in the mold cavity, thus improving the forming quality and the service life of the mold.

[0021] Thirdly, this application also provides a molding process suitable for producing battery boxes for new energy vehicles, including the following steps: S1. The bending equipment pre-bends the square tube to obtain a tube with a spatial profile that is basically consistent with the overall direction of the target side beam. S2. Place the pipe on the lubrication seat and spray lubricating oil on the outer surface of the pipe bend; S3. Place the pipe into the fixed mold, and then drive the moving mold to close with the fixed mold, so that the first mold cavity and the second mold cavity form a complete cavity. At the same time, the air pump drives the partition block in the partition to push outward, so that the partition block abuts against the outer wall of the pipe, thereby forming two mutually isolated chambers inside the cavity, namely the first chamber and the second chamber. S4. The sealing drive unit drives the punch to advance along the pipe axis, applying axial extrusion force to both ends of the pipe, causing the pipe material to migrate to the bending area. At the same time, the first injection pump injects emulsion into the pipe to form internal pressure support. The second injection pump injects liquid medium into the first chamber, while the second chamber remains unfilled, so that the inner side of the bend is liquid-supported, while the outer side of the bend is in a relatively free state. Under the action of axial compression, the outer side of the bend preferentially forms controllable folds to provide material reserves for subsequent cross-section shaping. S5. During the punching process, the first and second abutting bladders in the abutting parts are pressurized and hydraulic oil flows. Since the diameter of the first flow limiting hole is larger than that of the second flow limiting hole, the abutting plate generates different forces on both sides of the pipe, so that the clamping force acting on the outside of the bend is greater than that on the inside of the bend, thereby further promoting the material accumulation and wrinkle formation on the outside of the bend. S6. After the axial feeding is completed, the air pump drives the partition block to retract to release the cavity partition. At the same time, the second injection pump extracts the liquid from the first chamber. Then the first injection pump continues to increase the internal hydraulic pressure of the pipe, causing the pipe to undergo radial expansion under the action of internal high pressure. This stretches and unfolds the originally formed wrinkles and makes the outer wall of the pipe fully fit the cavity, thereby restoring and accurately reshaping the square cross section. S7. After the pipe is fully fitted into the cavity and the set forming pressure is reached, stop pressurizing, then release the hydraulic pressure and open the mold to remove the formed front or rear side beam structure to obtain an integrated side beam without welds.

[0022] By adopting the above technical solution, the forming process sequentially employs pre-bending, lubrication treatment, cavity partitioning control, axial feeding, differential compression to induce wrinkles, and final internal high-pressure bulging, enabling the tube to form a controllable material aggregation structure in the bending area. In the subsequent internal high-pressure bulging stage, the wrinkles are stretched and unfolded, thereby achieving precise forming of complex curved edge beam structures. This not only effectively avoids the weld defects present in traditional welded structures but also obtains an integrated edge beam structure without welds, improving the structural strength, airtightness, and manufacturing consistency of the battery box.

[0023] In summary, this application includes at least one of the following beneficial technical effects: 1. An abutment is provided on the punch, and a first flow limiting plate and a second flow limiting plate are respectively provided in the two chambers. The diameter of the first flow limiting hole is larger than that of the second flow limiting hole, thereby creating different flow resistances during the hydraulic oil flow process. This causes the first and second abutment bladders to produce different deformations under pressure, which in turn causes the abutment plates to form different clamping forces on both sides of the tube. In this way, an asymmetrical clamping state can be formed in the bending area of ​​the tube, so that the outer side of the bend is subject to a larger constraint force, while the inner side of the bend is subject to a relatively smaller constraint force. This guides the material to preferentially gather to the outer side of the bend and form a controllable fold structure. This fold structure can be gradually stretched and unfolded as material reserves during the subsequent internal high-pressure bulging process, thereby effectively compensating for the material thinning problem caused by the outer side of the bend during the forming process, avoiding local excessive wall thickness or cracking, thereby improving the forming stability and wall thickness uniformity of the bending complex structure, providing sufficient material reserves for subsequent cross-section shaping, and thus improving the structural strength and forming quality of the final integrally formed side beam. 2. A partition block that can move up and down along the sliding groove is set on the fixed mold. Compressed air is injected into the sliding groove using an air pump to drive the partition block to rise or retract. This allows the partition block to abut against the outer wall of the tube in the early stage of tube forming. In conjunction with the punch, the internal space of the cavity is divided into two independent chambers. This creates a liquid support environment on one side of the tube's bending area, while the other side remains relatively free. The material on the inner side of the bend remains stable under the liquid support, while the material on the outer side of the bend is more likely to migrate to the outer area under axial extrusion force and form a controllable fold structure. This enables active control of the material flow direction and material accumulation position, effectively improving the rationality of material distribution in the preforming stage of complex curved side beam structures. It also reduces the risk of wall thinning or cracking in the tube's bending area, thereby significantly improving the forming quality and dimensional accuracy of the side beam structure. 3. This allows a lubricating oil layer to form on the outer surface of the pipe before it enters the mold, thereby reducing the frictional resistance between the pipe and the mold, reducing surface scratches and local stress concentration during the forming process, and facilitating smooth material flow within the mold cavity, thus improving forming quality and mold lifespan. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the overall structure of the new energy vehicle battery box in the embodiments of this application.

[0025] Figure 2 This is a schematic diagram of the overall structure of the one-piece molding device in the embodiments of this application.

[0026] Figure 3 This is a schematic diagram of a half-section of the molding die in an embodiment of this application.

[0027] Figure 4 This is a schematic diagram of the overall structure of the rack in an embodiment of this application.

[0028] Figure 5 This is a schematic diagram of the overall structure of the liquid filling component in the embodiments of this application.

[0029] Figure 6 This is a schematic diagram of the overall structure of the abutment component in the embodiments of this application.

[0030] Figure 7 This is a partial cross-sectional view of the lubrication seat in an embodiment of this application.

[0031] Reference numerals: 11. Front beam; 12. Rear beam; 13. Side beam; 14. Crossbeam; 15. Longitudinal beam; 16. Receiving cavity; 2. Frame; 21. Controller; 22. Lower template; 23. Upper template; 3. Hydraulic drive components; 4. Molding mold; 41. Fixed mold; 411. First mold cavity; 412. Sliding groove; 413. Receiving groove; 414. Support frame; 42. Moving mold; 421. Second mold cavity; 43. Cavity; 431. First injection port; 432. Second injection port; 44. Separator; 441. Separator block; 442. Air pump; 45. Filling component; 451. Filling pipe; 4511. Outlet; 452. Plug; 453. Second injection pump; 454. Displacement drive component; 5. Feeding assembly; 51. Sealing component; 511. Mounting base; 512. Punch; 5121. Clearance groove; 513. Sealing drive component; 52. Injection head; 53. First injection pump; 54. Abutment component; 541. Abutment seat; 5411. Liquid storage tank; 5412. Third chamber; 5413. Fourth chamber; 542. First abutment bladder; 543. Second abutment bladder; 544. Abutment plate; 545. Divider plate; 5451. Connecting port; 546. First sliding plate; 547. Second sliding plate; 548. First flow limiting plate; 5481. First flow limiting orifice; 549. Second flow limiting plate; 5491. Second flow limiting orifice; 55. Liquid storage tank; 6. Lubrication components; 61. Support platform; 62. Lubrication seat; 621. Oil trough; 622. Oil drain hole; 63. Oil pipe; 64. Oil reservoir; 65. Sealing bead. Detailed Implementation

[0032] The following is in conjunction with the appendix Figure 1-7 This application will be described in further detail below.

[0033] It should be noted that the one-piece molding equipment mentioned in this application is used to manufacture the front / rear beams. Traditional front / rear beams require multiple steps such as stamping, bending, welding, and machining. This can easily lead to microscopic defects such as porosity, lack of fusion, and slag inclusions in the weld area. Long and numerous weld joints can also increase the risk of overall airtightness failure of the battery box, resulting in a lower pass rate during airtightness testing, potential leakage hazards, and difficulty in meeting the high sealing safety requirements of power battery systems.

[0034] In this application, the manufacturing process of the front / rear side beam is to first obtain the basic outline of the square tube by bending, which originally required three sections of welding, and then to precisely shape the local section by internal high pressure expansion process, so as to finally form a single, seamless integral structural component.

[0035] Although the square tube can be directly processed into the required shape through bending, there are physical limitations in the material forming capacity of bending. It is impossible to simultaneously meet the dual requirements of "cross-sectional shape" and "defect-free forming". That is, when the square tube is bent, it is subjected to tension on the outside and compression on the inside. Under the combined force, the originally regular square cross-section tends to become elliptical or collapse. For the front beam 11 of the battery lower box, the cross-sectional shape is directly related to the accuracy of the installation interface and the structural strength. A collapsed or wrinkled square tube cannot meet the requirements of airtightness and assembly. Therefore, after bending, it is necessary to perform micro-forming through water expansion forming. During water expansion forming, the punch on the water expansion forming equipment advances forward and replenishes material to the deformation area. This is like "infusing blood" into the stretched area, which can effectively avoid excessive thinning in some areas, thereby achieving a smaller bending radius or more drastic cross-sectional changes. The part finally formed in this way maintains the bending direction and has complex cross-sectional functional characteristics.

[0036] This application discloses a battery box for a new energy vehicle.

[0037] Reference Figure 1 A battery box for a new energy vehicle includes a front beam 11, a rear beam 12, a side beam 13, a cross beam 14, and a longitudinal beam 15. One end of the side beam 13 is fixedly connected to one end of the front beam 11, and the other end of the side beam 13 is fixedly connected to one end of the rear beam 12. Two sets of side beams 13 are provided, and the two sets of side beams 13 are symmetrically arranged along the length direction of the front beam 11. The front beam 11, the rear beam 12, and the two sets of side beams 13 are connected end to end to form a rectangular frame.

[0038] Both the crossbeam 14 and the longitudinal beam 15 are fixed on the rectangular frame. The longitudinal beam 15 is parallel to the length of the rectangular frame. One end of the longitudinal beam 15 is fixedly connected to the front beam 11, and the other end of the longitudinal beam 15 is fixedly connected to the rear beam 12. The crossbeam 14 and the longitudinal beam 15 are arranged perpendicularly to each other. The crossbeam 14 and the longitudinal beam 15 are fixedly connected. Both ends of the crossbeam 14 are fixedly connected to two sets of side beams 13. In this embodiment, there are three sets of crossbeams 14. The three sets of crossbeams 14 are arranged at equal intervals along the length of the side beams 13. The three sets of crossbeams 14 and the longitudinal beam 15 divide the rectangular frame into multiple sets of receiving cavities 16 for accommodating battery modules.

[0039] In this embodiment, the main substrate of the new energy vehicle battery box is high-strength steel. The front beam 11 and the rear beam 12 are both made into an integrated structure by water expansion molding process, and the fixed connection between each beam is achieved by welding.

[0040] This application also proposes an integrated molding equipment for a new energy vehicle battery box, referring to... Figure 2 The integrated molding equipment includes a frame 2, a hydraulic drive unit 3, a molding die 4, a feeding assembly 5, and a lubrication assembly 6. The hydraulic drive unit 3, molding die 4, and feeding assembly 5 are all mounted on the frame 2. The hydraulic drive unit 3 is located above the molding die 4, the feeding assembly 5 is mounted on both sides of the molding die 4, and the lubrication assembly 6 is mounted on one side of the frame 2. The hydraulic drive unit 3 is used to drive the opening and closing of the molding die 4, which provides a cavity 43 that conforms to the shape of the front beam 11 for integrated molding. The feeding assembly 5 injects high pressure into the pipe to make it fit the cavity 43. The lubrication assembly 6 is used to apply lubricant to the pipe.

[0041] Reference Figure 2 In the embodiment of the application, the frame 2 is configured as a gantry type, a controller 21 is installed on one side of the frame 2, a lower template 22 and an upper template 23 are provided on the frame 2, an installation platform is provided on the frame 2, the lower mold base is fixed on the installation platform, multiple sets of guide columns are fixed on the installation platform, the upper template 23 is slidably mounted on the guide columns, and the hydraulic drive component 3 is fixed on the frame 2. The hydraulic drive component 3 is electrically connected to the controller 21. In this embodiment, the hydraulic drive component 3 is configured as a hydraulic booster cylinder, and the output end of the hydraulic drive component 3 is fixedly connected to the side of the upper template 23 that is away from the lower template 22.

[0042] Reference Figure 3 and Figure 4In the embodiment of the application, the molding die 4 includes a fixed die 41, a movable die 42, a separator 44, and a liquid filling member 45. The fixed die 41 is fixed on the lower template 22, and the movable die 42 is fixed on the upper template 23. A first mold cavity 411 is opened on the side of the fixed die 41 facing away from the lower template 22, and a second mold cavity 421 is opened on the side of the movable die 42 facing the fixed die 41. When the fixed die 41 and the movable die 42 are closed, the first mold cavity 411 and the second mold cavity 421 are combined to form a complete cavity 43. A first liquid injection port 431 is provided at one end of the cavity 43, and a second liquid injection port 432 is provided at the other end of the cavity 43.

[0043] The separator 44 is disposed on the fixed mold 41. The separator 44 includes a separator block 441 and an air pump 442. The separator block 441 is a strip block and its shape is similar to that of the first mold cavity 411. A sliding groove 412 is provided on the bottom wall of the first mold cavity 411. One end of the separator block 441 is slidably disposed in the sliding groove 412, and the other end of the separator block 441 is in movable contact with the outer wall of the pipe. When the end of the separator block 441 extends into the sliding groove 412, it combines with the inner wall of the sliding groove 412 to form a closed chamber. Both the separator block 441 and the sliding groove 412 are precision cut and processed.

[0044] The air pump 442 is fixed on the installation platform and is electrically connected to the controller 21. The output end of the air pump 442 is connected to the sliding groove 412. In this embodiment, the air pump 442 is set as a piston air pump 442. The air pump 442 can inject compressed air into the sliding groove 412, thereby driving the partition block 441 to rise or fall.

[0045] Two sets of separators 44 are provided. One set of separators 44 is installed on the fixed mold 41, and the other set of separators 44 is installed on the moving mold 42. When the moving mold 42 is pressed onto the fixed mold 41 and the tube to be formed is also placed in the cavity 43, the controller 21 controls the two sets of separators 441 to be pushed outward through the air pump 442. The end of the separator 441 away from the sliding groove 412 is pressed against the outer wall of the tube to be formed in the width direction. The two sets of separators 441 and the tube to be formed, together with the feeding assembly 5, divide the cavity 43 into two chambers, which are respectively set as the first chamber and the second chamber.

[0046] Reference Figure 3 , Figure 4 and Figure 5In the embodiment of the application, the filling component 45 is installed on the fixed mold 41. The filling component 45 includes a filling pipe 451, a plug 452, a second injection pump 453, and a displacement drive component 454. The filling pipe 451 is slidably inserted into the fixed mold 41, and one end of the filling pipe 451 can extend into the first mold cavity 411. The plug 452 is fixedly installed at the end of the filling pipe 451 near the first mold cavity 411. A receiving groove 413 is provided on the inner side wall of the first mold cavity 411. The plug 452 is movably disposed in the receiving groove 413 and is tightly fitted with the receiving groove 413. A liquid outlet 4511 is provided at the end of the filling pipe 451 away from the first mold cavity 411. Multiple sets of liquid outlets 4511 are provided on the filling pipe 451, and the multiple sets of liquid outlets 4511 are arranged in a circle with the filling pipe 451 as the axis.

[0047] The second injection pump 453 is fixed on the frame 2 and is electrically connected to the controller 21. A delivery pipe is fixed on the output end of the second injection pump 453. A transition part is fixed on the end of the filling pipe 451 away from the first mold cavity 411. A delivery channel is opened inside the transition part. The end of the delivery pipe away from the second injection pump 453 is fixedly connected to the transition part. The second injection pump 453 is connected to the end of the filling pipe 451 away from the first mold cavity 411 through the delivery pipe. The second injection pump 453 can inject liquid into the first cavity through the delivery pipe and the filling pipe 451.

[0048] A support frame 414 is fixed on the outer wall of the fixed mold 41. The displacement drive 454 is fixed on the support frame 414. The displacement drive 454 can be configured as a hydraulic cylinder. The displacement drive 454 is electrically connected to the controller 21. The output end of the displacement drive 454 is fixedly connected to the adapter. The displacement drive 454 can drive the filling pipe 451 to reciprocate and slide on the fixed mold 41.

[0049] Of course, in other embodiments of this application, the displacement drive 454 can also be configured as a linear drive such as an electric telescopic cylinder.

[0050] Reference Figure 4 , Figure 5 and Figure 6 In the embodiment of the application, the feeding assembly 5 includes a sealing member 51, an injection head 52, a first injection pump 53, a storage tank 55, and an abutment member 54. The sealing member 51 is mounted on the mounting platform, and two sets of sealing members 51 are provided. The two sets of sealing members 51 are symmetrically arranged along the length direction of the fixed mold 41. The two sets of sealing members 51 are used to movably seal the first injection port 431 and the second injection port 432. The sealing component 51 includes a mounting base 511, a punch 512, and a sealing drive component 513. The mounting base 511 is fixed on the mounting platform, the sealing drive component 513 is fixed on the mounting base 511, and the punch 512 is fixed on the output end of the sealing drive component 513. The punch 512 has two sets of clearance grooves 5121, which are symmetrically arranged along their own length. The sealing drive component 513 is electrically connected to the controller 21. In this embodiment, the sealing drive component 513 can be configured as a hydraulic cylinder. The end of the punch 512 away from the sealing drive component 513 is configured as a first injection port 431 with a shape adaptation, and the two sets of punches 512 are respectively movably sealed on the first injection port 431 and the second injection port 432.

[0051] Two sets of sealing components 51 are respectively set as the first sealing component 51 and the second sealing component 51. The injection head 52 is installed on the first sealing component 51. The first injection pump 53 is fixed on the installation platform and is electrically connected to the controller 21. The storage tank 55 is installed on one side of the frame 2. The storage tank 55 is filled with emulsion. The storage tank 55 is fixed with the first injection pipe and the second injection pipe. The storage tank 55 is connected to the input end of the first injection pump 53 through the first injection pipe. The output end of the first injection pump 53 is connected to the injection head 52. The first injection pump 53 can inject emulsion into the cavity 43 through the injection head 52, thereby performing internal high-pressure molding of the pipe.

[0052] In addition, the input end of the second injection pump 453 is connected to the reservoir pump, and the second injection pump 453 can also inject the emulsion into the first chamber.

[0053] Reference Figure 5 and Figure 6 In the embodiment of the application, two sets of abutting members 54 are provided, and the two sets of abutting members 54 are respectively provided on two sets of sealing members 51. The abutting member 54 includes an abutting seat 541, a first abutting bladder 542, a second abutting bladder 543 and an abutting plate 544. The abutting seat 541 is fixed on the side of the punch 512 away from the mounting base 511. A liquid storage tank 5411 is provided on the side of the abutting seat 541 away from the punch 512. A partition plate 545 is fixed in the liquid storage tank 5411. The partition plate 545 divides the liquid storage tank 5411 into two chambers, which are respectively designated as the third chamber 5412 and the fourth chamber 5413. A connecting port 5451 is provided on the side of the abutting seat 541 near the punch 512. The third chamber 5412 and the fourth chamber 5413 are connected to each other through the connecting port 5451.

[0054] The third chamber 5412 is sealed and slidably equipped with a first sliding plate 546. A first spring is provided on the first sliding plate 546. One end of the first spring is fixedly connected to the first sliding plate 546, and the other end of the first spring is fixedly connected to the inner wall of the third chamber 5412.

[0055] The fourth chamber 5413 is sealed and slidably equipped with a second sliding plate 547. A second spring is provided on the second sliding plate 547. One end of the second spring is fixedly connected to the second sliding plate 547, and the other end of the second spring is fixedly connected to the inner wall of the fourth chamber 5413.

[0056] A first flow limiting plate 548 is fixedly installed in the third chamber 5412. The first flow limiting plate 548 is located on the side of the flow limiting seat opposite to the punch 512. Several sets of first flow limiting holes 5481 are evenly opened on the first flow limiting plate 548. A second flow limiting plate 549 is fixedly installed in the fourth chamber 5413. The second flow limiting plate 549 is located on the side of the flow limiting seat opposite to the punch 512. Several sets of second flow limiting holes 5491 are evenly opened on the second flow limiting plate 549. The diameter of the first flow limiting hole 5481 is much larger than the diameter of the second flow limiting hole 5491.

[0057] The first abutment bladder 542 and the second abutment bladder 543 are fixedly mounted on the side of the abutment seat 541 opposite to the punch 512. The first abutment bladder 542 and the second abutment bladder 543 are symmetrically arranged along the width direction of the abutment seat 541. The first abutment bladder 542 communicates with the third chamber 5412 through the first flow limiting hole 5481, and the second abutment bladder 543 communicates with the fourth chamber 5413 through the second flow limiting hole 5491. The abutment plate 544 is fixedly mounted on the side of the first abutment bladder 542 and the second abutment bladder 543 opposite to the abutment seat 541, and the abutment plate 544 movably abuts with one end of the pipe. The first abutment bladder 542 and the second abutment bladder 543 are filled with hydraulic oil, and the abutment seat 541 is filled with a certain amount of hydraulic oil.

[0058] In addition, an elastic protective cover is installed between the abutment plate 544 and the abutment seat 541. The elastic protective cover covers the first abutment 542 and the second abutment 543. One end of the first elastic cover is fixedly connected to the abutment seat 541, and the other end of the first elastic cover is fixedly connected to the abutment plate 544.

[0059] A sealing part is provided on the side of the abutment plate 544 facing away from the abutment seat 541. The sealing part is made of elastic material. One end of the injection head 52 passes through the punch 512, the abutment seat 541, the first abutment bladder 542, the second abutment bladder 543, the abutment plate 544 and the abutment part in sequence. The injection head 52 is set as a round tube made of elastic material. Therefore, the abutment member 54 and the sealing member 51 on the side where the injection head 52 is installed will be adapted.

[0060] Reference Figure 4 and Figure 6In the embodiment of the application, the lubrication assembly 6 includes a support platform 61, a lubrication seat 62, an oil supply pipe 63, and an oil storage box 64. The support platform 61 is located on one side of the frame 2. The lubrication seat 62 is fixed on the support platform 61 and has an oil covering groove 621. The oil storage box 64 is fixed on the support platform 61 and is filled with lubricating oil. An oil injection pump is installed on the oil storage box 64. The oil injection pump is electrically connected to the controller 21. The input end of the oil injection pump is connected to the oil storage box 64, and the output end of the oil injection pump is connected to one end of the oil supply pipe 63. The lubrication seat 62 has an oil covering groove 621. There is an oil drain hole 622. The end of the oil supply pipe 63 away from the oil storage box 64 is fixedly embedded in the oil drain hole 622. The oil supply pipe 63 is connected to the oil covering tank 621 through the oil drain hole 622. A sealing bead 65 is slidably arranged in the oil drain hole 622. A clamping spring is arranged between the sealing bead 65 and one end of the oil supply pipe 63. One end of the clamping spring is fixedly connected to one end of the oil supply pipe 63, and the other end of the clamping spring is connected to the sealing bead 65. A diameter reduction section is provided at the end of the oil drain hole 622 near the inner wall of the oil covering tank 621. The sealing bead 65 can movably seal the oil drain hole 622.

[0061] Under normal conditions, the oil pump injects lubricating oil from the oil reservoir 64 into the oil delivery pipe 63. The lubricating oil presses the sealing beads 65 against the reduced diameter section. At this time, some of the sealing beads 65 protrude above the inner wall of the oil coating groove 621. Once the pipe to be formed is placed in the oil coating groove 621, the pipe will squeeze the sealing beads 65, and the oil delivery pipe 63 will discharge the lubricating oil outward through the oil drain hole 622. During this period, the oil pump will provide a high-pressure environment for the discharge of the lubricating oil. Therefore, at the moment the sealing beads 65 are moved down, the lubricating oil will gush out of the oil drain hole 622 and quickly spray the lubricating oil on the bent outer side of the pipe to be formed.

[0062] In addition, a servo robot for picking up and placing the front beam 11 is also installed on one side of the frame 2. The servo robot is electrically connected to the control front.

[0063] More specifically, after the pre-bent and processed pipe is placed in the first mold cavity 411, the fixed mold 41 and the moving mold 42 close together. The sealing drive will drive the two sets of punches 512 to extend into the first injection port 431 and the second injection port 432 respectively. At the same time, the air pump 442 drives the partition block 441 to push outward. The two sets of partition blocks 441 are respectively pressed against both sides of the pipe in the width direction, and cooperate with the two sets of punches 512 to divide the cavity 43 into two independent closed chambers, namely the first chamber and the second chamber. Immediately, the first injection pump 53 injects emulsion into the pipe through the injection head 52. Simultaneously, the displacement drive 454 moves the filling pipe 451 to one side of the first chamber. The second injection pump 453 injects emulsion into the first chamber. In the initial stage of water expansion molding, the pipe is axially fed under the squeezing action of the punch 512. The material at both ends of the raw material migrates to the deformation area under the squeezing action. During this process, the controller 21 synchronously controls the air pump 442 to drive the partition block 441 to slowly retract inward. During this process, since the second chamber is not filled with liquid medium, there is no effective support on the outside of the pipe bend, and only lubricating oil is applied to the outside of the bend. On the inside of the pipe bend, there is liquid medium support. This causes the outside of the pipe bend to preferentially form wrinkles on the outside of the bend under the squeezing action of the punch 512. Meanwhile, since the punch 512 is equipped with abutment 54, when the punch 512 acts on both ends of the pipe, it will squeeze the first abutment bladder 542 and the second abutment bladder 543. At this time, since the aperture of the first flow limiting plate 548 is larger than the aperture of the second flow limiting plate 549, the hydraulic oil in the first abutment bladder 542 will be injected into the third chamber 5412 faster. Conversely, the hydraulic oil in the second abutment bladder 543 will be injected into the fourth chamber 5413 relatively slowly. This results in a difference in the force exerted by the abutment plate 544, which abuts against one end of the pipe, on both sides of the pipe. Specifically, the force exerted on the outside of the bend will be greater than the force exerted on the inside of the bend. After the punch 512 completes its stroke, the first injection pump 53 increases the hydraulic pressure into the pipe, the synchronous air pump 442 completely retracts the partition block 441, and the second injection pump 453 draws the liquid out of the first chamber, so that the pipe fully fits the cavity 43 under the action of hydraulic pressure, thereby completing the water expansion molding.

[0064] The implementation principle of the new energy vehicle battery box, integrated molding equipment and molding process in this application embodiment is as follows: In the actual working process, the pre-bent square tube is first placed in the first mold cavity 411 of the fixed mold 41. Then, the hydraulic drive 3 drives the moving mold 42 to move downward, so that the moving mold 42 and the fixed mold 41 close to form a complete cavity 43. At the same time, under the action of the sealing drive 513, the two sets of sealing parts 51 extend into the first injection port 431 and the second injection port 432 respectively to seal both ends of the tube. Subsequently, the air pump 442 drives the two sets of partition blocks 441 to extend outward, so that they abut against the outer walls on both sides of the tube in the width direction, thereby cooperating with the punch 512 to divide the cavity 43 into two independent spaces, the first chamber and the second chamber. Next, the first injection pump 53 injects emulsion into the pipe through the injection head 52 to form internal pressure. At the same time, the displacement drive 454 drives the filling pipe 451 to move towards the first chamber. The second injection pump 453 injects liquid medium into the first chamber. In the initial stage of water expansion molding, the punch 512 moves forward under the action of the sealing drive 513, generating axial extrusion on both ends of the pipe, causing the material to migrate to the bending deformation area, thus realizing axial material replenishment.

[0065] During the material replenishment process, since the outer side of the bend lacks liquid support, and the lubrication component 6 sprays lubricating oil on the outer side of the bend to reduce the frictional resistance on that side, the material on the outer side of the bend preferentially forms a controllable folded storage area under axial compression; while the inner side of the bend can maintain cross-sectional stability due to the support provided by the liquid medium. At the same time, when the punch 512 pushes the abutment plate 544 to compress the first abutment bladder 542 and the second abutment bladder 543, the hydraulic oil in the first abutment bladder 542 flows faster because the diameter of the first flow limiting hole 5481 is larger than that of the second flow limiting hole 5491, causing the abutment force on the corresponding side to decrease rapidly; while the hydraulic oil in the second abutment bladder 543 flows slower, keeping the abutment force on the other side larger, thus forming an asymmetrical axial feeding force distribution in the width direction of the pipe, allowing the outer side of the bend to receive a larger amount of material. After the punch 512 completes the axial feeding stroke, the first injection pump 53 further increases the hydraulic pressure inside the pipe, while the air pump 442 drives the partition block 441 to retract completely, reconnecting the two originally separated chambers; simultaneously, the second injection pump 453 extracts the liquid from the first chamber, creating a relative release space outside the pipe; at this time, under the action of the high-pressure liquid inside the pipe, the pipe wall is evenly expanded outward and fully fits the cavity 43, achieving precise shaping and final shaping of the cross-section after bending.

[0066] This application also discloses a molding process for a battery box for new energy vehicles, including the following steps: S1. Pipe preforming: The square pipe is pre-bent using a bending equipment to give the pipe a spatial profile that is basically consistent with the overall direction of the target side beam, thus forming the pipe. S2. Lubrication pretreatment: The robot places the pipe on the lubrication seat 62 and sprays lubricating oil on the outer surface of the pre-bent pipe. S3. Loading and mold closing: The pipe is placed into the first mold cavity 411. Then, the moving mold 42 and the fixed mold 41 are driven to close, so that the first mold cavity 411 and the second mold cavity 421 form a complete cavity 43. At the same time, the air pump 442 drives the partition block 441 in the partition 44 to push outward, so that the partition block 441 abuts against the outer wall of the pipe, thereby forming two mutually isolated chambers inside the cavity 43, namely the first chamber and the second chamber. S4, Axial feeding and wrinkle induction, the sealing drive 513 drives the punch 512 to advance along the pipe axis, apply axial extrusion force to both ends of the pipe, causing the pipe material to migrate to the bending area, and at the same time inject emulsion into the pipe through the first injection pump 53 to form internal pressure support. During this stage, liquid medium is injected into the first chamber through the second injection pump 453, while the second chamber remains unfilled, so that the inner side of the bend is liquid-supported, while the outer side of the bend is in a relatively free state. Under the action of axial compression, the outer side of the bend preferentially forms controllable folds to provide material reserves for subsequent cross-section shaping. S5. Differentiated loading: During the advancement of the punch 512, the first abutting bladder 542 and the second abutting bladder 543 in the abutting member 54 are pressurized and hydraulic oil flows. Since the diameter of the first flow limiting hole 5481 is larger than that of the second flow limiting hole 5491, the abutting plate 544 generates different forces on both sides of the tube, so that the clamping force acting on the outside of the bend is greater than that on the inside of the bend, thereby further promoting the material accumulation and wrinkle formation on the outside of the bend. S6. Internal high-pressure expansion forming: After the axial feeding is completed, the air pump 442 drives the partition block 441 to retract to release the cavity 43 partition. At the same time, the second injection pump 453 extracts the liquid from the first chamber. Then, the first injection pump 53 continues to increase the internal hydraulic pressure of the pipe, so that the pipe undergoes radial expansion under the action of internal high pressure, so that the originally formed wrinkles are stretched and unfolded, and the outer wall of the pipe fully fits the cavity 43, thereby restoring and accurately reshaping the square cross section. S7. Shaping and demolding: After the tube is fully fitted into the cavity 43 and the set forming pressure is reached, stop pressurizing, then release the hydraulic pressure and open the mold to remove the formed front side beam 11 or rear side beam 12 structural component, resulting in an integrated side beam without weld seams.

[0067] The above are all optional embodiments of this application and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A battery box for a new energy vehicle, characterized in that, The front beam (11), the rear beam (12) and two sets of side beams (13) are connected end to end to form a rectangular frame. The front beam (11) and the rear beam (12) are both made as an integral structure by an integral molding process, and the front beam (11) has a consistent cross-sectional shape along its own length direction. A rectangular frame is provided with a crossbeam (14) and a longitudinal beam (15). The crossbeam (14) and the longitudinal beam (15) are arranged perpendicularly to each other. One end of the crossbeam (14) is fixedly connected to a set of side beams (13). One end of the longitudinal beam (15) is fixedly connected to the front beam (11). The other end of the longitudinal beam (15) is fixedly connected to the rear beam (12). The crossbeam (14) and the longitudinal beam (15) divide the rectangular frame to form multiple sets of receiving cavities (16) for accommodating battery modules.

2. An integrated molding equipment for a new energy vehicle battery box, used to produce the new energy vehicle battery box as described in claim 1, characterized in that, include: A frame (2) is provided with a controller (21) on one side. A lower template (22) and an upper template (23) are provided on the frame (2). The lower template (22) is fixed on the frame (2). The upper template (23) is slidably disposed on the frame (2). A hydraulic drive component (3) is provided on the frame (2). The output end of the hydraulic drive component (3) is connected to the upper template (23). The hydraulic drive component (3) can drive the upper template (23) to reciprocate on the frame (2). A molding die (4) includes a fixed die (41) and a moving die (42). The fixed die (41) is fixed on the lower template (22), and the moving die (42) is fixed on the upper template (23). The fixed die (41) has a first mold cavity (411), and the moving die (42) has a second mold cavity (421). When the fixed die (41) and the moving die (42) are closed, the first mold cavity (411) and the second mold cavity (421) are combined to form a complete cavity (43). One end of the cavity (43) is provided with a first injection port (431), and the other end of the cavity (43) is provided with a second injection port (432). The feeding assembly (5) includes a plugging component (51), an injection head (52), and a first injection pump (53). The plugging component (51) and the first injection pump (53) are both mounted on the frame (2). The injection head (52) is mounted on the plugging component (51) and is connected to the first injection pump (53). There are two sets of plugging components (51). The two sets of plugging components (51) are symmetrically arranged along the length of the frame (2). The two sets of plugging components (51) can respectively block the first injection port (431) and the second injection port (432).

3. The integrated molding equipment for a new energy vehicle battery box according to claim 2, characterized in that: The sealing component (51) includes a mounting base (511), a punch (512), and a sealing drive component (513). The mounting base (511) is fixed on the frame (2), the sealing drive component (513) is fixed on the mounting base (511), the punch (512) is fixed on the output end of the sealing drive component (513), the sealing drive component (513) is electrically connected to the controller (21), and the end of the punch (512) facing away from the sealing drive component (513) is adapted to the shape of the first injection port (431). The sealing drive component (513) is used to drive the punch (512) to reciprocate.

4. The integrated molding equipment for a new energy vehicle battery box according to claim 3, characterized in that: The feeding assembly (5) further includes an abutment (54), which includes an abutment seat (541), a first abutment bladder (542), a second abutment bladder (543), and an abutment plate (544). The abutment seat (541) is fixed on the side of the punch (512) facing away from the mounting base (511). A liquid storage tank (5411) is provided on the abutment seat (541), and a partition plate (545) is fixed inside the liquid storage tank (5411). The partition plate (545) divides the liquid storage tank (5411) into two equal chambers, which are respectively designated as a third chamber (5412) and a fourth chamber. The third chamber (5413) and the fourth chamber (5413) are connected to each other through the connecting port (5451) on the side of the partition plate (545) near the punch (512). A first sliding plate (546) is slidably disposed in the third chamber (5412), and a second sliding plate (547) is slidably disposed in the fourth chamber (5413). A first flow limiting plate (548) is fixedly disposed in the third chamber (5412), and the first flow limiting plate (548) is located away from the connecting port (5451) on the first sliding plate (546). On one side, the first flow limiting plate (548) is evenly provided with a plurality of first flow limiting holes (5481), and the fourth chamber (5413) is fixedly provided with a second flow limiting plate (549). The second flow limiting plate (549) is located on the side of the second sliding plate (547) away from the connecting port (5451). The second flow limiting plate (549) is evenly provided with a plurality of second flow limiting holes (5491). The diameter of the first flow limiting hole (5481) is larger than the diameter of the second flow limiting hole (5491). The first abutting bladder (542) and the second abutting bladder (543) are both fixedly provided on the punch (512). The first abutment bladder (542) is connected to the third chamber (5412) through the first flow limiting hole (5481), and the second abutment bladder (543) is connected to the fourth chamber (5413) through the second flow limiting hole (5491). The first abutment bladder (542) and the second abutment bladder (543) are filled with hydraulic oil, and the abutment seat (541) is filled with a certain amount of hydraulic oil. The abutment plate (544) is fixed on the side of the first abutment bladder (542) and the second abutment bladder (543) opposite to the abutment seat (541). The abutment plate (544) is in movable contact with the outer wall of the pipe.

5. The integrated molding equipment for a new energy vehicle battery box according to claim 4, characterized in that: The fixed mold (41) is provided with a partition (44), which includes a partition block (441) and an air pump (442). A sliding groove (412) is provided on the bottom wall of the first mold cavity (411). The partition block (441) is slidably disposed in the sliding groove (412). The side of the partition block (441) away from the sliding groove (412) is in contact with the outer wall of the pipe. The air pump (442) is disposed on the frame (2). The air pump (442) is electrically connected to the controller (21). The output end of the air pump (442) is connected to the sliding groove (412) in a transmission manner. The air pump (442) can inject compressed air into the sliding groove (412), thereby driving the partition block (441) to rise or retract.

6. The integrated molding equipment for a new energy vehicle battery box according to claim 5, characterized in that: The fixed mold (41) is also provided with a liquid filling component (45), which includes a liquid filling pipe (451), a plug (452), a second liquid injection pump (453), and a displacement drive component (454). The liquid filling pipe (451) slides through the fixed mold (41). A receiving groove (413) is provided on the inner wall of the first mold cavity (411). One end of the liquid filling pipe (451) extends into the receiving groove (413). The plug (452) is fixed at one end of the liquid filling pipe (451) near the first mold cavity (411). The plug (452) is adapted to the shape of the receiving groove (413), and the plug (452) is tightly sealed to the receiving groove (413). The end of the liquid filling pipe (451) facing away from the first mold cavity (411) has... An outlet (4511) is provided. The second injection pump (453) is fixed on the frame (2). The second injection pump (453) is electrically connected to the controller (21). The second injection pump (453) is driven to the end of the filling pipe (451) away from the plug (452). A support frame (414) is fixed on the outer wall of the fixed mold (41). The displacement drive (454) is fixed on the support frame (414). The displacement drive (454) is electrically connected to the controller (21). The output end of the displacement drive (454) is connected to the end of the filling pipe (451) away from the plug (452). The displacement drive (454) can drive the filling pipe (451) to reciprocate on the fixed mold (41).

7. The integrated molding equipment for a new energy vehicle battery box according to claim 6, characterized in that: A liquid storage tank (55) is provided on one side of the frame (2). The liquid storage tank (55) is filled with emulsion. The input end of the first injection pump (53) is connected to the liquid storage tank (55) in a drive connection. The input end of the second injection pump (453) is also connected to the liquid storage tank (55) in a drive connection.

8. The integrated molding equipment for a new energy vehicle battery box according to claim 7, characterized in that: It also includes a lubrication assembly (6), which includes a support platform (61), a lubrication seat (62), an oil supply pipe (63), and an oil storage box (64). The support platform (61) is located on one side of the frame (2). The lubrication seat (62) is fixed on the support platform (61) and has an oil covering groove (621). The oil storage box (64) is fixed on the support platform (61) and is filled with lubricating oil. (62) has an oil drain hole (622) on it. One end of the oil supply pipe (63) is connected to the oil storage box (64). The end of the oil supply pipe (63) away from the oil storage box (64) is set in the oil drain hole (622). The oil supply pipe (63) is connected to the oil covering groove (621) through the oil drain hole (622). A sealing bead (65) is slidably arranged in the oil drain hole (622). The sealing bead (65) can actively seal the oil drain hole (622).

9. A molding process applicable to the battery box body of a new energy vehicle according to any one of claims 2-8, characterized in that: The following steps are adopted: S1. The bending equipment pre-bends the square tube to obtain a tube with a spatial profile that is basically consistent with the overall direction of the target side beam. S2. Place the pipe on the lubrication seat (62) and spray lubricating oil on the outer surface of the pipe when it is bent. S3. Place the pipe into the fixed mold (41), and then drive the moving mold (42) to close with the fixed mold (41), so that the first mold cavity (411) and the second mold cavity (421) form a complete cavity (43). At the same time, the air pump (442) drives the partition block (441) in the partition (44) to push outward, so that the partition block (441) abuts against the outer wall of the pipe, thereby forming two mutually isolated chambers inside the cavity (43), namely the first chamber and the second chamber. S4. The sealing drive (513) drives the punch (512) to advance along the pipe axis, applying axial extrusion force to both ends of the pipe, causing the pipe material to migrate to the bending area, and at the same time injecting emulsion into the pipe through the first injection pump (53) to form internal pressure support. The second injection pump (453) injects liquid medium into the first chamber, while the second chamber remains unfilled, so that the inner side of the bend is liquid-supported, while the outer side of the bend is in a relatively free state. Under the action of axial compression, the outer side of the bend preferentially forms controllable folds to provide material reserves for subsequent cross-section shaping. S5. During the advancement of the punch (512), the first abutting bladder (542) and the second abutting bladder (543) in the abutting part (54) are pressurized and hydraulic oil flows. Since the diameter of the first flow limiting hole (5481) is larger than the diameter of the second flow limiting hole (5491), the abutting plate (544) generates different forces on both sides of the pipe, so that the clamping force acting on the outside of the bend is greater than the clamping force on the inside of the bend, so as to further promote the material accumulation and wrinkle formation on the outside of the bend. S6. After the axial feeding is completed, the air pump (442) drives the partition block (441) to retract to release the cavity (43) partition. At the same time, the second injection pump (453) extracts the liquid from the first chamber. Then the first injection pump (53) continues to increase the internal hydraulic pressure of the pipe, so that the pipe undergoes radial expansion under the action of internal high pressure, so that the originally formed wrinkles are stretched and unfolded, and the outer wall of the pipe fully fits the cavity (43), thereby restoring and accurately reshaping the square cross section. S7. After the pipe is fully fitted into the cavity (43) and the set forming pressure is reached, stop pressurizing, then release the hydraulic pressure and open the mold to take out the formed front side beam (11) or rear side beam (12) structural parts to obtain an integrated side beam without weld seams.

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