A 3D printing detection tool for copper plate sheet metal parts and a manufacturing method thereof

Abstract

The application relates to a 3D printing detection tool for a copper bar sheet metal part and a manufacturing method thereof, and relates to the technical field of detection equipment. The detection tool comprises a tool body, the tool body is formed by 3D printing of a plastic material, a detection profile is arranged on the upper side of the tool body, and the detection profile is used for matching the theoretical shape of the copper bar to be detected. A plurality of positioning pins are arranged on the tool body, the positioning pins are made of a metal material, the positioning pins are used for plug-in cooperation with reference holes on the copper bar to be detected, the positioning pins are vertically arranged and located above the detection profile, and the lower end of the positioning pin is connected with the tool body. The tool body is formed by 3D printing, which can effectively reduce the development and manufacturing period and manufacturing cost of the detection tool, so that the iteration optimization efficiency of the copper bar is improved and the production cost is reduced.

Description

Technical Field

[0001] This application relates to the technical field of testing equipment, and in particular to a 3D-printed testing fixture for copper busbar sheet metal parts and its manufacturing method. Background Technology

[0002] In the field of new energy, especially in electric vehicles and energy storage systems, copper busbars are key conductive connection components, and their dimensional accuracy directly affects the assembly safety and electrical connection reliability of battery packs. To ensure the product quality of copper busbars, specialized inspection fixtures (i.e., inspection tools) are typically used to quickly inspect the key geometric dimensions of the copper busbars, such as their outline and hole positions, to verify whether they meet design standards.

[0003] Currently, in existing technologies, the inspection fixtures used for quality inspection of copper busbars are typically made of metal materials (such as steel and aluminum). Their manufacturing process mainly relies on CNC (Computer Numerical Control) machining, that is, machining metal blanks into solid tooling with inspection surfaces that match the workpiece being tested through subtractive manufacturing. Due to the material properties, these metal inspection fixtures usually possess high mechanical strength and good inspection accuracy, making them a widely used inspection tool in the industry.

[0004] Regarding the aforementioned technologies, the use of metal gauges and CNC machining results in high manufacturing costs and long processing cycles for a single gauge. Especially during the R&D phase of new energy products, product designs often undergo frequent changes and iterations. If even a minor modification occurs to the copper busbar design, the existing metal gauges are often difficult to modify and must be scrapped, requiring remanufacturing. Therefore, limited by long development and manufacturing cycles and high manufacturing costs, existing metal gauges severely restrict the improvement of efficiency in copper busbar iteration optimization and the reduction of production costs when facing the development, verification, and quality inspection needs of multi-variety, small-batch, and rapidly iterating copper busbars. Summary of the Invention

[0005] This application provides a 3D printed inspection fixture for copper busbar sheet metal parts and its manufacturing method, the purpose of which is to reduce the development and manufacturing cycle and manufacturing cost of the inspection fixture, thereby improving the efficiency of copper busbar iterative optimization and reducing production costs.

[0006] Firstly, the 3D printing inspection fixture for copper busbar sheet metal parts provided in this application adopts the following technical solution: A 3D-printed inspection fixture for copper busbar sheet metal parts includes a fixture body, which is formed by 3D printing from plastic material. The upper side of the fixture body has an inspection surface that matches the theoretical shape of the copper busbar to be tested. The fixture body has several positioning pins made of metal, which are used to engage with reference holes on the copper busbar to be tested. The positioning pins are vertically positioned above the inspection surface, and their lower ends are connected to the fixture body.

[0007] By adopting the above technical solution, since the inspection surface matches the theoretical shape of the copper busbar to be tested, when the copper busbar is placed on the fixture body, the locating pin engages with the reference hole. Thus, under the action of the locating pin, the copper busbar is positioned on the fixture body, restricting its degrees of freedom, while simultaneously verifying whether the diameter and position of the reference hole meet the design requirements. Furthermore, by observing the degree of fit between the copper busbar and the inspection surface, the bending angle and contour shape of the copper busbar can be directly judged to determine whether they are qualified. This enables rapid inspection of the copper busbar, quickly determining its qualification and fulfilling the function of the inspection fixture.

[0008] Building upon this foundation, since the tooling body is manufactured using 3D printing, unlike existing metal inspection fixtures which rely on cutting and shearing processes, 3D printing eliminates the need for complex CNC toolpath programming, tooling preparation, and multiple machining steps. Instead, it directly forms a single piece based on 3D model data through material stacking. This manufacturing method simplifies the transformation process of inspection tooling from design data to physical products, significantly reducing processing time and lowering material and labor costs. Furthermore, when the inspection tooling design changes, only the model data needs to be adjusted in the software for rapid reprinting. This effectively reduces the development and manufacturing cycle and cost of inspection tooling, thereby improving the efficiency of copper busbar iteration optimization and reducing production costs.

[0009] Furthermore, by using plastic materials in conjunction with 3D printing to manufacture the tooling body, on the one hand, the low density and low molding temperature of plastic make the 3D printing of inspection tooling more efficient; on the other hand, the relatively low market price of plastic consumables further reduces the manufacturing cost of inspection tooling.

[0010] Furthermore, during the inspection of the copper busbar, the locating pin is subjected to repeated scratches and impacts from the edge of the reference hole of the copper busbar under test. To address this, the locating pin is made of metal, utilizing the inherent high hardness and excellent wear resistance of the metal to effectively resist such mechanical wear and prevent deformation or dimensional reduction due to long-term stress. This avoids a decrease in positioning accuracy caused by locating pin wear, thus ensuring the long-term stability of the inspection results and extending the service life of the inspection fixture.

[0011] Optionally, the tooling body is made of polylactic acid or ABS engineering plastic.

[0012] By adopting the above-mentioned technical solutions, polylactic acid (PLA) and ABS engineering plastics are the most mature thermoplastic materials in fused deposition modeling (FDM) 3D printing. Utilizing the low density, low cost, and good processing flow properties of these two materials, on the one hand, the weight of the tooling body can be reduced, alleviating the hand burden on operators during batch testing and improving work efficiency; on the other hand, compared with existing metal materials or high-performance specialty engineering plastics, the raw material market price of PLA and ABS is low, which can minimize the manufacturing cost of the testing tooling. Simultaneously, the thermal shrinkage properties of these two materials have been widely understood through industrial practice, and combined with the shrinkage compensation method of this application, molding accuracy can be more easily controlled, balancing the economy and functionality of the testing tooling.

[0013] Optionally, a plurality of positioning holes are provided on the detection surface, and the positioning pins are provided in a one-to-one correspondence with the positioning holes, and the positioning pins are inserted into the corresponding positioning holes.

[0014] By adopting the above technical solution, the locating pin and the tooling body are designed as separate structures, assembled and connected through locating holes. This structure avoids the problems of weak interlayer bonding, insufficient shear strength, and difficulty in controlling printing accuracy that may occur when directly printing slender locating pins as a single unit during 3D printing. At the same time, this design gives the locating pin independent replaceability. When the locating pin is damaged or worn due to long-term use, only the locating pin needs to be disassembled and replaced, without scrapping the entire inspection tooling, thereby extending the overall service life of the inspection tooling and reducing maintenance costs.

[0015] Optionally, the locating pin is interference-fitted with the corresponding locating hole.

[0016] By adopting the above technical solution, the interference fit formed by the dimensional tolerances of the locating pin and the locating hole generates radial pressure and friction after assembly, improving the stability of the locating pin fixation without the need for threaded fasteners or adhesives. This connection method not only simplifies the assembly steps and improves assembly efficiency, but also effectively resists the vibration and lateral force generated by repeated insertion and removal of the copper busbar during the testing process, preventing the locating pin from loosening or falling off, and ensuring the stability of the testing and positioning.

[0017] Optionally, the locating pin is made of carbide or stainless steel.

[0018] By adopting the above technical solutions, both cemented carbide and stainless steel possess excellent mechanical strength and wear resistance, with surface hardness far exceeding that of the copper material of the tested busbar and the plastic of the fixture body. During frequent insertion and removal tests, the locating pin, as the core force-bearing and positioning component, directly bears the rigid impact and scratches from the edge of the copper busbar reference hole. Using cemented carbide or stainless steel effectively resists this continuous mechanical wear, preventing surface scratches, deformation, or diameter reduction in the locating pin due to long-term use. This ensures the long-term stability of the positioning reference of the testing fixture, extends the service life of the testing fixture, and also avoids the risk of contaminating the surface of the tested copper busbar due to rust on the locating pin.

[0019] Optionally, a detection through hole is provided on the detection surface, and the detection through hole is configured to be aligned with the mounting hole on the copper busbar to be tested.

[0020] By adopting the above technical solution, after the copper busbar is positioned and installed, the inspection through-hole and the mounting hole on the copper busbar are aligned, providing operators with a visual observation channel. Operators can directly visually inspect whether there is any misalignment between the mounting hole and the inspection through-hole, or use a standard go / no-go gauge to pass through the mounting hole and into the inspection through-hole. With this design, once the copper busbar is installed on the fixture, it is possible to quickly and qualitatively determine whether there is any significant deviation in the position of the copper busbar mounting hole, thereby improving the efficiency of on-site inspection.

[0021] Optionally, a reinforcing rib is provided on the side of the tooling body opposite to the detection surface, and the reinforcing rib is integrally formed with the tooling body.

[0022] By adopting the above technical solution, the tooling body is supported and reinforced using a reinforcing rib structure, thereby enhancing its structural rigidity. During the 3D printing manufacturing stage and subsequent cooling process of the tooling body, the reinforcing ribs can effectively resist the internal stress generated by material shrinkage, preventing the tooling body from warping and deforming. During use, they also prevent elastic deformation caused by pressure applied by the operator. This ensures the flatness of the inspection surface and the stability of the overall dimensions, thus guaranteeing the accuracy and reliability of the inspection results.

[0023] Optionally, the upper surface of the detection surface is covered with a wear-resistant layer, and the wear-resistant layer is a different color from the detection surface.

[0024] By adopting the above technical solution, during long-term testing and use, the wear-resistant layer is gradually worn away due to repeated contact and friction between the copper busbar under test and the test surface. When the surface wear-resistant layer is worn to a certain depth, the underlying test surface, which is a completely different color, will be revealed. This sharp color difference caused by wear creates an intuitive visual early warning mechanism, which can promptly alert operators that the wear in this area has exceeded the tolerance and that the surface accuracy of the testing fixture has failed. This avoids misjudging the copper busbar as qualified due to undetected hidden wear of the testing fixture, thus reducing the risk of misjudgment.

[0025] Optionally, the tooling body includes a support base and a detection panel. The detection panel is located above the support base and is detachably connected to the support base. The detection surface is located on the side of the detection panel opposite to the support base.

[0026] By adopting the above technical solution, the tooling body achieves a modular design through the coordinated design of the support base and the detection panel. The detection panel directly contacts the copper busbar and changes with the busbar design, while the support base primarily serves a structural support function. When the detection panel wears out due to long-term use, only a smaller, thinner detection panel needs to be reprinted for replacement, while the larger, more time-consuming support base can be retained and reused. This design significantly reduces the consumption of 3D printing materials, shortens the printing time required for maintenance and updates, and enables rapid maintenance and iteration at extremely low cost.

[0027] Secondly, the manufacturing method of a 3D printed inspection fixture for copper busbar sheet metal parts provided in this application adopts the following technical solution: A method for manufacturing a 3D-printed inspection fixture for copper busbar sheet metal parts, comprising at least the following steps: S1, establishing a theoretical three-dimensional model of the copper busbar and acquiring data of the theoretical three-dimensional model; S2, establishing inspection fixture model data based on the theoretical three-dimensional model of the copper busbar; S3, according to the shrinkage characteristics of the material used to manufacture the inspection fixture, superimposing a shrinkage rate compensation value of the corresponding material onto the inspection fixture model data, and generating inspection fixture printing data; S4, importing the inspection fixture printing data into a 3D printer, and the 3D printer printing the inspection fixture; S5, after the fixture body has cooled and solidified, installing the positioning pins to complete the manufacturing of the inspection fixture.

[0028] By adopting the above technical solution, this manufacturing method introduces a shrinkage compensation data processing step into the conventional printing process. Addressing the physical characteristic of thermoplastic materials shrinking in volume when cooling from a molten state to a solid state during 3D printing, resulting in smaller finished product dimensions, shrinkage compensation values ​​are pre-added in the model data stage. This pre-compensation processing of model data effectively offsets material shrinkage errors during the physical manufacturing process, enabling the final printed fixture's dimensional accuracy to be controlled at a high level (e.g., ±0.06mm). This ensures the accuracy of the inspection fixture while reducing its manufacturing cost, thereby guaranteeing the accuracy of copper busbar inspection.

[0029] In summary, this application includes at least one of the following beneficial technical effects: 1. The tooling body of this application is formed by 3D printing. This technology is based on three-dimensional model data and is integrally formed by material stacking. This manufacturing method simplifies the transformation process of the inspection tooling from design data to physical product, which not only shortens processing time and reduces material and labor costs, but also allows for rapid reprinting when the design of the inspection tooling changes, simply by adjusting the model data in the software. This effectively reduces the development and manufacturing cycle and cost of the inspection tooling, thereby improving the efficiency of copper busbar iterative optimization and reducing production costs.

[0030] 2. This application incorporates metal positioning pins embedded in a plastic tooling body. This structure retains the advantages of quick and low-cost manufacturing brought about by the combination of plastic materials and 3D printing technology in the tooling body. At the same time, it utilizes the high hardness and wear resistance of the metal positioning pins to make up for the shortcomings of poor wear resistance at key stress points of the tooling body. The metal positioning pins can withstand repeated scraping and impact from the reference holes of the copper busbar under test, thereby preventing the positioning accuracy from failing rapidly due to wear, and thus improving the durability and positioning accuracy of the testing tooling in the batch testing process.

[0031] 3. This application utilizes a double-layer structure design with different colors for the inspection surface and the wear-resistant layer. When the wear-resistant layer on the inspection surface is worn down to its limit, the lower inspection surface, with its distinctly different color, is revealed, creating a clear color contrast. This intuitive and visual wear indication can promptly alert operators that the precision of their workpieces has failed, solving the problem of existing inspection tools' wear being difficult to quantify and monitor, which can easily lead to misjudgments of product qualification, thus ensuring the reliability of quality control. Attached Figure Description

[0032] Figure 1 This is a schematic diagram of the overall structure of the testing fixture used in Embodiment 1 of this application when testing copper busbars.

[0033] Figure 2 This is a schematic diagram of the exploded structure of the testing fixture used in Embodiment 1 of this application when testing the copper busbar.

[0034] Figure 3 This is a schematic diagram of the overall structure of the bottom of the tooling body in Embodiment 1 of this application.

[0035] Figure 4 This is a schematic diagram of the overall structure of the testing fixture in Embodiment 2 of this application.

[0036] Figure 5 This is an exploded structural diagram of the testing fixture of Embodiment 2 of this application.

[0037] Figure 6 This is a schematic diagram of the overall structure of the detection panel in Embodiment 2 of this application.

[0038] Figure 7 This is a cross-sectional view of the detection panel in Embodiment 2 of this application.

[0039] Figure 8 yes Figure 7 A magnified schematic diagram of part A in the middle.

[0040] In the diagram, 1. Tooling body; 11. Support base; 111. Embedded hole; 112. Embedded nut; 113. Butt hole; 114. Reinforcing channel; 12. Inspection panel; 121. Mounting through hole; 122. Butt joint pipe; 13. Mounting bolt; 2. Inspection profile; 3. Positioning assembly; 31. Positioning pin; 32. Positioning hole; 4. Inspection through hole; 5. Reinforcing rib; 6. Wear-resistant layer; 7. Rigid support tube; 100. Copper busbar; 101. Reference hole; 102. Mounting hole. Detailed Implementation

[0041] The following is in conjunction with the appendix Figure 1 - Appendix Figure 8 This application will be described in further detail below.

[0042] Example 1: A 3D printed inspection fixture for copper busbar sheet metal parts, referring to... Figure 1 and Figure 2 The fixture includes a fixture body 1, which is formed by 3D printing. A detection surface 2 is formed on the upper side of the fixture body 1, and the outline of the detection surface 2 matches the theoretical three-dimensional shape of the copper busbar 100. A positioning component 3 is also provided on the fixture body 1. The positioning component 3 includes several positioning pins 31, and several positioning holes 32 are formed on the detection surface 2. The positioning pins 31 are located above the detection surface 2, are vertically arranged, and correspond one-to-one with the positioning holes 32. The lower end of the positioning pin 31 is coaxially inserted into the corresponding positioning hole 32.

[0043] Reference Figure 1 and Figure 2The position of the positioning pin 31 corresponds to the position of the reference hole 101 on the copper busbar 100 to be tested. When the copper busbar 100 to be tested is installed on the tooling body 1, the positioning pin 31 is inserted and engaged with the corresponding reference hole 101.

[0044] Based on the structural design of the testing fixture, when the copper busbar 100 to be tested is installed on the fixture body 1, the positioning pin 31 is inserted into the reference hole 101 on the copper busbar 100 to be tested, thereby constraining the position of the copper busbar 100 to be tested on the testing surface 2, ensuring that the copper busbar 100 to be tested is accurately positioned on the fixture body 1, and thus ensuring the accuracy of the testing results.

[0045] Reference Figure 2 In this embodiment, the tooling body 1 is made of plastic material. Specifically, it is integrally printed using a polymer thermoplastic material through FDM (Fused Deposition Modeling) process. The polymer thermoplastic material can be polylactic acid (PLA) or acrylonitrile-butadiene-styrene copolymer (ABS) engineering plastic.

[0046] When using plastic materials and 3D printing technology to manufacture the tooling body 1, on the one hand, such material selection can reduce the manufacturing cost and weight of the tooling body 1; on the other hand, using 3D printing technology to manufacture the tooling body 1 can increase the manufacturing speed of the tooling body 1, so that the manufacturing time of the tooling body 1 can be shortened to five hours, which makes the manufacturing speed of the tooling body 1 compatible with the iterative optimization speed of the copper busbar 100.

[0047] Reference Figure 2 In this embodiment, the locating pin 31 is made of metal. Specifically, it is made of cemented carbide or stainless steel standard parts, whose hardness is much higher than that of the tooling body 1.

[0048] During continuous testing, the copper busbar 100 on the fixture body 1 needs to be frequently disassembled and reassembled. At this time, the positioning pin 31 is the main stress point and friction point. Using metal material can improve the wear resistance and impact resistance of the positioning pin 31, prevent the detection accuracy from decreasing due to wear of the positioning pin 31, and thus extend the service life of the entire testing fixture.

[0049] Reference Figure 2 The positioning pin 31 and the positioning hole 32 are fixed by an interference fit, which can ensure the stability of the positioning pin 31 during repeated disassembly and assembly of the copper busbar 100 under test and reduce the possibility of the positioning pin 31 becoming loose.

[0050] In another embodiment, to further improve the stability of the positioning pin 31, adhesive can be applied to the inner wall of the positioning hole 32 before the positioning pin 31 is pressed into the positioning hole 32, so as to achieve dual fixation by adhesive bonding and interference fit.

[0051] Reference Figure 1 and Figure 4 The detection surface 2 is also provided with a detection through hole 4, which is opened in the vertical direction and the position of the detection through hole 4 corresponds to the position of the mounting hole 102 on the copper busbar 100 to be tested.

[0052] The diameter of the detection through-hole 4 is greater than or equal to the diameter of the mounting hole 102 on the copper busbar 100 to be tested. When the copper busbar 100 to be tested is installed on the fixture body 1, the detection through-hole 4 corresponds to the corresponding mounting hole 102 on the copper busbar 100 to be tested. Thus, the operator should be able to see the mounting hole 102 without obstruction through the detection through-hole 4, or a standard go / no-go gauge should be able to pass smoothly through the mounting hole 102 and enter the detection through-hole 4. If the position is off, the go / no-go gauge will not be able to pass or there will be obvious obstruction visible to the naked eye. This allows for rapid determination of the positional accuracy of the mounting hole 102.

[0053] Reference Figure 3 The tool body 1 is provided with a reinforcing rib 5 on the side away from the detection surface 2. The reinforcing rib 5 is preferably distributed in a triangular or honeycomb grid structure.

[0054] The reinforcing rib 5 is integrally printed with the tooling body 1, which can effectively enhance the structural rigidity of the tooling body 1 and prevent the tooling body 1 from warping due to material shrinkage during the 3D printing cooling process. It also prevents elastic deformation due to stress during use, thereby ensuring the flatness and detection accuracy of the detection surface 2.

[0055] In this embodiment, in order to facilitate the handheld inspection fixture to inspect the copper busbar 100, anti-slip stripes are designed on the fixture body 1 to improve the stability of the handheld inspection fixture.

[0056] The implementation principle of this application embodiment is as follows: When inspecting the copper busbar 100, the operator places the copper busbar 100 to be inspected on the fixture body 1. First, the reference hole 101 on the copper busbar 100 is fitted onto the corresponding positioning pin 31 for positioning and installation. Then, the copper busbar 100 is pressed to fit against the inspection surface 2, and the edges and surfaces of the copper busbar 100 are visually inspected to determine whether they fit tightly against the inspection surface 2, thereby judging whether the contour is qualified. Afterwards, a go / no-go gauge is inserted through the inspection through hole 4 or the coaxiality of the inspection through hole 4 and the corresponding mounting hole 102 is visually inspected to determine whether the position of the mounting hole 102 on the copper busbar 100 has shifted.

[0057] Because the tooling body 1 is manufactured using 3D printing, its manufacturing cost is low and its manufacturing speed is fast. When it is necessary to optimize and iterate the copper busbar 100, the 3D model data of the tooling body 1 can be adjusted accordingly, and then it can be reprinted. This allows the design and manufacturing speed of the tooling body 1 to be adapted to the iterative optimization speed of the copper busbar 100, thereby ensuring the optimization and iteration speed of the copper busbar 100.

[0058] This embodiment also discloses a method for manufacturing a 3D-printed inspection fixture for copper busbar sheet metal parts, including the following steps: S1. Establish a theoretical three-dimensional model of the copper busbar 100.

[0059] S2. Based on the theoretical 3D model of copper busbar 100, establish the tooling body model 1.

[0060] Specifically, in the 3D design software, the outer surface contour features of the 3D model of the copper busbar 100 are extracted; based on the contour features, a detection surface 2 entity that perfectly fits the shape of the copper busbar 100 is generated through Boolean operations or surface offset stretching; then, positioning holes 32 are designed on the entity at the positions corresponding to the reference holes 101 on the copper busbar 100, and detection through holes 4 are designed at the positions corresponding to the mounting holes 102 on the copper busbar 100, and reinforcing ribs 5 are added to finally form the tooling body 1 model.

[0061] S3. Based on the shrinkage characteristics of the material used to manufacture tooling body 1, superimpose the corresponding shrinkage rate compensation value of the material onto the tooling body 1 model, and generate the tooling body 1 printing data.

[0062] Specifically, because the FDM (Fused Deposition Modeling) process involves cooling thermoplastic materials from a high-temperature molten state to a room-temperature solid state, the material will shrink in volume due to thermal expansion and contraction and / or crystallization. To ensure the dimensional accuracy of the final product, shrinkage rate measurement and compensation must be performed beforehand. The specific procedures are as follows: Shrinkage determination: Design a standard-sized calibration block, for example, 20mm × 20mm × 20mm. Print the calibration block using the same printing parameters as the actual production block. After printing and cooling, measure the actual dimensions of the standard block and calculate the actual volume shrinkage rate of the corresponding material in the X, Y, and Z axis directions.

[0063] Setting the compensation value: When polylactic acid (PLA) is selected as the printing material, its shrinkage rate is relatively low and stable, typically measured to be 0.2%–0.5%. Therefore, in the slicing software, using the geometric center of the tooling model as a reference, the X / Y axis dimensions of the model are preset to be enlarged by 1.002 to 1.005 times, i.e., the shrinkage compensation value is 0.2%–0.5%. When ABS engineering plastic is selected as the printing material, its volume shrinkage rate is usually measured to be 0.4% to 0.8% due to its significant thermal shrinkage effect and large internal stress. Therefore, the X / Y axis dimensions of the model are preset to be enlarged by 1.004 to 1.008 times, that is, the shrinkage compensation value is 0.4%-0.8%.

[0064] Data generation: The 3D model after size enlargement compensation is sliced ​​to generate G-code that can be recognized by the printer, which is the printing data of tooling body 1.

[0065] S4. Import the printing data of tooling body 1 into the 3D printer, and the 3D printer prints tooling body 1.

[0066] Specifically, the printing data of the testing fixture is imported into the 3D printer, and the corresponding thermoplastic polymer (PLA or ABS) filament is loaded. During the printing process, the nozzle temperature and heated bed temperature are strictly controlled, and the fixture body 1 is printed by stacking layers.

[0067] S5. After the tooling body 1 has cooled and solidified, install the positioning pin 31 to complete the manufacturing of the testing tooling.

[0068] Specifically, after 3D printing is completed and the fixture body 1 has cooled sufficiently, the support structure on the fixture body 1 is removed. Then, using a press or fixture fixture, the locating pin 31 is vertically pressed into the corresponding locating hole 32. Since the locating hole 32 has been designed with an interference fit, the locating pin 31 can form a tight interference fit after being pressed into the corresponding locating hole 32, thereby completing the final assembly of the inspection fixture.

[0069] The implementation principle of this application embodiment is as follows: By using the above manufacturing method and shrinkage compensation at the software algorithm level, the problem of insufficient dimensional accuracy caused by material cooling shrinkage in 3D printing technology is effectively improved, so that the accuracy of the printed tooling body 1 can reach ±0.06mm, which meets the industrial inspection requirements.

[0070] Meanwhile, by combining the hybrid manufacturing process of embedding metal positioning pins 31, the advantages of 3D printing—fast, low-cost, and capable of manufacturing irregular structures—are retained, while the shortcomings of poor wear resistance of plastic materials are made up for. This results in a high-precision, long-life, and cost-effective rapid testing tooling manufacturing solution.

[0071] Example 2: A 3D printing inspection fixture for copper busbar sheet metal parts, referring to... Figure 4 and Figure 5The difference between this embodiment and the previous embodiment is that the tooling body 1 includes a general support base 11 and a detection panel 12. The detection panel 12 is disposed on the support base 11 and is detachably connected to the support base 11. The detection surface 2 is disposed on the upper surface of the detection panel 12.

[0072] With this design, the tooling body 1 achieves modular design through the cooperation of the support base 11 and the detection panel 12. When the detection panel 12 is worn out or damaged, it is only necessary to reprint the detection panel 12, remove the old detection panel 12 from the support base 11, and then install the reprinted detection panel 12 onto the support base 11. At this time, the tooling body 1 can continue to be used.

[0073] Reference Figure 5 and Figure 6 In this embodiment, the support base 11 has several pre-embedded holes 111, and pre-embedded nuts 112 are inserted into the pre-embedded holes 111. The pre-embedded holes 111 and the corresponding pre-embedded nuts 112 are snapped together or glued together. The detection panel 12 has several mounting through holes 121, which are arranged one-to-one with the pre-embedded holes 111 and are directly connected to each other. Several mounting bolts 13 are provided between the detection panel 12 and the support base 11. The mounting bolts 13 are arranged one-to-one with the mounting through holes 121, and the mounting bolts 13 pass through the corresponding mounting through holes 121 and are screwed together with the corresponding pre-embedded nuts 112.

[0074] With the cooperation of the pre-embedded nut 112 and the mounting bolt 13, the detection panel 12 can be fixed on the support base 11. This structure facilitates the quick replacement and maintenance of the detection panel 12.

[0075] Reference Figure 5 and Figure 6 Positioning holes 32 are all formed through the detection panel 12. Several connecting pipes 122 are arranged vertically below the detection panel 12, and their upper ends are fixedly connected to the detection panel 12. The positioning holes 32 correspond one-to-one with the connecting pipes 122, and are coaxially connected to each other. Positioning pins 31 correspond one-to-one with the connecting pipes 122, with their lower ends passing through the corresponding positioning holes 32 and coaxially engaging with the corresponding connecting pipes 122. Several mating holes 113 are provided on the support base 11, each corresponding one-to-one with the connecting pipes 122, and are coaxially engaged with the corresponding mating holes 113.

[0076] Based on the insertion and engagement of the connector 122 and the docking hole 113, not only is rapid positioning and connection between the detection panel 12 and the universal support base 11 achieved, but the positioning pin 31 can also obtain a longer support arm through the connector 122, thereby improving the verticality and resistance to lateral forces of the positioning pin 31 and ensuring positioning accuracy.

[0077] In this embodiment, refer to Figure 4 and Figure 6 The detection through hole 4 is also opened through the detection panel 12, and the support base 11 is also provided with a docking hole 113 corresponding to the detection through hole 4. There is also a connecting pipe 122 below the detection panel 12 that is directly connected to the detection through hole 4, and the connecting pipe 122 and the corresponding docking hole 113 are also coaxially inserted and engaged.

[0078] Reference Figure 7 and Figure 8 The surface of the detection panel 12 away from the support base 11 is covered with a wear-resistant layer 6. The wear-resistant layer 6 covers the detection surface 2 and is fixedly connected to the detection panel 12. The wear-resistant layer 6 and the detection panel 12 are made of the same material but have different colors.

[0079] Reference Figure 7 and Figure 8 In this embodiment, the detection panel 12 is made of red polylactic acid (PLA), and the wear-resistant layer 6 is made of white polylactic acid (PLA). The thickness of the wear-resistant layer 6 is 0.1 mm to 0.3 mm. The thickness range of the wear-resistant layer 6 corresponds to the maximum wear tolerance threshold allowed by the detection fixture. That is, when the wear depth of the detection fixture exceeds the maximum wear tolerance threshold, the dimensional accuracy of the detection fixture can no longer meet the detection requirements.

[0080] Specifically, the dual-layer, heterogeneous structure formed by the detection panel 12 and the wear-resistant layer 6 is manufactured using a multi-color FDM (Fused Deposition Modeling) 3D printing process. During 3D printing, red polylactic acid (PLA) filament is first loaded as the printing material, and the base portion of the detection panel 12 is printed layer by layer according to a preset path. When the printing height reaches the boundary between the detection panel 12 and the wear-resistant layer 6 (i.e., the remaining unprinted height equals the set thickness of the wear-resistant layer 6), the 3D printer is paused. Then, the printing material is switched to white PLA filament, and the printing program is resumed. At this point, the high-temperature molten white PLA filament extruded from the nozzle is directly deposited on the surface of the still partially cooled detection panel 12. Utilizing the fusion bonding properties of thermoplastic materials, the wear-resistant layer 6 and the detection panel 12 achieve a molecular-level thermal fusion bond at the interface. After the entire printing is completed and cooled, the wear-resistant layer 6 and the detection panel 12 form a tightly bonded, non-detachable integrated structure with a clear color boundary, thus providing a physical basis for wear determination.

[0081] Reference Figure 4 The support base 11 has several reinforcing channels 114 on its sidewalls. These channels 114 are axially arranged horizontally and penetrate the support base 11 along their own axial direction. A rigid support tube 7 is mounted on the support base 11, corresponding one-to-one with each reinforcing channel 114. The rigid support tube 7 is inserted into the corresponding reinforcing channel 114. The elastic modulus of the rigid support tube 7 is greater than the elastic modulus of the tooling body 1 material, and the rigid support tube 7 is bonded to the inner wall of the reinforcing channel 114 by adhesive or interference fit. In this embodiment, the rigid support tube 7 can be made of stainless steel or carbon fiber.

[0082] By inserting the rigid support tube 7, the support base 11 becomes a composite material structure, thereby improving the bending stiffness and thermal stability of the general support base 11 and reducing the possibility of deformation of the support base 11 after long-term use.

[0083] The implementation principle of this application embodiment is as follows: During the inspection of the copper busbar 100, the copper busbar 100 under test frequently comes into contact with and rubs against the inspection panel 12. Since the inspection panel 12 is provided with a wear-resistant layer 6, when the wear-resistant layer 6 is worn down to the preset tolerance limit, the substrate of the inspection panel 12 underneath is exposed and forms a sharp color difference contrast with the original color of the wear-resistant layer 6, thus intuitively alerting the operator that the inspection panel 12 has failed. At this time, the operator only needs to re-manufacture the corresponding inspection panel 12 by 3D printing, then disassemble the worn inspection panel 12 and replace it with a new inspection panel 12.

[0084] With this design, the bulky and time-consuming general support base 11 can be retained and reused, and only the thin and fast-printing inspection panel 12 needs to be replaced, thereby reducing the maintenance cost of the inspection tooling and shortening the downtime.

[0085] This embodiment also discloses a manufacturing method for a 3D printed inspection fixture for copper busbar sheet metal parts. The difference between this embodiment and Embodiment 1 is that: in step S2, independent three-dimensional models of the support base 11 and the inspection panel 12 need to be established respectively; in step S4, the printing process of the inspection panel 12 includes a multi-color printing process, that is, the base of the inspection panel 12 is printed first, and after reaching the preset height, it is paused and different colors of consumables are replaced to print the wear-resistant layer 6; in particular, for step S5, after the inspection panel 12 cools and solidifies, the positioning pin 31 is installed into the positioning hole 32 of the inspection panel 12; at the same time, the rigid support tube 7 is installed into the reinforcing channel 114 of the support base 11; finally, the inspection panel 12 with the positioning pin 31 installed is assembled onto the support base 11 by the mounting bolt 13 to complete the manufacturing of the inspection fixture.

[0086] The implementation principle of this application embodiment is as follows: During the testing process, the copper busbar 100 to be tested frequently comes into contact and rubs against the testing surface 2 covered with the wear-resistant layer 6. Utilizing the color difference between the wear-resistant layer 6 and the main body of the testing panel 12, when the wear-resistant layer 6 is worn down to its maximum thickness, the underlying testing panel 12 substrate, which is a completely different color, is exposed, forming an intuitive visual warning that indicates to the operator that the tooling accuracy has failed. At this time, thanks to the split modular design, the operator only needs to reprint a smaller, faster-forming testing panel 12 and disassemble and replace the failed old testing panel 12, while the larger, longer-printing support base 11 can be retained and reused. This method reduces the maintenance cost of the testing tooling and shortens the production line downtime caused by tooling wear while ensuring testing accuracy.

[0087] The embodiments described in this specific implementation are preferred embodiments of this application and are not intended to limit the scope of protection of this application. Identical components are represented by the same reference numerals. Therefore, all equivalent changes made to the structure, shape, and principle of this application should be covered within the scope of protection of this application.

Claims

1. A 3D-printed inspection fixture for copper busbar sheet metal parts, characterized in that, include: The tooling body (1) is formed by 3D printing of plastic material. The upper side of the tooling body (1) is provided with a detection surface (2), which is used to match the theoretical shape of the copper busbar (100) to be tested. The tooling body (1) is provided with a number of positioning pins (31). The positioning pins (31) are made of metal material. The positioning pins (31) are used to be inserted into the reference hole (101) on the copper busbar (100) to be tested. The positioning pins (31) are vertically arranged and located above the detection surface (2). The lower end of the positioning pins (31) is connected to the tooling body (1).

2. The 3D printing inspection fixture for copper busbar sheet metal parts according to claim 1, characterized in that, The tooling body (1) is made of polylactic acid or ABS engineering plastic.

3. The 3D printing inspection fixture for copper busbar sheet metal parts according to claim 1, characterized in that, The detection surface (2) is provided with a plurality of positioning holes (32), and the positioning pins (31) are provided in a one-to-one correspondence with the positioning holes (32), and the positioning pins (31) are inserted into the corresponding positioning holes (32).

4. The 3D printing inspection fixture for copper busbar sheet metal parts according to claim 3, characterized in that, The positioning pin (31) is interference-fitted with the corresponding positioning hole (32).

5. A 3D printing inspection fixture for copper busbar sheet metal parts according to claim 3, characterized in that, The positioning pin (31) is made of hard alloy or stainless steel.

6. A 3D printing inspection fixture for copper busbar sheet metal parts according to claim 1, characterized in that, The detection surface (2) is provided with a detection through hole (4), which is used to be aligned with the mounting hole (102) on the copper busbar (100) to be tested.

7. A 3D printing inspection fixture for copper busbar sheet metal parts according to claim 1, characterized in that, The tooling body (1) is provided with a reinforcing rib (5) on the side away from the detection surface (2), and the reinforcing rib (5) is integrally formed with the tooling body (1).

8. A 3D printing inspection fixture for copper busbar sheet metal parts according to claim 1, characterized in that, The upper surface of the detection surface (2) is covered with a wear-resistant layer (6), and the wear-resistant layer (6) is a different color from the detection surface (2).

9. A 3D printing inspection fixture for copper busbar sheet metal parts according to claim 1, characterized in that, The tooling body (1) includes a support base (11) and a detection panel (12). The detection panel (12) is located above the support base (11) and is detachably connected to the support base (11). The detection surface (2) is located on the side of the detection panel (12) away from the support base (11).

10. A method for manufacturing a 3D-printed inspection fixture for copper busbar sheet metal parts, used in the manufacturing of the 3D-printed inspection fixture for copper busbar sheet metal parts as described in any one of claims 1-9, characterized in that, At least the following steps are included: S1. Establish a theoretical three-dimensional model of the copper busbar (100); S2. Based on the theoretical three-dimensional model of copper busbar (100), establish the tooling body (1) model accordingly; S3. Based on the shrinkage characteristics of the material used to manufacture the tooling body (1), superimpose the corresponding shrinkage rate compensation value of the material on the tooling body (1) model and generate the tooling body (1) printing data. S4. Import the printing data of the tooling body (1) into the 3D printer, and the 3D printer prints the tooling body (1). S5. After the tooling body (1) has cooled and solidified, install the positioning pin (31) to complete the manufacturing of the testing tooling.

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