Ultrasonic welding inspection equipment for high-voltage wiring harness

Abstract

The utility model discloses ultrasonic welding inspection equipment and a welding inspection method for high-voltage wire harnesses, which have the advantages of nondestructive inspection, high inspection efficiency, convenience in use and strong practicability. According to the technical scheme, the device comprises a detection table, a first XY-axis sliding table, a second XY-axis sliding table and a Y-axis sliding table, the first XY-axis sliding table and the second XY-axis sliding table are oppositely arranged on the detection table, the Y-axis sliding table is arranged between the first XY-axis sliding table and the second XY-axis sliding table, a first detection assembly is arranged on the first XY-axis sliding table, and a second detection assembly is arranged on the second XY-axis sliding table. A workpiece fixing seat is arranged on the Y-axis sliding table; the first detection assembly comprises two positive electrode probes, a first buffer spring and a positive electrode probe mounting seat, and the two positive electrode probes are arranged at an interval.

Description

Technical Field

[0001] This utility model belongs to the field of new energy vehicles, and in particular relates to an ultrasonic welding inspection device for high-voltage wire harnesses. Background Technology

[0002] High-voltage wiring harnesses are key components of the high-voltage electrical systems in electric vehicles, and the connection quality between the harness cables and terminals has a significant impact on the safe and reliable operation of the high-voltage electrical system. Currently, there are three main methods for connecting high-voltage wiring harness cables to terminals: welding, crimping, and mechanical connection. Ultrasonic welding can achieve lower resistance and higher bonding strength, offering advantages over traditional welding methods, and has been widely used in the automotive industry in recent years. Traditionally, the welding quality inspection of high-voltage wiring harnesses and terminals is conducted according to the USCAR38 test method, requiring a resistance measurement point at least 100±3mm away from the welded end of the terminal. This method requires damaging the wiring harness during measurement, making it a destructive test and unsuitable for 100% product measurement in mass production. Utility Model Content

[0003] The technical problem to be solved by this utility model is to provide a high-voltage wire harness ultrasonic welding inspection equipment that is non-destructive, has high testing efficiency, is easy to use, and is highly practical.

[0004] To solve the above problems, the technical solution adopted by this utility model includes: a detection table, a first XY axis slide and a second XY axis slide oppositely disposed on the detection table, and a Y axis slide disposed between the first XY axis slide and the second XY axis slide. A first detection component is provided on the first XY axis slide, a second detection component is provided on the second XY axis slide, and a workpiece fixing seat is provided on the Y axis slide.

[0005] The first detection component includes a positive electrode probe, a positive electrode probe, a first buffer spring, and a positive electrode probe mounting base. The positive electrode probe consists of two pieces spaced apart. At least two of the positive electrode probes are movably inserted into the shaft holes at the rear ends of the positive electrode probes. The positive electrode probes are fixed on the positive electrode probe mounting base, with their rear ends extending out of the positive electrode probe mounting base. The first buffer spring is disposed between the positive electrode probes and the positive electrode probe mounting base. The positive electrode probe mounting base is mounted on the first XY axis slide.

[0006] The second detection component includes a negative electrode probe, a negative electrode probe, a second buffer spring, and a negative electrode probe mounting base. The negative electrode probe consists of two pieces spaced apart. At least two of the negative electrode probes are movably inserted into the shaft holes at the rear ends of the negative electrode probes. The negative electrode probes are fixed on the negative electrode probe mounting base, with their rear ends extending out of the negative electrode probe mounting base. The second buffer spring is disposed between the negative electrode probes and the negative electrode probe mounting base. The negative electrode probe mounting base is mounted on the second XY axis slide.

[0007] The positive electrode probe mounting base includes a fixed positive electrode probe mounting base and a movable positive electrode probe mounting base. Two positive electrode probes are mounted on the fixed positive electrode probe mounting base, and the other two positive electrode probes are mounted on the movable positive electrode probe mounting base. A first slide groove is provided on the first XY axis slide, and a slidable first nut is provided in the first slide groove. The movable positive electrode probe mounting base is connected to the first nut.

[0008] The negative electrode probe mounting base includes a fixed negative electrode probe mounting base and a movable negative electrode probe mounting base. Two negative electrode probes are mounted on the fixed negative electrode probe mounting base, and the other two negative electrode probes are mounted on the movable negative electrode probe mounting base. A second slide groove is provided on the second XY axis slide, and a slidable second nut is provided in the second slide groove. The movable negative electrode probe mounting base is connected to the second nut.

[0009] The workpiece fixing seat is provided with an L-shaped positioning groove and a photoelectric detection switch is provided above it.

[0010] Both the positive and negative electrode probes are rectangular, and their front ends are provided with serrated probe surfaces.

[0011] It also includes a benchmark verification motherboard.

[0012] The advantages of the high-voltage wire harness ultrasonic welding inspection equipment and welding detection method of this utility model are as follows:

[0013] 1. By aligning the detection component with the welding surface to perform micro-resistance measurement, the welding quality can be judged without damaging the insulation layer of the high-voltage wire harness, thus achieving non-destructive testing. It also has the advantages of high detection efficiency, ease of use, and strong practicality, and can achieve 100% inspection of products.

[0014] 2. By setting a retractable probe at the tip of the probe, the welding surface can be fully covered, which has the advantages of a large testing range and more accurate testing results. In addition, the interval between two adjacent probes is adjustable, which can meet the testing of high-voltage wire harnesses of different specifications.

[0015] The present invention will be further described below with reference to the accompanying drawings. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of the high-voltage wire harness ultrasonic welding inspection equipment of this utility model;

[0017] Figure 2 This is a side view of the ultrasonic welding inspection equipment for high-voltage wire harnesses of this utility model;

[0018] Figure 3 This is a schematic diagram of the structure of the first detection component of this utility model;

[0019] Figure 4 This is a schematic diagram of the structure of the second detection component of this utility model;

[0020] Figure 5 This is a schematic diagram of the structure of the first XY axis slide of this utility model;

[0021] Figure 6 This is a schematic diagram of the structure of the second XY axis slide of this utility model;

[0022] Figure 7 This is a schematic diagram of the structure of the positive electrode probe mounting base of this utility model;

[0023] Figure 8 This is a schematic diagram of the structure of the workpiece fixing seat of this utility model;

[0024] Figure 9 This is a schematic diagram of the structure of the reference verification motherboard of this utility model. Detailed Implementation

[0025] Reference Figures 1-9As shown, the high-voltage wire harness ultrasonic welding inspection equipment of this utility model includes a testing platform 1, a first XY-axis slide 2 and a second XY-axis slide 3 oppositely mounted on the testing platform 1, and a Y-axis slide 4 located between the first XY-axis slide 2 and the second XY-axis slide 3. The first XY-axis slide 2, the second XY-axis slide 3, and the Y-axis slide 4 each include a slider, a lead screw, a motor fixing module, and a stepper motor to achieve precise positional movement. A first detection component 5 is provided on the first XY-axis slide 2, a second detection component 6 is provided on the second XY-axis slide 3, and a workpiece fixing seat 7 is provided on the Y-axis slide 4. The first detection component 5 includes a positive electrode probe 8, a positive electrode probe 9, a first buffer spring 10, and a positive electrode probe mounting seat 11. The positive electrode probe 8 consists of two pieces spaced apart. Two positive electrode probes 9 are movably inserted into the shaft hole 12 at the rear end of the positive electrode probe 8. The positive electrode probe 8 is fixed on the positive electrode probe mounting base 11, with its rear end extending out of the positive electrode probe mounting base 11 for connection to a resistance tester. A first buffer spring 10 is disposed between the positive electrode probe 8 and the positive electrode probe mounting base 11, allowing the positive electrode probe 8 to extend and retract. The positive electrode probe mounting base 11 is mounted on the first XY axis slide 2. The second detection assembly 6 includes a negative electrode probe 13, a negative electrode probe 14, a second buffer spring 15, and a negative electrode probe mounting base 16. The negative electrode probe 13 consists of two pieces spaced apart. Two negative electrode probes 14 are movably inserted into the shaft hole 12 at the rear end of the negative electrode probe 13. The negative electrode probe 13 is fixed on the negative electrode probe mounting base 16, with its rear end extending out of the negative electrode probe mounting base 16 for connection to a resistance tester. The second buffer spring 15 is disposed between the negative electrode probe 13 and the negative electrode probe mounting base 16, allowing the negative electrode probe 13 to extend and retract. The negative electrode probe mounting base 16 is mounted on the second XY axis slide 3.

[0026] Preferably, the positive electrode probe mounting base 11 includes a fixed positive electrode probe mounting base 111 and a movable positive electrode probe mounting base 112, wherein two positive electrode probes 9 are mounted on the fixed positive electrode probe mounting base 111, and the other two positive electrode probes 9 are mounted on the movable positive electrode probe mounting base 112. The first XY axis slide 2 is provided with a first sliding groove 17, and a slidable first nut 18 is provided within the first sliding groove 17. The movable positive electrode probe mounting base 112 is connected to the first nut 18. Through the above structure, the interval between the two positive electrode probes 8 is adjustable.

[0027] Preferably, the negative electrode probe mounting base 16 includes a fixed negative electrode probe mounting base 161 and a movable negative electrode probe mounting base 162. Two negative electrode probes 14 are mounted on the fixed negative electrode probe mounting base 161, and the other two negative electrode probes 14 are mounted on the movable negative electrode probe mounting base 162. The second XY axis slide 3 is provided with a second sliding groove 19, and a slidable second nut 20 is provided in the second sliding groove 19. The movable negative electrode probe mounting base 162 is connected to the second nut 20. Through the above structure, the interval between the two negative electrode probes 13 is adjustable.

[0028] Preferably, the workpiece holder 7 is provided with an L-shaped positioning groove 21 to facilitate the fixing of the workpiece for inspection. Furthermore, a photoelectric detection switch 22 is provided above the workpiece holder 7 to confirm whether the test workpiece has been placed in the correct position.

[0029] Preferably, both the positive electrode probe 8 and the negative electrode probe 13 are rectangular, and their front ends are provided with serrated probe surfaces 23. The serrated probe surface design can significantly increase the contact area with the workpiece surface, thereby improving friction and fixation effect, and thus improving the accuracy of inspection.

[0030] Preferably, it also includes a reference calibration motherboard 24. The reference calibration motherboard 24 is made of the same conductor material as the high-voltage wiring harness, typically copper, to provide a reference value for resistance testing.

[0031] The inspection methods for the aforementioned high-voltage wire harness ultrasonic welding inspection equipment are as follows:

[0032] Step 1: By controlling the movement of the first XY axis slide, the second XY axis slide, and the Y axis slide, the first detection component, the second detection component, and the workpiece fixture are brought to the detection position.

[0033] Step 2: Place the reference calibration motherboard vertically on the workpiece holder. By controlling the X-axis movement of the first XY-axis slide, the second XY-axis slide, and the Y-axis slide, apply pressure to both sides of the end face of the reference calibration motherboard, and measure its resistance value. This measurement is used to determine the accuracy of the current inspection equipment. Since the reference resistance value of the reference calibration motherboard is fixed, if the measured resistance value deviates too much from the reference resistance value, the current measurement accuracy is considered unqualified, requiring adjustment or calibration.

[0034] Step 3: By controlling the movement of the first XY axis slide, the second XY axis slide and the Y axis slide, the first detection component and the second detection component are reset. After removing the reference calibration motherboard, the welding end face of the high voltage wire harness is placed vertically on the workpiece fixing seat.

[0035] Step 4: By controlling the movement positions of the first XY axis slide, the second XY axis slide, and the Y axis slide, the positive electrode probe and the negative electrode probe are respectively connected to the two sides of the welding end face of the high voltage wire harness, and the resistance value of the welding end face is measured by a resistance tester.

[0036] Step 5: Determine the welding quality by measuring the resistance value of the solder joint. If the resistance value is unstable or too high, there is a problem with the solder joint being incomplete, and the welding quality is deemed unqualified. The maximum allowable voltage drop or resistance requirements vary depending on the wire diameter; please refer to the table below:

[0037]

[0038] mΩ * Most dry circuit measuring instruments can directly display and read the values; alternatively, calculations can be performed using the formula 1mV / A = 1mΩ (for wire diameter > 6mm). 2 *The intermediate value of the conductor must meet the voltage drop or resistance requirements of the conductor of the larger specification.

[0039] As stated above, this is not intended to limit the present invention in any way. Although the present invention has been disclosed above with preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed structure and technical content to create equivalent embodiments without departing from the scope of the present invention. However, any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A high-voltage wire harness ultrasonic welding inspection device, characterized in that: The device includes a testing table (1), a first XY axis slide (2) and a second XY axis slide (3) disposed opposite to each other on the testing table (1), and a Y axis slide (4) disposed between the first XY axis slide (2) and the second XY axis slide (3). The first XY axis slide (2) is provided with a first testing component (5), the second XY axis slide (3) is provided with a second testing component (6), and the Y axis slide (4) is provided with a workpiece fixing seat (7). The first detection component (5) includes a positive electrode probe (8), a positive electrode probe (9), a first buffer spring (10), and a positive electrode probe mounting base (11). The positive electrode probe (8) consists of two pieces, which are spaced apart. At least two of the positive electrode probes (9) are movably inserted into the shaft hole (12) at the rear end of the positive electrode probe (8). The positive electrode probe (8) is fixed on the positive electrode probe mounting base (11), and its rear end extends out of the positive electrode probe mounting base (11). The first buffer spring (10) is disposed between the positive electrode probe (8) and the positive electrode probe mounting base (11). The positive electrode probe mounting base (11) is mounted on the first XY axis slide (2). The second detection component (6) includes a negative electrode probe (13), a negative electrode probe (14), a second buffer spring (15), and a negative electrode probe mounting base (16). The negative electrode probe (13) consists of two pieces spaced apart. At least two of the negative electrode probes (14) are movably inserted into the shaft hole (12) at the rear end of the negative electrode probe (13). The negative electrode probe (13) is fixed on the negative electrode probe mounting base (16) and its rear end extends out of the negative electrode probe mounting base (16). The second buffer spring (15) is disposed between the negative electrode probe (13) and the negative electrode probe mounting base (16). The negative electrode probe mounting base (16) is mounted on the second XY axis slide (3).

2. The high-voltage wire harness ultrasonic welding inspection equipment according to claim 1, characterized in that: The positive electrode probe mounting base (11) includes a fixed positive electrode probe mounting base (111) and a movable positive electrode probe mounting base (112). Two positive electrode probes (9) are mounted on the fixed positive electrode probe mounting base (111), and the other two positive electrode probes (9) are mounted on the movable positive electrode probe mounting base (112). The first XY axis slide (2) is provided with a first slide groove (17), and a slidable first nut (18) is provided in the first slide groove (17). The movable positive electrode probe mounting base (112) is connected to the first nut (18).

3. The high-voltage wire harness ultrasonic welding inspection equipment according to claim 1, characterized in that: The negative electrode probe mounting base (16) includes a fixed negative electrode probe mounting base (161) and a movable negative electrode probe mounting base (162). Two negative electrode probes (14) are mounted on the fixed negative electrode probe mounting base (161), and the other two negative electrode probes (14) are mounted on the movable negative electrode probe mounting base (162). The second XY axis slide (3) is provided with a second slide groove (19), and a slidable second nut (20) is provided in the second slide groove (19). The movable negative electrode probe mounting base (162) is connected to the second nut (20).

4. The high-voltage wire harness ultrasonic welding inspection equipment according to claim 1, characterized in that: The workpiece fixing seat (7) is provided with an L-shaped positioning groove (21) and a photoelectric detection switch (22) is provided above it.

5. The high-voltage wire harness ultrasonic welding inspection equipment according to claim 1, characterized in that: Both the positive electrode probe (8) and the negative electrode probe (13) are rectangular and have serrated probe surfaces (23) on their front ends.

6. The high-voltage wire harness ultrasonic welding inspection equipment according to claim 1, characterized in that: It also includes a benchmark verification motherboard (24).

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