A low-cost dispensing tool for customized film capacitors for new energy vehicles

Abstract

This utility model discloses a low-cost dispensing fixture for customized thin-film capacitors in new energy vehicles. It includes a filling mother plate, which is fixedly connected to the working platform of a dispensing machine. A fixing device is provided on each of the left and right sides of the filling mother plate. Each fixing device includes a base plate, a first positioning plate, a second positioning plate, and a clamping plate. The base plate is fixedly connected to the filling mother plate, the first positioning plate is fixedly connected to the base plate, the second positioning plate is fixedly connected to the right side of the first positioning plate, and the clamping plate is fixedly connected to the left side of the first positioning plate. The filling mother plate, base plate, first positioning plate, second positioning plate, and clamping plate are all made of internal gypsum or foam adhesive with copper or zinc plating on the outside. This utility model significantly reduces the cost of the fixture by machining each component from gypsum or foam adhesive blocks into their respective shapes and then vapor-plating a layer of copper or zinc onto their outer surfaces. This ensures the strength and smoothness of the fixture while maintaining its performance.

Description

Technical Field

[0001] This utility model relates to the field of thin film capacitor manufacturing technology, and in particular to a low-cost dispensing tooling for customized thin film capacitors for new energy vehicles. Background Technology

[0002] With the rapid development of power electronics technology, metallized film capacitors have been widely used in new energy, automotive electronics, rail transportation, industrial control, frequency conversion and other fields due to their advantages such as high safety, long life, high temperature and current resistance and stable performance. In particular, the demand for film capacitors in the field of new energy vehicles is increasing. However, the space inside new energy vehicles is small, and capacitors basically need to be customized. During dispensing, the relative positions of the mounting holes and busbar leads need to be fixed with tooling.

[0003] Custom metallized film capacitors mainly consist of multiple cores, busbars, a plastic shell, and epoxy potting compound. The main process involves soldering the cores in parallel to the busbar's solder joints, then inserting them into the plastic shell, applying epoxy potting compound, and finally curing at high temperature for encapsulation. External terminals on the busbar are left exposed for performance testing and customer installation. Current production processes primarily use machined aluminum and steel tooling, secured with screws to ensure the dimensions of the customized products. Currently, tooling costs are relatively high, with a basic set costing between 1500 and 2500 yuan. For mass production, 100 to 200 sets of tooling are typically needed for assembly line production, making the cost prohibitively high.

[0004] Inventing low-cost tooling to reduce dispensing tooling costs has become a future development trend for this type of metallized film capacitor. Utility Model Content

[0005] To address the issue of high costs associated with existing custom film capacitor dispensing fixtures made of aluminum and steel, this invention provides a low-cost dispensing fixture for custom film capacitors used in new energy vehicles. By machining each component of the fixture from plaster blocks or foam blocks into their respective shapes, and then depositing a layer of copper or zinc onto their outer surfaces, the fixture achieves its strength and smoothness while meeting the required dimensional specifications of each component. This significantly reduces fixture costs while ensuring optimal performance.

[0006] To achieve the above objectives, this utility model provides a low-cost dispensing fixture for customized thin-film capacitors in new energy vehicles. Its features include: a filling mother plate, which is fixedly connected to the dispensing machine's working platform; a fixing device on each of the left and right sides of the filling mother plate; each fixing device comprising a base plate, a first positioning plate, a second positioning plate, and a clamping plate; two base plates fixedly connected side-by-side to the front and rear sides of the upper surface of the filling mother plate; the first positioning plate comprising a crossbeam and two columns respectively located at the front and rear ends of the right side of the crossbeam; the lower ends of the right sides of the front and rear columns are fixedly connected to the left side of the base plate; a plurality of first positioning pins on the left side of the crossbeam, which are respectively used to insert into the mounting holes at the upper ends of the busbars of a plurality of capacitor cores within the plastic casing; the shape of the first positioning pins is consistent with the shape of the mounting holes, thereby positioning the capacitor cores within the plastic casing; and two second positioning pins on the left side of each of the front and rear columns, which are respectively used to engage with the front and rear mounting holes of the plastic casing. The mounting holes on the plate are correspondingly inserted to limit the longitudinal position of the plastic shell; the second positioning plate is located in the middle right side of the first positioning plate and is fixedly connected to the first positioning plate by washers and bolts. The plastic shell passes through the first positioning plate, and the end face of the through plate is in contact with the left side of the second positioning plate, thereby positioning the lateral position of the plastic shell; the clamping plate is located on the left side of the first positioning plate and is fixedly connected to the first positioning plate by multiple locking bolts. The clamping plate has a first groove that cooperates with the busbar of the capacitor core at the corresponding position. When the locking bolts lock the clamping plate to the first positioning plate, the first groove and the left side of the crossbeam clamp the busbar of the capacitor core. The bottom surface of the first groove has a first clearance hole that cooperates with the first positioning pin at the corresponding position. The clamping plate has a second clearance hole that cooperates with the second positioning pin at the corresponding position. The clamping plate has a clearance groove that cooperates with the mounting plate of the plastic shell at the corresponding position. When the locking bolts are tightened, the bottom surface of the clearance groove is in contact with the left side of the mounting plate of the plastic shell, thereby locking the plastic shell in place.

[0007] The filling mother plate, base plate, first positioning plate, second positioning plate and clamping plate are all made of internal gypsum or foam and external copper or zinc plated material.

[0008] Preferably, the thickness of the copper or zinc plating is set to 0.5 to 1 mm.

[0009] Preferably, the fixing device further includes a reinforcing rib, the bottom surface of which is fixedly connected to the base plate and the left side surface of which is fixedly connected to the first positioning plate. The reinforcing rib is made of internal gypsum or foam and external copper or zinc plating, with the copper or zinc plating thickness set to 0.5-1mm.

[0010] Preferably, the crossbeam is located on the upper left side of the column, and the length of the crossbeam is less than the distance between the front side of the front column and the rear side of the rear column, forming a step between the front column and the rear column.

[0011] The upper right side of the clamping plate is provided with a rectangular groove, which is engaged with the crossbeam. The first groove is provided on the bottom surface of the rectangular groove.

[0012] Preferably, the front and rear columns are provided with a second groove on their opposite sides, and the bottom surface of the front and rear second grooves engages with the front and rear sidewalls of the plastic shell.

[0013] Preferably, the filling mother plate is provided with a plurality of evenly distributed third threaded holes for mounting on dispensing fixture base plates for various specifications of film capacitors, so that the filling mother plate is suitable for dispensing various specifications of film capacitors.

[0014] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0015] 1. This utility model uses plaster blocks or foam blocks to machine each component of the tooling into its shape, and then deposits a layer of copper or zinc on its outer surface to ensure the strength and smoothness of the tooling and achieve the required dimensions of each component. This greatly reduces the tooling cost while ensuring the tooling's performance.

[0016] 2. The filling mother plate of this utility model is equipped with two sets of fixing devices, which are simple in structure, easy to operate, and highly efficient;

[0017] 3. The filling mother plate of this utility model is provided with several evenly distributed threaded holes in an array, which can be used for dispensing operations of various film capacitors of different specifications. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the embodiment of the present utility model and the workpiece assembly structure;

[0019] Figure 2 This is a schematic diagram of the structure after removing the clamping plate on one side and the clamping plate and workpiece on the other side according to an embodiment of the present invention;

[0020] Figure 3 for Figure 2 Another structural diagram;

[0021] Figure 4 This is a schematic diagram of the front and rear structures of the first positioning plate in an embodiment of this utility model;

[0022] Figure 5 This is a schematic diagram of the front and rear structures of the clamping plate in an embodiment of this utility model;

[0023] Figure 6This is a schematic diagram of the cross-sectional structure of the second positioning plate in an embodiment of this utility model.

[0024] In the diagram: 1. Filling mother plate, 101. Third threaded hole, 2. Second positioning plate, 3. Washer, 4. Base plate, 5. First positioning plate, 501. Crossbeam, 5011. First threaded hole, 502. Column, 5021. Second groove, 5022. Second threaded hole, 6. Clamping plate, 601. Rectangular groove, 602. First groove, 603. First clearance hole, 604. Second clearance hole, 605. Clearance groove, 606. First bolt hole, 607. Second bolt hole, 7. Locking bolt, 8. First positioning pin, 9. Second positioning pin, 10. Reinforcing rib, g1. Plastic shell, g2. Capacitor core, g3. Busbar, g4. Mounting plate. Detailed Implementation

[0025] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0026] like Figures 1-5As shown, Embodiment 1 of this utility model includes a filling mother plate 1, which is fixedly connected to the working platform of a dispensing machine. A fixing device is provided on each of the left and right sides of the filling mother plate 1. The fixing device includes a base plate 4, a first positioning plate 5, a second positioning plate 2, and a clamping plate 6. The base plate 4 has two parts, which are fixedly connected side-by-side to the front and rear sides of the upper plane of the filling mother plate 1. The first positioning plate 5 includes a crossbeam 501 and two columns 502 respectively located at the front and rear ends of the right side of the crossbeam 501. The lower right side of both the front and rear columns 502 is fixedly connected to the left side of the base plate 4. Six first positioning pins 8 are provided on the left side of the crossbeam 501. These six first positioning pins 8 are respectively used to insert into the mounting holes at the upper end of the busbars g3 of the six capacitor cores inside the plastic casing g1. The shape of the first positioning pins 8 is consistent with the shape of the mounting holes, thereby positioning the capacitor cores g2 inside the plastic casing g1. Two second positioning pins 9 are provided on the left side of both the front and rear columns 502. These two second positioning pins 9 are respectively used to insert into the mounting holes on the front and rear mounting plates g4 of the plastic casing g1, thereby limiting the longitudinal position of the plastic casing g1. The second positioning plate 2 is located in the middle of the right side of the first positioning plate 5 and is fixedly connected to the first positioning plate 5 by washers 3 and bolts. The plastic shell g1 passes through the first positioning plate 5, and its end face is attached to the left side of the second positioning plate 2, thereby positioning the lateral position of the plastic shell g1. The clamping plate 6 is located on the left side of the first positioning plate 5 and is fixedly connected to the first positioning plate 5 by four locking bolts 7. The clamping plate 6 has a first groove 602 that cooperates with the busbar g3 of the capacitor core g2 at the corresponding position. The locking bolts 7 lock the clamping plate 6 to the first positioning plate 5. When the first groove 602 and the left side of the crossbeam 501 clamp and fix the busbar g3 of the capacitor core g2, the bottom surface of the first groove 602 is provided with a first clearance hole 603 corresponding to the first positioning pin 8, the clamping plate 6 is provided with a second clearance hole 604 corresponding to the second positioning pin 9, and the mounting plate g4 of the plastic shell g1 is provided with a clearance groove 605 corresponding to the mounting plate g4 of the plastic shell g1. When the locking bolt 7 is tightened, the bottom surface of the clearance groove 605 is in contact with the left side of the mounting plate g4 of the plastic shell g1, thereby locking and fixing the plastic shell g1.

[0027] The filling mother plate 1, base plate 4, first positioning plate 5, second positioning plate 2 and clamping plate 6 are all made of gypsum inside and copper plated outside.

[0028] Preferably, the copper plating thickness is set to 0.6 mm.

[0029] In this embodiment 1, each component of the tooling is machined from plaster blocks into its shape, and then a layer of copper is vapor-plated onto its outer surface to ensure the strength and smoothness of the tooling and to achieve the required dimensions of each component. This greatly reduces the tooling cost while ensuring the tooling's performance.

[0030] like Figure 6 As shown, the cross-section of the second positioning plate 2 includes an inner plaster layer 201 and an outer copper plating layer 202, and the thickness of the copper plating layer is set to 0.6 mm. The cross-sections of the other components are consistent with the cross-sectional structure of the second positioning plate 2.

[0031] Preferably, the fixing device also includes a reinforcing rib 10, the bottom surface of which is fixedly connected to the base plate 4, and the left side is fixedly connected to the first positioning plate 5. The reinforcing rib 10 is made of gypsum inside and copper plated outside, with a copper plate thickness of 0.6mm.

[0032] Preferably, the crossbeam 501 is located on the upper left side of the column 502, and the length of the crossbeam 501 is less than the distance between the front side of the front column 502 and the rear side of the rear column 502, forming a step between the crossbeam 501 and the front column 502 and the rear column 502.

[0033] A rectangular groove 601 is provided on the upper right side of the clamping plate 6. The rectangular groove 601 is engaged with the crossbeam 501. The first groove 602 is provided on the bottom surface of the rectangular groove 601.

[0034] Preferably, the front and rear columns 502 are provided with a second groove 5021 on their opposite sides, and the bottom surface of the front and rear second grooves 5021 engages with the front and rear side walls of the plastic shell g1.

[0035] Preferably, the crossbeam 501 is provided with two first threaded holes 5011, and the clamping plate 6 is provided with first bolt holes 606 corresponding to the first threaded holes 5011. The crossbeam 501 and the clamping plate 6 are threadedly locked to the first threaded holes 5011 by passing the first bolts through the first bolt holes 606. The front and rear columns 502 are each provided with two second threaded holes 5022, and the clamping plate 6 is provided with second bolt holes 607 corresponding to the second threaded holes 5022. The front and rear columns 502 and the clamping plate 6 are threadedly locked to the second threaded holes 5022 by passing the second bolts through the second bolt holes 607.

[0036] Preferably, the filling mother plate 1 is provided with 64 evenly distributed third threaded holes 101 for mounting the base plate 4 of dispensing fixtures for various specifications of film capacitors, so that the filling mother plate 1 is suitable for dispensing various specifications of film capacitors.

[0037] Embodiment 2 of this utility model is basically the same as Embodiment 1, except that: the filling mother plate 1, the bottom plate 4, the first positioning plate 5, the second positioning plate 2 and the clamping plate 6 are all made of internal foamed rubber and external galvanized material.

[0038] Preferably, the zinc plating thickness is set to 0.9 mm.

[0039] In this embodiment 2, each component of the tooling is made of foamed rubber blocks and machined into its shape. Then, a layer of zinc is vapor-plated on its outer surface to ensure the strength and smoothness of the tooling and to achieve the required dimensions of each component. This greatly reduces the tooling cost while ensuring the tooling's performance.

[0040] The above are merely preferred embodiments of this utility model. It should be noted that, for those skilled in the art, several improvements and substitutions can be made without departing from the technical principles of this utility model, and these improvements and substitutions should also be considered within the protection scope of this utility model.

Claims

1. A low-cost dispensing tooling for customized thin-film capacitors for new energy vehicles, characterized in that: The system includes a filling master plate, which is fixedly connected to the dispensing machine's working platform. One fixing device is provided on each of the left and right sides of the filling master plate. Each fixing device includes a base plate, a first positioning plate, a second positioning plate, and a clamping plate. Two base plates are fixedly connected side-by-side to the front and rear sides of the upper surface of the filling master plate. The first positioning plate includes a crossbeam and two columns located at the front and rear ends of the right side of the crossbeam. The lower right side of both the front and rear columns is fixedly connected to the left side of the base plate. Several first positioning pins are provided on the left side of the crossbeam. These first positioning pins are used to engage with the mounting holes at the upper ends of the busbars of several capacitor cores inside the plastic casing. The shape of the first positioning pins matches the shape of the mounting holes, thereby positioning the capacitor cores inside the plastic casing. Two second positioning pins are provided on the left side of each of the front and rear columns. These two second positioning pins are used to engage with the mounting holes on the front and rear mounting plates of the plastic casing, thereby adjusting the longitudinal position of the plastic casing. The first positioning plate is located on the right side of the first positioning plate and is fixedly connected to the first positioning plate by washers and bolts. The plastic shell passes through the first positioning plate and its end face is in contact with the left side of the second positioning plate, thereby positioning the lateral position of the plastic shell. The clamping plate is located on the left side of the first positioning plate and is fixedly connected to the first positioning plate by multiple locking bolts. The clamping plate has a first groove that cooperates with the busbar of the capacitor core at the corresponding position. When the locking bolts lock the clamping plate to the first positioning plate, the first groove and the left side of the crossbeam clamp the busbar of the capacitor core. The bottom surface of the first groove has a first clearance hole that cooperates with the first positioning pin at the corresponding position. The clamping plate has a second clearance hole that cooperates with the second positioning pin at the corresponding position. The clamping plate has a clearance groove that cooperates with the mounting plate of the plastic shell at the corresponding position. When the locking bolts are tightened, the bottom surface of the clearance groove is in contact with the left side of the mounting plate of the plastic shell, thereby locking the plastic shell. The filling mother plate, base plate, first positioning plate, second positioning plate and clamping plate are all made of internal gypsum or foam and external copper or zinc plated material.

2. The low-cost dispensing fixture for customized thin-film capacitors for new energy vehicles according to claim 1, characterized in that: The thickness of the copper or zinc plating is set to 0.5–1 mm.

3. The low-cost dispensing fixture for customized thin-film capacitors for new energy vehicles according to claim 1, characterized in that: The fixing device also includes a reinforcing rib, the bottom surface of which is fixedly connected to the base plate and the left side surface of which is fixedly connected to the first positioning plate. The reinforcing rib is made of internal gypsum or foam and external copper or zinc plating material, and the thickness of the copper or zinc plating is set to 0.5-1mm.

4. The low-cost dispensing fixture for customized thin-film capacitors for new energy vehicles according to claim 1, characterized in that: The crossbeam is located on the upper left side of the column, and the length of the crossbeam is less than the distance between the front side of the front column and the rear side of the rear column, forming a step between the front column and the rear column. The upper right side of the clamping plate is provided with a rectangular groove, which is engaged with the crossbeam. The first groove is provided on the bottom surface of the rectangular groove.

5. The low-cost dispensing fixture for customized thin-film capacitors for new energy vehicles according to claim 1, characterized in that: The front and rear columns are each provided with a second groove on their opposite sides, and the bottom surfaces of the front and rear second grooves engage with the front and rear side walls of the plastic shell.

6. The low-cost dispensing fixture for customized thin-film capacitors for new energy vehicles according to claim 1, characterized in that: The filling motherboard is provided with a number of evenly distributed threaded holes for mounting dispensing fixture base plates for various specifications of film capacitors, making the filling motherboard suitable for dispensing various specifications of film capacitors.

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