Fully automatic grinding device for conductive busbars in new energy vehicles

Abstract

This utility model relates to the field of new energy busbar production technology, specifically a fully automatic grinding device and method for new energy vehicle busbars. It includes a chain transmission mechanism, a grinding transmission mechanism, and a grinding mechanism. The chain transmission mechanism is equipped with multiple sets of busbar clamping mechanisms. The chain transmission mechanism drives the busbar clamping mechanisms for cyclical transmission, and the clamping mechanisms hold and fix the busbars. The grinding transmission mechanism drives the grinding mechanism to move. The grinding mechanism includes a mirror transmission module, a grinding drive module, and an alloy grinding wheel. Two sets of grinding drive modules are arranged opposite each other and mounted on the mirror transmission module. The mirror transmission module drives the two grinding drive modules to move mirror-to-rear. This utility model achieves high efficiency, high precision, and high reliability in busbar grinding. It significantly improves production efficiency, reduces labor costs, and ensures high-quality product standards.

Description

Technical Field

[0001] This utility model relates to the field of new energy conductive busbar production technology, and in particular to a fully automatic grinding device and method for new energy vehicle conductive busbars. Background Technology

[0002] With increasing global emphasis on environmental protection and sustainable development, new energy vehicles, as a green and efficient mode of transportation, are gradually becoming the development direction of the automotive industry. One of the core components of new energy vehicles is the battery system, and the battery busbar plays a crucial role in this system. It is responsible for connecting the individual battery cells in the battery module, realizing the transmission and distribution of electrical energy, and its performance directly affects the safety, stability, and charging / discharging efficiency of the battery system.

[0003] Welding is a critical process in the manufacturing of conductive busbars for new energy vehicle batteries. Since conductive busbars are typically made of metals such as copper and aluminum, these metals readily react with oxygen in the air to form an oxide layer. The presence of this oxide layer increases the resistance at the weld joint, reduces power transmission efficiency, and may even lead to localized overheating, affecting the performance and safety of the battery system. Therefore, before welding, the weld joints of the conductive busbar must be ground to remove the oxide layer and ensure good weld quality. Current grinding methods rely on manual labor, which is inefficient and costly. Therefore, a new design is needed for grinding existing copper busbars. Utility Model Content

[0004] To address the aforementioned issues, this invention achieves high efficiency, high precision, and high reliability in electric busbar grinding. It significantly improves production efficiency, reduces labor costs, and ensures high-quality product standards. This fully automated grinding device and method for electric busbars in new energy vehicles...

[0005] The technical solution adopted by this utility model is: a fully automatic grinding device for conductive busbars of new energy vehicles, including a chain transmission mechanism, a grinding transmission mechanism, and a grinding mechanism. The chain transmission mechanism is equipped with a busbar clamping mechanism, and multiple sets of the busbar clamping mechanism are provided. The chain transmission mechanism is used to drive the busbar clamping mechanism to circulate and transmit, and the busbar clamping mechanism is used to clamp and fix the busbar. The grinding transmission mechanism is used to drive the grinding mechanism to move. The grinding mechanism includes a mirror transmission module, a grinding drive module, and alloy grinding wheels. Two sets of grinding drive modules are arranged opposite each other and are set on the mirror transmission module. The mirror transmission module is used to drive the two sets of grinding drive modules to move mirror-to-relative to grind both sides of the busbar. The alloy grinding wheel is a conductive wheel. When it contacts the busbar, the two sets of alloy grinding wheels are electrically connected to determine that the busbar is being ground.

[0006] A further improvement to the above solution is that the chain transmission mechanism includes a fixed panel, a ring track, a ring chain, and a transmission drive module. The ring track is disposed on the fixed panel, the electric busbar clamping mechanism is disposed on the ring track and slides along the ring track, the ring chain is disposed on the fixed panel, and the transmission drive module is disposed on the fixed panel and is used to drive the ring chain for transmission. One side of the electric busbar clamping mechanism is connected to the ring chain so as to slide along the ring track under the action of the transmission drive module.

[0007] A further improvement to the above solution is that a movable positioning module is provided on the fixed panel, which is used to position the electric busbar clamping mechanism on the annular track. The movable positioning module includes a positioning drive cylinder, a positioning rotating connecting rod, and a movable block. A positioning pin is provided on the movable block, and a positioning groove is provided on the electric busbar clamping mechanism to cooperate with the positioning pin. The positioning drive cylinder is provided on the fixed panel, and the positioning rotating connecting rod is provided with a positioning bushing and is mounted on the fixed panel through the positioning bushing. The movable block is provided on the positioning connecting rod. The positioning drive cylinder is used to drive the positioning rotating connecting rod to rotate, thereby moving the movable block toward the electric busbar clamping mechanism so that the positioning pin cooperates with the positioning groove.

[0008] A further improvement to the above solution is that the busbar clamping mechanism includes a clamping slider, a clamping fixture, a clamping support base, a first clamping drive module, and a second clamping drive module. The clamping slider is mounted on the chain transmission mechanism, the clamping fixture is mounted on the clamping slider, and the clamping support base is mounted on the clamping slider and opposite to the clamping fixture. The clamping fixture is used to fix the rear end of the busbar. The first clamping drive module is used to drive a first clamping plate to clamp and fix the side of the busbar to the clamping support base. The second clamping drive module is used to drive a second clamping plate to clamp and fix the surface of the busbar to the clamping support base.

[0009] A further improvement to the above scheme is that the mirror transmission module drives the grinding drive module to move relative to the two sides of the busbar according to the electric conduction of the alloy grinding wheel, and grinds the busbar through the alloy grinding wheel.

[0010] A further improvement to the above solution is that the grinding transmission mechanism includes a fixed base and an XZ axis transmission module. The fixed base is a cast iron base, the XZ axis transmission module is mounted on the fixed base, and the mirror transmission module is mounted on the fixed base. The XZ axis transmission module is used to drive the mirror transmission module to move the alloy grinding wheel toward the electric busbar fixing device.

[0011] A further improvement to the above solution is that the mirror drive module is a synchronous belt drive module, and the two grinding drive modules are respectively set on the bidirectional transmission side of the synchronous belt, so that the two grinding drive modules are mirror driven when the synchronous belt is driven; the grinding drive module is a servo motor, and the driving end of the servo motor is provided with a grinding spindle, and the alloy grinding wheel is set on the grinding spindle.

[0012] A further improvement to the above scheme is that the cross-sectional shape of the alloy grinding wheel is tower-shaped, the alloy grinding wheel includes a tower-shaped frame and a grinding ring, the tower-shaped frame is used to connect the grinding spindle, and the grinding ring is disposed at the end of the tower-shaped frame for grinding the busbar and removing the oxide layer on the surface of the busbar.

[0013] A further improvement to the above solution is that a protective cover is provided on the outside of the alloy grinding wheel, and a dust suction pipe is provided on the outside of the protective cover. The dust suction pipe is used to collect the dust generated by the alloy grinding wheel during the grinding process.

[0014] An automatic grinding method for electric busbars based on a fully automatic grinding device for electric busbars in new energy vehicles includes the following steps:

[0015] Step S1. Transmission and Positioning: Multiple sets of electric busbar clamping mechanisms are driven to move cyclically along the circular track by a chain transmission mechanism. When the target electric busbar clamping mechanism moves to the grinding station, the positioning drive cylinder of the moving positioning module drives the positioning rotating linkage to rotate, which drives the positioning pin on the movable block to insert into the positioning groove of the electric busbar clamping mechanism, thereby achieving precise positioning of the tooling.

[0016] Step S2. Layered clamping and fixing: The first clamping drive module drives the first clamping plate to clamp the side of the electric busbar, and at the same time the second clamping drive module drives the second clamping plate to press the surface of the electric busbar, so that the rear end of the electric busbar is fixed between the clamping fixture and the clamping support.

[0017] Step S3. Mirror feed: Drive the mirror transmission module to move as a whole through the XZ axis transmission module, so that the two alloy grinding wheels approach the end face of the electric busbar to be ground;

[0018] Step S4. Synchronous mirror polishing: Start the synchronous belt drive of the mirror drive module to drive the two sets of polishing drive modules to move relative to each other, while the servo motor drives the alloy polishing wheel to rotate at high speed.

[0019] Step S5. Real-time conductivity determination: When the two combined alloy polishing wheels simultaneously contact the surfaces on both sides of the electric busbar, an electrical conduction circuit is formed, triggering the polishing depth control signal; detect and verify the electrical conduction signal: the contact pressure reaches 0.5-0.8MPa; the current intensity is stable in the range of 5-20mA; the signal duration is ≥10ms; after the conditions are met, trigger the reference zero point calibration;

[0020] Step S6. Dynamic Grinding Execution: Using the electrical conduction trigger position as the reference zero point, control the mirror drive module to drive the alloy grinding wheel synchronously to feed according to the preset compensation amount Δd, and remove the oxide layer on the surface of the electric busbar through the tower-shaped grinding ring; perform layered feeding according to the aluminum busbar grinding process:

[0021] Rough grinding stage: feed compensation amount Δd1 at a speed of 0.8-1.2 mm / s to remove oxide layer;

[0022] Fine grinding stage: reduce the feed speed to 0.3-0.5 mm / s for Δd2, and control the surface roughness Ra≤1.6 μm;

[0023] Edge treatment: The drive mirror transmission module is tilted at an angle θ, and an additional compensation amount Δd_e=0.1-0.2mm is added for chamfering and grinding.

[0024] The beneficial effects of this utility model are:

[0025] Compared to existing electric arc wheel grinding systems, this invention combines a chain transmission mechanism with multiple sets of electric arc wheel clamping mechanisms. These clamping stations circulate along a ring track, allowing the loading, grinding, and unloading processes to be executed in parallel, eliminating waiting time in traditional single-station systems and improving production efficiency. The mirror drive module, in conjunction with conductive alloy wheels, solves the problem of precision in simultaneous double-sided grinding. It forces the two alloy grinding wheels to move in strict synchronous mirror-image relative motion, ensuring perfectly symmetrical grinding depth on both sides of the electric arc wheel and completely resolving the tilting grinding problem caused by traditional dual-machine independent drive. The conductive alloy wheel's electrical conductivity determination mechanism automatically forms a conductive circuit when both grinding wheels simultaneously contact the surfaces of both sides of the electric arc wheel, directly triggering the grinding action without the need for additional sensors, simplifying the system structure and avoiding misjudgments. The grinding transmission mechanism is linked with the mirror drive module: through graded motion control, overall positioning is achieved first, followed by mirror fine-tuning, eliminating accumulated positioning errors and ensuring precise alignment of the grinding wheels and the electric arc wheel. The conductive properties of the alloy grinding wheel work in synergy with mirror motion: using electrical conduction as a real-time feedback signal for physical contact, automatic calibration of the grinding zero point is achieved, avoiding accuracy fluctuations caused by manual intervention.

[0026] This invention achieves stable clamping and cyclic transmission of the electric busbar by combining a chain transmission mechanism with an electric busbar clamping mechanism. The chain transmission mechanism ensures the continuity and stability of the electric busbar during the polishing process, avoiding errors and inefficiencies caused by manual operation. Multiple clamping mechanisms further enhance the device's production capacity, making mass production possible. The coordinated operation of the polishing transmission mechanism and the polishing mechanism ensures precise control of the polishing process. The polishing transmission mechanism drives the movement of the polishing mechanism, which consists of a mirror transmission module, a polishing drive module, and an alloy polishing wheel. The mirror transmission module design allows the two polishing drive modules to move relative to each other, thus simultaneously polishing both sides of the electric busbar, ensuring the flatness and consistency of the busbar surface. Simultaneous double-sided polishing not only improves polishing efficiency but also effectively reduces deformation caused by single-sided polishing. The selection of the alloy polishing wheel and its conductive properties provide additional safety and quality monitoring for the polishing process. As a type of conductive wheel, the alloy grinding wheel forms an electrical connection when it comes into contact with the electric busbar. This connection allows for real-time monitoring of the grinding status, ensuring a smooth grinding process. Furthermore, the wear resistance and durability of the alloy material guarantee the stable performance of the grinding wheel over extended use, reducing maintenance costs. This embodiment achieves high efficiency, high precision, and high reliability in electric busbar grinding. It significantly improves production efficiency, reduces labor costs, and ensures high-quality product standards.

[0027] The automatic grinding method for electric busbars based on a fully automated grinding device for new energy vehicle electric busbars utilizes a transfer positioning and layered clamping mechanism for zero-displacement machining of the workpiece. This mechanism employs a cyclical transfer and positioning pin slot mechanism: chain-like multi-station flow and physical locking of the positioning pins eliminate accumulated transfer errors, resulting in high repeatability and positioning accuracy. Synchronous constraint of the electric busbar's lateral displacement and surface vibration solves the problem of vibration during thin-walled electric busbar machining, improving clamping rigidity. XZ-axis coarse adjustment + mirror fine adjustment dual-stage positioning: first overall approximation followed by mirror micro-feeding avoids mechanical system backlash errors, ensuring high alignment accuracy. By combining current intensity, pressure threshold, and duration judgments, traditional sensors are replaced, reducing the false trigger rate to below 0.1% and improving zero-point calibration efficiency. Dynamic layered grinding, with continuous execution of three stages: coarse grinding, fine grinding, and chamfering, simultaneously achieves thorough oxide layer removal and substrate protection through segmented speed reduction and compensation control. Chamfering is completed synchronously during mirror motion, eliminating edge burrs caused by traditional secondary clamping. Attached Figure Description

[0028] Figure 1 This is a three-dimensional schematic diagram of the fully automatic grinding device for conductive busbars of new energy vehicles according to this utility model;

[0029] Figure 2 for Figure 1A three-dimensional schematic diagram of the fully automatic grinding device for the conductive busbar of China's new energy vehicles from another perspective.

[0030] Figure 3 for Figure 1 A front view schematic diagram of a fully automatic grinding device for conductive busbars in new energy vehicles.

[0031] Figure 4 for Figure 2 Enlarged diagram of point A in the diagram;

[0032] Figure 5 for Figure 1 A schematic diagram of the internal structure of the fully automatic grinding device for the conductive busbars of new energy vehicles.

[0033] Figure 6 for Figure 1 A schematic diagram of the alloy grinding wheel in the fully automatic grinding device for conductive busbars of new energy vehicles.

[0034] Figure 7 This is a flowchart illustrating the automatic polishing method using an electric arc deflector according to this utility model.

[0035] Explanation of reference numerals in the attached drawings: 1. Chain transmission mechanism; 11. Fixed panel; 12. Circular track; 13. Circular chain; 14. Transmission drive module; 15. Moving positioning module; 15. Positioning drive cylinder; 151. Positioning rotating connecting rod; 152. Movable block; 153. Positioning pin; 154. Positioning bushing; 155. Grinding transmission mechanism; 2. Fixed base; 21. XZ axis transmission module; 22. Grinding mechanism; 3. Mirror transmission module; 31. Grinding drive module; 32. Grinding spindle; 321. Alloy grinding wheel; 33. Tower frame; 331. Grinding ring; 332. Protective cover; 333. Dust suction pipe; 334. Transmission mechanism; 34. Electric clamping mechanism; 4. Clamping slider; 41. Clamping fixture; 42. Clamping support; 43. First clamping drive module; 44. First clamping plate; 441. Second clamping drive module; 45. Second clamping plate; 451. Detailed Implementation

[0036] To facilitate understanding of this utility model, a more complete description will be given below with reference to the accompanying drawings. Preferred embodiments of this utility model are shown in the drawings. However, this utility model can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a more thorough and complete understanding of the disclosure of this utility model.

[0037] It should be noted that when a component is said to be "fixed to" another component, it can be directly attached to the other component or there may be an intervening component. When a component is said to be "connected to" another component, it can be directly connected to the other component or there may be an intervening component.

[0038] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. Figures 1-7 As shown, in one embodiment of this utility model, a fully automatic grinding device for conductive busbars in new energy vehicles is disclosed. The device includes a chain transmission mechanism 1, a grinding transmission mechanism 2, and a grinding mechanism 3. The chain transmission mechanism 1 is equipped with a busbar clamping mechanism 4, which has multiple sets. The chain transmission mechanism 1 drives the busbar clamping mechanism 4 for cyclic transmission, and the busbar clamping mechanism 4 clamps and fixes the busbar. The grinding transmission mechanism 2 drives the grinding mechanism 3 to move. The grinding mechanism 3 includes a mirror transmission module 31, a grinding drive module 32, and alloy grinding wheels 33. Two sets of grinding drive modules 32 are arranged opposite each other on the mirror transmission module 31. The mirror transmission module 31 drives the two sets of grinding drive modules 32 to move relative to each other in a mirror image for grinding both sides of the busbar. The alloy grinding wheels 33 are conductive wheels; when in contact with the busbar, the two sets of alloy grinding wheels 33 are electrically connected to determine that grinding is being performed on the busbar. This embodiment combines a chain transmission mechanism 1 with multiple sets of electric busbar clamping mechanisms 4. These clamping stations circulate along a ring track, allowing the loading, grinding, and unloading processes to be executed in parallel, eliminating the waiting time of traditional single-station operations and improving production efficiency. The mirror drive module 31, in conjunction with conductive alloy wheels, solves the problem of double-sided synchronous grinding accuracy. The two sets of alloy grinding wheels 33 are forced to move in strict synchronous mirror-image relative motion, ensuring completely symmetrical grinding depth on both sides of the electric busbar and completely resolving the tilting grinding problem caused by traditional dual-machine independent drive. The conductive alloy wheel's electrical conductivity determination mechanism automatically forms a conductive circuit when both grinding wheels simultaneously contact the surfaces of both sides of the electric busbar, directly triggering the grinding action without the need for additional sensors, simplifying the system structure and avoiding misjudgments. The grinding transmission mechanism 2 is linked with the mirror drive module 31: through graded motion control, overall positioning is achieved first, followed by mirror fine-tuning, eliminating accumulated positioning errors and ensuring precise alignment of the grinding wheels and the electric busbar. The conductive properties of the alloy grinding wheel 33 work in conjunction with the mirror motion: using electrical conduction as a real-time feedback signal for physical contact, automatic calibration of the grinding zero point is achieved, avoiding precision fluctuations caused by manual intervention.

[0039] In the above embodiments, the combination of the chain transmission mechanism 1 and the electric busbar clamping mechanism 4 achieves stable clamping and cyclic transmission of the electric busbar. The use of the chain transmission mechanism 1 ensures the continuity and stability of the electric busbar during the polishing process, avoiding errors and inefficiencies caused by manual operation. The multiple sets of electric busbar clamping mechanisms 4 further improve the production capacity of the device, making mass production possible. The coordinated work of the polishing transmission mechanism 2 and the polishing mechanism 3 ensures precise control of the polishing process. The polishing transmission mechanism 2 is responsible for driving the movement of the polishing mechanism 3, which consists of a mirror transmission module 31, a polishing drive module 32, and an alloy polishing wheel 33. The design of the mirror transmission module 31 allows the two polishing drive modules 32 to move relative to each other in a mirror image, thereby simultaneously polishing both sides of the electric busbar and ensuring the flatness and consistency of the electric busbar surface. The method of polishing both sides simultaneously not only improves polishing efficiency but also effectively reduces the deformation problem of the electric busbar caused by single-sided polishing. The selection of the alloy grinding wheel 33 and its conductive properties provide additional safety and quality monitoring for the grinding process. As a conductive wheel, the two alloy grinding wheels 33 form an electrical connection when in contact with the electric busbar, allowing for real-time monitoring of the grinding status and ensuring smooth operation. Furthermore, the wear resistance and durability of the alloy material guarantee the stable performance of the grinding wheel over extended use, reducing maintenance costs. This embodiment achieves high efficiency, high precision, and high reliability in electric busbar grinding. It significantly improves production efficiency, reduces labor costs, and ensures high-quality product standards.

[0040] See Figures 2-3As shown, the chain transmission mechanism 1 includes a fixed panel 11, a circular track 12, a circular chain 13, and a transmission drive module 14. The circular track 12 is mounted on the fixed panel 11, and the electric busbar clamping mechanism 4 is mounted on the circular track 12 and slides along it. The circular chain 13 is mounted on the fixed panel 11, and the transmission drive module 14 is mounted on the fixed panel 11 and drives the circular chain 13 for transmission. One side of the electric busbar clamping mechanism 4 is connected to the circular chain 13 so that it can slide along the circular track 12 under the action of the transmission drive module 14. In this embodiment, the fixed panel 11 serves as the basic support structure, ensuring the stability and reliability of the entire transmission system. The circular track 12, mounted on the fixed panel 11, provides a precise sliding path for the electric busbar clamping mechanism 4, ensuring the positioning accuracy and smooth operation of the electric busbar during transmission. The sliding of the electric busbar clamping mechanism 4 along the circular track 12 enables the orderly transport of the electric busbar, avoiding the inefficiency and human error caused by traditional manual operation. The combination of the ring chain 13 and the transmission drive module 14 further enhances the power performance and control precision of the transmission system. The ring chain 13 is fastened to the fixed panel 11 and, driven by the transmission drive module 14, achieves continuous and stable power output. One side of the busbar clamping mechanism 4 is connected to the ring chain 13, and with the help of the transmission drive module 14, it can slide smoothly along the ring track 12, ensuring rapid switching of the busbar between various workstations and significantly improving production efficiency. The adoption of the chain transmission mechanism 1 also significantly improves the intelligence level of the fully automatic grinding device for electric busbars in new energy vehicles. Through precise mechanical transmission and intelligent control system, the grinding process of the busbar is fully automated, not only reducing labor costs but also effectively improving product quality and consistency.

[0041] A movable positioning module 15 is provided on the fixed panel 11. The movable positioning module 15 is used to position the electric busbar clamping mechanism 4 on the annular track 12. The movable positioning module 15 includes a positioning drive cylinder 151, a positioning rotating connecting rod 152, and a movable block 153. A positioning pin 154 is provided on the movable block 153, and a positioning groove is provided on the electric busbar clamping mechanism 4 to cooperate with the positioning pin 154. The positioning drive cylinder 151 is provided on the fixed panel 11, the positioning rotating connecting rod 152 is provided with a positioning bushing 155 and is provided on the fixed panel 11 through the positioning bushing 155, and the movable block 153 is provided on the positioning connecting rod. The positioning drive cylinder 151 is used to drive the positioning rotating connecting rod 152 to rotate, so as to move the movable block 153 toward the electric busbar clamping mechanism 4, so that the positioning pin 154 cooperates with the positioning groove. In this embodiment, the mobile positioning module 15 consists of a positioning drive cylinder 151, a positioning rotating connecting rod 152, and a movable block 153. The movable block 153 is equipped with a positioning pin 154, while the electric busbar clamping mechanism 4 has a matching positioning groove. This ensures a perfect fit between the positioning pin 154 and the positioning groove, thereby achieving precise fixation of the electric busbar clamping mechanism 4. The positioning drive cylinder 151 is mounted on the fixed panel 11. By driving the positioning rotating connecting rod 152 to rotate, it drives the movable block 153 to move towards the electric busbar clamping mechanism 4, completing the docking of the positioning pin 154 and the positioning groove. The positioning bushing 155 on the positioning rotating connecting rod 152 is installed through the fixed panel 11, ensuring the smoothness and reliability of the connecting rod rotation and avoiding positioning errors caused by vibration or offset, further improving the overall performance of the device.

[0042] See Figure 4As shown, the EMP (Electrical Busbar) clamping mechanism 4 includes a clamping slider 41, a clamping fixture 42, a clamping support 43, a first clamping drive module 44, and a second clamping drive module 45. The clamping slider 41 is mounted on the chain transmission mechanism 1, the clamping fixture 42 is mounted on the clamping slider 41, and the clamping support 43 is mounted on the clamping slider 41 and opposite to the clamping fixture 42. The clamping fixture 42 is used to fix the rear end of the EMP. The first clamping drive module 44 is used to drive a first clamping plate 441 to clamp and fix the side of the EMP onto the clamping support 43. The second clamping drive module 45 is used to drive a second clamping plate 451 to clamp and fix the surface of the EMP onto the clamping support 43. In this embodiment, the clamping slider 41 is mounted on the chain transmission mechanism 1, ensuring the stability and positioning accuracy of the EMP during transmission. The clamping fixture 42 is mounted on the clamping slider 41, opposite the clamping support 43, and is specifically used to fix the rear end of the busbar, effectively preventing displacement of the busbar during the grinding process and ensuring the consistency and reliability of the grinding. The first clamping drive module 44 clamps the side of the busbar by driving the first clamping plate 441, firmly fixing it to the clamping support 43. The side clamping method not only enhances the stability of the busbar, but also provides a good foundation for subsequent surface grinding. The second clamping drive module 45 further drives the second clamping plate 451, tightly adhering the surface of the busbar to the clamping support 43, realizing comprehensive fixation of the busbar in multiple dimensions, and greatly improving the precision and efficiency of grinding.

[0043] The mirror drive module 31 drives the grinding drive module 32 to move relative to both sides of the busbar based on the electrical conduction of the alloy grinding wheel 33, and grinds the busbar through the alloy grinding wheel 33. In this embodiment, the design of the mirror drive module 31 ensures symmetry and stability during the grinding process. By grinding both sides of the busbar simultaneously, the uneven stress and deformation problems that may be caused by single-sided grinding are avoided, thereby ensuring the overall flatness and dimensional accuracy of the busbar. The bidirectional synchronous grinding mechanism not only improves grinding efficiency but also effectively reduces the need for subsequent correction processes, thereby reducing production costs.

[0044] The grinding transmission mechanism includes a fixed base 21 and an XZ-axis transmission module 22. The fixed base 21 is a cast iron base, and the XZ-axis transmission module 22 is mounted on the fixed base 21. A mirror transmission module 31 is also mounted on the fixed base 21. The XZ-axis transmission module 22 drives the mirror transmission module 31 to move the alloy grinding wheel 33 towards the electric busbar fixing device. In this embodiment, the XZ-axis transmission module 22 is mounted on the fixed base 21, achieving precise driving of the mirror transmission module 31. This allows the alloy grinding wheel 33 to move towards the electric busbar fixing device along a preset trajectory, ensuring the accuracy and consistency of the grinding operation. Through the synergistic effect of the XZ-axis transmission module 22, the position and angle of the grinding wheel can be flexibly adjusted to adapt to the grinding needs of different specifications of electric busbars, greatly improving the versatility and applicability of the equipment. The combined use of the mirror transmission module 31 and the XZ-axis transmission module 22 further enhances the automation level of the system.

[0045] The mirror drive module 31 is a synchronous belt drive module. Two grinding drive modules 32 are respectively set on the bidirectional transmission side of the synchronous belt, driving the two grinding drive modules 32 to mirror drive during synchronous belt transmission. The grinding drive module 32 is a servo motor, and the driving end of the servo motor is equipped with a grinding spindle 321. The alloy grinding wheel 33 is mounted on the grinding spindle 321. In this embodiment, the grinding drive module 32 uses a servo motor, which further enhances the controllability and flexibility of the system. Due to its high precision, fast response, and stability, the servo motor can precisely control the speed and torque of the grinding spindle 321 when it is set at the driving end, ensuring the stability and efficiency of the alloy grinding wheel 33 during operation. This not only improves grinding efficiency but also greatly reduces the risk of material damage caused by speed fluctuations or torque instability. The alloy grinding wheel 33 is mounted on the grinding spindle 321, and through the precise drive of the servo motor, it can achieve uniform and efficient grinding on the surface of the electric busbar with different materials and hardness. It adapts to the processing needs of various electric discharge materials, and also significantly extends the service life of the grinding wheel and reduces maintenance costs.

[0046] The alloy grinding wheel 33 has a tower-shaped cross-section. It includes a tower-shaped frame 331 and a grinding ring 332. The tower-shaped frame 331 connects to the grinding spindle 321, and the grinding ring 332 is located at the end of the tower-shaped frame 331 for grinding the busbar and removing the oxide layer from its surface. In this embodiment, the alloy grinding wheel 33 consists of two parts: the tower-shaped frame 331 and the grinding ring 332. The tower-shaped frame 331 connects to the grinding spindle 321, ensuring stability and accuracy during the grinding process. The grinding ring 332 is cleverly positioned at the end of the tower-shaped frame 331, directly acting on the surface of the busbar to effectively remove the oxide layer. The tower-shaped structure gives the grinding wheel better mechanical properties, allowing it to maintain good balance during high-speed rotation and avoiding uneven grinding caused by vibration. The combined design of the tower-shaped frame 331 and the grinding ring 332 not only increases the grinding area but also optimizes the force transmission path, resulting in a more uniform distribution of grinding force and thus improving grinding efficiency and surface finish. The special design of the tower-shaped frame 331 also enhances the durability of the grinding wheel. Under prolonged high-load working conditions, the tower-shaped frame 331 effectively disperses stress, reduces wear, and extends the service life of the grinding wheel.

[0047] The alloy grinding wheel 33 is equipped with a protective cover 333, and a dust collection pipe 334 is installed outside the protective cover 333. The dust collection pipe 334 is used to collect dust generated by the alloy grinding wheel 33 during the grinding process. In this embodiment, the introduction of the protective cover 333 can effectively prevent metal chips and dust from splashing during the grinding process, avoiding injury to operators, and also protecting surrounding equipment from damage, ensuring the continuity and stability of the production process. The dust collection pipe 334 is further configured outside the protective cover 333, which can collect the dust generated by the alloy grinding wheel 33 during the grinding process in real time, effectively reducing the dust concentration in the workshop, improving the working environment, and reducing occupational health risks.

[0048] like Figures 1-7As shown, an automatic grinding method for electric busbars based on a fully automatic grinding device for electric busbars in new energy vehicles includes the following steps: Step S1. Transmission and positioning: Multiple sets of electric busbar clamping mechanisms 4 are driven to move cyclically along the circular track 12 by a chain transmission mechanism 1. When the target electric busbar clamping mechanism 4 moves to the grinding station, the positioning drive cylinder 151 of the moving positioning module 15 drives the positioning rotating connecting rod 152 to rotate, causing the positioning pin 154 on the movable block 153 to insert into the positioning groove of the electric busbar clamping mechanism 4, thereby achieving precise positioning of the tooling; Step S2. Layered clamping and fixing: The first clamping drive module 44 drives the first clamping plate 441 to clamp the side of the electric busbar, and at the same time, the second clamping drive module 45 drives the second clamping plate 451 to press the surface of the electric busbar, so that the rear end of the electric busbar is fixed between the clamping fixture 42 and the clamping support 43; Step S3. Mirror feed: The mirror transmission module 31 is moved as a whole by the XZ axis transmission module 22. Step S4. Synchronous mirror polishing: Start the synchronous belt drive of the mirror drive module 31 to drive the two polishing drive modules 32 to move relative to each other in a mirror manner, while the servo motor drives the alloy polishing wheel 33 to rotate at high speed; Step S5. Real-time conductivity determination: When the two alloy polishing wheels 33 contact the two sides of the electric busbar at the same time, an electrical conduction circuit is formed, triggering the polishing depth control signal; Detect and verify the electrical conduction signal: the contact pressure reaches 0.5-0.8MPa; the current intensity is stable in the range of 5-20mA; the signal duration is ≥10ms; after the conditions are met, the reference zero point calibration is triggered; Step S6. Dynamic polishing execution: With the electrical conduction trigger position as the reference zero point, control the mirror drive module 31 to drive the alloy polishing wheel 33 to feed synchronously according to the preset compensation amount Δd, and remove the oxide layer on the surface of the electric busbar through the tower-shaped polishing ring 332; Perform layered feeding according to the aluminum busbar polishing process:

[0049] Rough grinding stage: feed compensation amount Δd1 at a speed of 0.8-1.2 mm / s to remove the oxide layer; Fine grinding stage: reduce the speed to 0.3-0.5 mm / s and feed Δd2 to control the surface roughness Ra≤1.6μm; Edge treatment: drive the mirror transmission module 31 to tilt at an angle θ, and add compensation amount Δd_e=0.1-0.2mm for chamfering and grinding. In this embodiment, based on the zero-displacement machining foundation of workpiece positioning and layered clamping, the cyclic transmission and positioning pin 154 slot mechanism: chain-type multi-station flow and physical locking of positioning pin 154 eliminate transmission cumulative error and high repeatability positioning accuracy. Synchronously constrain the lateral displacement and surface vibration of the electric busbar to solve the problem of vibration in thin-walled electric busbar machining and improve clamping rigidity. XZ axis coarse adjustment + mirror fine adjustment dual-stage positioning: first overall approximation and then mirror micro-feeding to avoid mechanical system return backlash error and achieve high alignment accuracy. By combining current intensity, pressure threshold, and duration for judgment, this technology replaces traditional sensors, reducing the false trigger rate to below 0.1% and improving zero-point calibration efficiency. Dynamic layered grinding, with three stages of continuous execution (rough grinding, fine grinding, and chamfering), simultaneously achieves thorough oxide layer removal and substrate protection through segmented speed reduction and compensation amount control. Chamfering is completed synchronously during mirror motion, eliminating edge burrs caused by traditional secondary clamping.

[0050] Specifically, the transmission and positioning step S1 ensures the precise positioning of the electric busbar at the grinding station. The synergistic effect of the chain transmission mechanism 1 and the moving positioning module 15 enables the efficient cyclic movement and precise positioning of the electric busbar clamping mechanism 4, laying the foundation for subsequent grinding processes. This improves production efficiency and ensures the consistency of the starting position for each grinding operation, thereby enhancing the overall product quality. The layered clamping and fixing step S2, through the dual action of the first clamping drive module 44 and the second clamping drive module 45, ensures the stability and safety of the electric busbar during the grinding process. This effectively prevents displacement or deformation of the electric busbar during high-speed grinding, ensuring grinding accuracy and surface flatness. The mirror feed S3 and synchronous mirror grinding S4 steps further enhance the uniformity and symmetry of the grinding. The combined use of the XZ axis drive module 22 and the mirror drive module 31 allows the two alloy grinding wheels 33 to move synchronously and relative to each other. At the same time, the servo motor drives the alloy grinding wheels 33 to rotate at high speed, ensuring the efficiency and consistency of the grinding process. Suitable for busbars requiring simultaneous double-sided grinding, this method significantly shortens processing time and improves yield. The S5 step, real-time conductivity determination, introduces a detection mechanism for the electrical conduction circuit, enabling precise control of grinding depth. Through comprehensive verification of contact pressure, current intensity, and signal duration, a zero-point calibration is triggered, ensuring the accuracy and stability of the grinding depth. This effectively avoids over-grinding or under-grinding, improving product reliability and consistency. The S6 step, dynamic grinding execution, achieves refined surface treatment of the busbar through layered feeding in three stages: rough grinding, fine grinding, and edge treatment. The rough grinding stage rapidly removes the oxide layer, the fine grinding stage finely adjusts surface roughness, and the edge treatment stage performs chamfering. The entire process ensures grinding efficiency while maintaining surface quality and edge integrity. This multi-stage grinding strategy not only improves the appearance quality of the busbar but also enhances its electrical performance and mechanical strength. This embodiment achieves high efficiency, high precision, and high quality in busbar surface treatment through key technologies such as precise positioning, stable clamping, mirror grinding, real-time determination, and dynamic execution.

[0051] The above embodiments only illustrate several implementation methods of this utility model, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of this utility model patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this utility model, and these all fall within the protection scope of this utility model. Therefore, the protection scope of this utility model patent should be determined by the appended claims.

Claims

1. A new energy automobile conductive row full-automatic polishing device, characterized in that: The device includes a chain transmission mechanism, a grinding transmission mechanism, and a grinding mechanism. The chain transmission mechanism is equipped with an electric busbar clamping mechanism, and multiple sets of electric busbar clamping mechanisms are provided. The chain transmission mechanism is used to drive the electric busbar clamping mechanism to circulate and transmit, and the electric busbar clamping mechanism is used to clamp and fix the electric busbar. The grinding transmission mechanism is used to drive the grinding mechanism to move. The grinding mechanism includes a mirror transmission module, a grinding drive module, and alloy grinding wheels. Two sets of grinding drive modules are arranged opposite each other and are mounted on the mirror transmission module. The mirror transmission module is used to drive the two sets of grinding drive modules to move relative to each other in a mirror image for grinding both sides of the electric busbar. The alloy grinding wheel is a conductive wheel. When it contacts the electric busbar, the two sets of alloy grinding wheels are electrically connected to determine that the electric busbar is being ground. The mirror transmission module drives the grinding drive module to move relative to both sides of the electric busbar according to the electrical conductivity of the alloy grinding wheel, and grinds the electric busbar through the alloy grinding wheel. ​ 2. The new energy vehicle conductive row full-automatic polishing device according to claim 1, characterized in that: The chain transmission mechanism includes a fixed panel, a ring track, a ring chain, and a transmission drive module. The ring track is mounted on the fixed panel, and the electric busbar clamping mechanism is mounted on the ring track and slides along the ring track. The ring chain is mounted on the fixed panel, and the transmission drive module is mounted on the fixed panel and is used to drive the ring chain for transmission. One side of the electric busbar clamping mechanism is connected to the ring chain so that it slides along the ring track under the action of the transmission drive module.

3. The new energy vehicle conductive row full-automatic polishing device according to claim 2, characterized in that: A movable positioning module is provided on the fixed panel. The movable positioning module is used to position the electric busbar clamping mechanism on the annular track. The movable positioning module includes a positioning drive cylinder, a positioning rotating connecting rod, and a movable block. The movable block is provided with a positioning pin, and the electric busbar clamping mechanism is provided with a positioning groove to cooperate with the positioning pin. The positioning drive cylinder is provided on the fixed panel, the positioning rotating connecting rod is provided with a positioning bushing and is mounted on the fixed panel through the positioning bushing, and the movable block is provided on the positioning connecting rod. The positioning drive cylinder is used to drive the positioning rotating connecting rod to rotate, so as to move the movable block toward the electric busbar clamping mechanism, so that the positioning pin cooperates with the positioning groove.

4. The fully automatic grinding device for conductive busbars in new energy vehicles according to claim 1, characterized in that: The busbar clamping mechanism includes a clamping slider, a clamping fixture, a clamping support, a first clamping drive module, and a second clamping drive module. The clamping slider is mounted on a chain transmission mechanism, the clamping fixture is mounted on the clamping slider, and the clamping support is mounted on the clamping slider and opposite to the clamping fixture. The clamping fixture is used to fix the rear end of the busbar. The first clamping drive module is used to drive a first clamping plate to clamp and fix the side of the busbar to the clamping support. The second clamping drive module is used to drive a second clamping plate to clamp and fix the surface of the busbar to the clamping support.

5. The new energy vehicle conductive row full-automatic polishing device according to claim 1, characterized in that: The grinding transmission mechanism includes a fixed base and an XZ axis transmission module. The fixed base is a cast iron base. The XZ axis transmission module is mounted on the fixed base. The mirror transmission module is mounted on the fixed base. The XZ axis transmission module is used to drive the mirror transmission module to move the alloy grinding wheel toward the electric busbar fixing device.

6. The new energy vehicle conductive row full-automatic polishing device according to claim 1, characterized in that: The mirror drive module is a synchronous belt drive module. Two grinding drive modules are respectively set on the bidirectional transmission side of the synchronous belt. When the synchronous belt is driven, it drives the two grinding drive modules to mirror drive. The grinding drive module is a servo motor. The drive end of the servo motor is equipped with a grinding spindle. The alloy grinding wheel is set on the grinding spindle.

7. The new energy vehicle conductive row full-automatic polishing device according to claim 1, characterized in that: The alloy grinding wheel has a tower-shaped cross section. The alloy grinding wheel includes a tower-shaped frame and a grinding ring. The tower-shaped frame is used to connect the grinding spindle. The grinding ring is located at the end of the tower-shaped frame to grind the busbar and remove the oxide layer on the surface of the busbar.

8. The new energy vehicle conductive row full-automatic polishing device according to claim 1, characterized in that: The alloy grinding wheel is provided with a protective cover, and a dust suction pipe is provided outside the protective cover. The dust suction pipe is used to remove the dust generated by the alloy grinding wheel during the grinding process.

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