New energy vehicle conductive busbar wrapping floating device

Abstract

This utility model relates to the field of new energy busbar production technology, specifically a floating device and method for wrapping new energy vehicle busbars. It includes a frame, a feeding mechanism, a conveying mechanism, a wrapping mechanism, and a pressing mechanism. The frame is equipped with a worktable, and a column is mounted on the worktable. The conveying mechanism is mounted on the column, which divides the frame into a feeding area and a wrapping area. The feeding mechanism is located in the feeding area, and the wrapping mechanism is located in the wrapping area and around the conveying mechanism. The feeding mechanism conveys the busbar towards the conveying mechanism. The conveying mechanism includes a fixed sleeve, a first floating seat, an elastic element, a second floating seat, and a fixed ring. This utility model allows the busbar to float radially during the wrapping process, effectively solving the problem of busbar offset during conveying and wrapping.

Description

Technical Field

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

[0002] In the manufacturing process of conductive busbars for new energy vehicle batteries, in order to improve the insulation performance of the busbars, prevent them from being corroded by external environmental factors, and avoid short circuits with other components, it is usually necessary to wrap the busbars with a protective strip material. This strip material generally has good insulation, corrosion resistance, and flexibility, and can effectively wrap the busbars, providing them with reliable protection.

[0003] However, existing wrapping processes suffer from numerous problems, resulting in poor stability and low efficiency. In terms of stability, current wrapping equipment and processes struggle to precisely control the tension and winding speed of the strip material. Unstable tension during wrapping leads to uneven winding on the conductor surface, resulting in inconsistent tightness. This not only affects the appearance quality of the conductor but can also significantly reduce the protective effect in localized areas, decreasing the conductor's insulation performance and corrosion resistance, thus impacting the safety and reliability of the entire battery system. Furthermore, unstable winding speeds can cause inconsistencies in the number of winding layers and spacing, further compromising the stability and uniformity of the wrapping. Therefore, a new design is needed for the existing wrapping structure. Utility Model Content

[0004] To address the aforementioned problems, this invention utilizes a combination of a floating cavity within a fixed sleeve, a first floating seat, an elastic element, and a second floating seat to form a flexible floating structure. This allows the busbar to float radially during the wrapping process, effectively solving the problem of busbar misalignment during transport and wrapping in new energy vehicles.

[0005] The technical solution adopted by this utility model is: a floating device for wrapping conductive busbars in new energy vehicles, including a frame, a feeding mechanism, a feeding mechanism, a wrapping mechanism, and a pressing mechanism. The frame is provided with a worktable, and a column is provided on the worktable. The feeding mechanism is mounted on the column, which divides the frame into a feeding area and a wrapping area. The feeding mechanism is located in the feeding area, and the wrapping mechanism is located in the wrapping area and around the feeding mechanism. The feeding mechanism is used to convey the busbars towards the feeding mechanism. The feeding mechanism includes a fixed sleeve, a first floating seat, an elastic element, a second floating seat, and a fixed ring. The fixed sleeve is fixedly mounted on the column and has a floating cavity. The first floating seat, the elastic element, and the second floating seat are sequentially arranged inside the floating cavity. The fixing ring is located at the port of the floating cavity to restrict the movement of the second floating cavity within the floating cavity. A gap is provided between the outer diameter of the first and second floating seats and the inner diameter of the floating cavity to allow the first and second floating seats to move within the floating cavity. The floating cavity, the first floating seat, and the second floating seat are concentrically provided with a feeding groove for feeding the electric busbar. The wrapping mechanism is used to wrap the electric busbar with strip material passing through the feeding mechanism. During wrapping, the electric busbar is allowed to float radially through the first and second floating seats. The pressing mechanism is located behind the wrapping mechanism to compact the wrapped strip material.

[0006] A further improvement to the above scheme is that the feeding mechanism includes a feeding module and a feeding straightening module. The feeding module is used to feed the coiled electric discharge to the feeding straightening module, and the feeding straightening module is used to straighten the electric discharge and then feed it into the feeding mechanism.

[0007] A further improvement to the above scheme is that the feeding straightening module includes a position adjustment module, a straightening support frame, a horizontal straightening module, and a vertical straightening module. The position adjustment module is located in the feeding area, the straightening support frame is located on the position adjustment module, and the horizontal straightening module and the vertical straightening module are sequentially located on the straightening support frame for sequentially performing horizontal and vertical straightening on the electric busbar.

[0008] A further improvement to the above scheme is that the position adjustment module is used to adjust the straightening support frame along the transmission direction of the electric busbar; the horizontal straightening module includes a horizontal adjustment component and a horizontal straightening roller; the horizontal adjustment component is used to adjust the position of the horizontal straightening roller to perform roll straightening of the electric busbar in the horizontal direction; the vertical straightening module includes a vertical adjustment component and a vertical straightening roller; the vertical adjustment component is used to adjust the position of the vertical straightening roller to perform roll straightening of the electric busbar in the vertical direction.

[0009] A further improvement to the above solution is that the fixed sleeve is provided with a fixed support frame, the fixed sleeve is fixed to the frame by the fixed support frame, the fixed sleeve passes through the column axially, and the wrapping mechanism is arranged on the outer periphery of the fixed sleeve.

[0010] A further improvement to the above scheme is that the first floating seat is provided with a first positioning step, the second floating seat is provided with a second positioning step, and the elastic element is a spring, with the two ends of the spring abutting against the first positioning step and the second positioning step respectively.

[0011] A further improvement to the above scheme is that both the first floating seat and the second floating seat are formed by processing Teflon.

[0012] A further improvement to the above solution is that the wrapping mechanism includes a wrapping drive module, a wrapping turntable, a wrapping guide arm, and a wrapping reel. The wrapping drive module drives the wrapping turntable to rotate around a fixed sleeve as its axis. The wrapping turntable is provided with a receiving cavity. The wrapping reel is disposed in the receiving cavity and fixedly connected to the fixed sleeve. The wrapping guide arm is disposed on one side of the wrapping turntable and rotates with the wrapping turntable. The wrapping guide arm is provided with multiple wrapping guide rollers for guiding the strip material toward the electric busbar. When the wrapping turntable rotates, the wrapping reel guides the material toward the electric busbar through the guide rollers and wraps the material around the outer circumference of the electric busbar during the rotation process.

[0013] A further improvement to the above solution is that the pressing mechanism includes an XY adjustment module, a pressing connecting bracket, a horizontal pressing module, and a vertical pressing module. The XY adjustment module is located on the rear side of the wrapping mechanism. The pressing connecting bracket is mounted on the XY adjustment module. The horizontal pressing module and the vertical pressing module are sequentially mounted on the XY adjustment module. The horizontal pressing module is equipped with multiple horizontal pressing rollers, and the vertical pressing module is equipped with multiple vertical pressing rollers for pressing the wrapped strip material tightly onto the electric busbar.

[0014] A method for wrapping electric busbars is implemented using a floating device for wrapping electric busbars in new energy vehicles. The feeding mechanism, wrapping mechanism, and pressing mechanism are all provided in two sets. The feeding mechanism, wrapping mechanism, and pressing mechanism at the front end constitute a forward wrapping system, and the feeding mechanism, wrapping mechanism, and pressing mechanism at the rear end constitute a reverse wrapping system. This allows for the wrapping of bidirectional strip materials on the outer diameter of the electric busbar.

[0015] The wrapping method includes the following steps:

[0016] Step S1: The coiled electric discharge material is fed through the feeding mechanism and then straightened bidirectionally using a straightening module.

[0017] Horizontal straightening: Applying a roller pressure of 5~15MPa in the width direction of the electric busbar by using horizontal straightening rollers eliminates horizontal bending;

[0018] Vertical straightening: Vertical bending is eliminated by applying a roller pressure of 3~10MPa in the thickness direction of the electric busbar using vertical straightening rollers;

[0019] Step S2: The straightened electric busbar is conveyed to the feeding mechanism, which compensates for radial displacement during wrapping through a floating structure.

[0020] The electric busbar passes through the feed chute of the fixed sleeve, and the first and second floating seats, supported by spring elastic elements, allow the electric busbar to float radially by 0.5~2mm.

[0021] Step S3, forward wrapping of mica tape:

[0022] The wrapping turntable of the forward wrapping system rotates clockwise at a speed of 200~600r / min, driving the wrapping guide arm to wrap the mica tape to the outer diameter of the electric busbar at a wrapping angle of 55°~65°.

[0023] The overlap rate of the mica tape is controlled at 0.1%~10% to form the first insulating layer;

[0024] Step S4, reverse wrapping of mica tape:

[0025] The wrapping turntable of the reverse wrapping system rotates counterclockwise at the same speed, wrapping the mica tape at a reverse wrapping angle of 55°~65°, with the overlap rate controlled synchronously at 0.1%~10%, forming a second insulating layer that intersects with the first layer;

[0026] Step S5, bidirectional pressing and curing:

[0027] After each wrapping, the pressing mechanism compacts the mica tape in multiple directions:

[0028] A horizontal pressing roller applies a pressure of 8~12MPa to eliminate interlayer air bubbles;

[0029] A vertical pressing roller applies a pressure of 6~10MPa to ensure that the mica tape adheres to the surface of the electric busbar at a rate of ≥95%.

[0030] The pressing temperature is maintained at 80~120℃ to activate the adhesiveness of the mica tape resin.

[0031] Step S6: The distance between the forward wrapping system and the reverse wrapping system is 1.2 to 1.5 times the width of the busbar, to ensure no interference between the bidirectional wrapping layers.

[0032] The beneficial effects of this utility model are:

[0033] Compared to existing electric busbar wrapping systems, this invention utilizes a combination of a floating cavity within a fixed sleeve, a first floating seat, an elastic element, and a second floating seat to create a flexible floating structure. This allows the electric busbar to float radially during the wrapping process, effectively solving the problem of busbar misalignment during conveying and wrapping. Specifically, when the electric busbar passes through the feeding chute, the first and second floating seats can move freely within the floating cavity, automatically adjusting the busbar's position and quickly resetting after being misaligned during wrapping. This improves wrapping accuracy and avoids uneven wrapping or material waste caused by busbar misalignment, thus enhancing wrapping quality. During busbar conveying, the elastic element absorbs some vibration and impact, reducing mechanical wear and extending equipment lifespan. It also provides appropriate elasticity during radial floating, ensuring stable passage of the busbar through the feeding chute and preventing positional fluctuations caused by vibration. This invention features a clearly defined division of labor between the feeding mechanism, the wrapping mechanism, and the pressing mechanism, forming an efficient workflow. The feeding mechanism accurately conveys the electric busbar to the feeding mechanism, which in turn uses a floating structure to ensure stable conveying and wrapping of the busbar. The wrapping mechanism then performs precise wrapping, and finally, the pressing mechanism compacts the wrapped strip of material. The entire process is highly automated and easy to operate, significantly reducing the need for manual intervention and improving production efficiency. The column divides the workbench into a feeding area and a wrapping area. This separation ensures that the conveying and wrapping processes of the electric busbar do not interfere with each other, improving work safety.

[0034] The EDM wrapping method involves feeding a rolled EDM into a feed mechanism and then performing bidirectional straightening using a straightening module. Horizontal straightening rollers apply a pressure of 5-15 MPa in the width direction of the EDM, effectively eliminating horizontal bending; vertical straightening rollers apply a pressure of 3-10 MPa in the thickness direction of the EDM, eliminating vertical bending. This bidirectional straightening method comprehensively corrects EDM deformation, ensuring its straightness and surface flatness, providing high-quality base material for subsequent wrapping processes. The straightened EDM has high straightness, reducing material waste and uneven wrapping caused by the EDM's own bending during the wrapping process, thus improving the stability and reliability of the finished product. The feeding mechanism compensates for radial displacement during wrapping through a floating structure. The EDM passes through a feeding groove in a fixed sleeve, and the first and second floating seats, supported by spring elastic elements, allow for radial displacement of 0.5-2 mm. This solves the problem of radial offset caused by uneven force or mechanical vibration during the wrapping process, ensuring the stability and consistency of the EDM during wrapping. The introduction of the floating structure not only improves the wrapping accuracy but also enhances the adaptability and robustness of the equipment, reducing the failure rate and maintenance costs during production. The coordinated operation of the forward and reverse wrapping systems enables bidirectional wrapping of strip material on the outer diameter of the busbar. The forward wrapping system's wrapping turntable rotates clockwise at 200-600 r / min, driving the wrapping guide arm to wind the mica strip at a 65° wrap angle to the outer diameter of the busbar, with the mica strip overlap rate controlled at 0.1%-10%, forming the first insulation layer. Subsequently, the reverse wrapping system's wrapping turntable rotates counterclockwise at the same speed, winding the mica strip at a reverse 65° wrap angle, with the overlap rate simultaneously controlled at 0.1%-10%, forming the second insulation layer that intersects with the first layer. This bidirectional wrapping method not only improves the density and uniformity of the insulation layer but also enhances its mechanical strength and electrical properties, effectively preventing partial discharge and insulation breakdown that may occur during the use of the busbar. The pressing mechanism performs multi-directional compaction of the mica tape, maintaining the pressing temperature at 80~120℃. This activates the adhesiveness of the mica tape resin, further enhancing the bonding strength and integrity of the insulation layer. Multi-directional pressing and curing not only improves the density and stability of the insulation layer but also effectively avoids the generation of interlayer bubbles and voids, improving the voltage withstand performance and service life of the busbar. The spacing between the forward and reverse wrapping systems is designed to be 1.2~1.5 times the width of the busbar, ensuring no interference between the bidirectional wrapping layers. By fully considering the busbar dimensions and wrapping process requirements, mutual influence and interference between the forward and reverse wrapping layers are avoided, ensuring the independence and integrity of each insulation layer. Attached Figure Description

[0035] Figure 1 This is a three-dimensional schematic diagram of the new energy vehicle conductive busbar winding floating device of this utility model;

[0036] Figure 2 for Figure 1 A side view schematic diagram of the floating device for the conductive busbar wrapping in new energy vehicles;

[0037] Figure 3 for Figure 1 A three-dimensional schematic diagram of the floating device for the conductive busbar wrapping of new energy vehicles from another perspective;

[0038] Figure 4 for Figure 1 A three-dimensional schematic diagram of the floating device for the conductive busbar wrapping of new energy vehicles from another perspective;

[0039] Figure 5 for Figure 1 A three-dimensional schematic diagram of the wrapping mechanism of the conductive busbar wrapping floating device for new energy vehicles;

[0040] Figure 6 for Figure 1 A schematic diagram of the feeding mechanism of the floating device for the conductive busbar winding package in China's new energy vehicles.

[0041] Explanation of reference numerals in the attached drawings: Frame 1, Worktable 11, Column 12, Feeding mechanism 2, Unloading module 21, Feeding straightening module 22, Position adjustment module 221, Straightening support frame 222, Horizontal straightening module 223, Horizontal adjustment component 2231, Horizontal straightening roller 2232, Vertical straightening module 224, Vertical adjustment component 2241, Vertical straightening roller 2242, Feeding mechanism 3, Fixed sleeve 31, Floating cavity 311, Fixed support frame 312. First floating seat 32, first positioning step 321, elastic element 33, second floating seat 34, second positioning step 341, fixing ring 35, wrapping mechanism 4, wrapping drive module 41, wrapping turntable 42, wrapping guide arm 43, wrapping guide roller 431, wrapping reel 44, pressing mechanism 5, XY adjustment module 51, pressing connecting bracket 52, horizontal pressing module 53, horizontal pressing roller 531, vertical pressing module 54, vertical pressing roller 541. Detailed Implementation

[0042] 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.

[0043] 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.

[0044] 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 1-6As shown, in one embodiment of this utility model, a floating device for wrapping conductive busbars in new energy vehicles is disclosed, comprising a frame 1, a feeding mechanism 2, a feeding mechanism 3, a wrapping mechanism 4, and a pressing mechanism 5. The frame 1 is provided with a worktable 11, on which a column 12 is provided. The feeding mechanism 3 is mounted on the column 12, which divides the frame 1 into a feeding area and a wrapping area. The feeding mechanism 2 is located in the feeding area, and the wrapping mechanism 4 is located in the wrapping area and on the outer periphery of the feeding mechanism 3. The feeding mechanism 2 is used to convey the busbars towards the feeding mechanism 3. The feeding mechanism 3 includes a fixed sleeve 31, a first floating seat 32, an elastic element 33, a second floating seat 34, and a fixed ring 35. The fixed sleeve 31 is fixedly mounted on the column 12 and has a floating cavity 311. The first floating seat 32, the elastic element 33, and the second floating seat 34 are sequentially arranged in the floating cavity 311. The fixing ring 35 is arranged at the port of the floating cavity 311 to restrict the second floating cavity 311 to move within the floating cavity 311. A gap is provided between the outer diameter of the first floating seat 32 and the second floating seat 34 and the inner diameter of the floating cavity 311 to allow the first floating seat 32 and the second floating seat 34 to move within the floating cavity 311. The floating cavity 311, the first floating seat 32, and the second floating seat 34 are concentrically provided with a feeding groove for feeding the electric busbar. The wrapping mechanism 4 is used to wrap the electric busbar that passes through the feeding mechanism 3 with strip material. During wrapping, the electric busbar is allowed to float radially through the first floating seat 32 and the second floating seat 34. The pressing mechanism 5 is located behind the wrapping mechanism 4 to compact the wrapped strip material. This invention forms a flexible floating structure through the combination of a floating cavity 311 within a fixed sleeve 31, a first floating seat 32, an elastic element 33, and a second floating seat 34. This allows the electric busbar to float radially during the wrapping process, effectively solving the problem of busbar misalignment during conveying and wrapping. Specifically, when the electric busbar passes through the feeding chute, the first floating seat 32 and the second floating seat 34 can move freely within the floating cavity 311, automatically adjusting the position of the electric busbar. It can quickly reset after being misaligned during wrapping. This improves wrapping accuracy and avoids uneven wrapping or material waste caused by busbar misalignment, thus enhancing wrapping quality. During the electric busbar conveying process, the elastic element 33 absorbs some vibration and impact, reducing mechanical wear and extending equipment lifespan. It also provides appropriate elasticity when the electric busbar floats radially, ensuring stable passage through the feeding chute and preventing position fluctuations caused by vibration. This invention, with its clearly defined functions of the feeding mechanism 2, feeding mechanism 3, wrapping mechanism 4, and pressing mechanism 5, forms an efficient workflow.The feeding mechanism 2 accurately conveys the electric busbar to the feeding mechanism 3, which in turn ensures stable conveying and wrapping of the busbar through a floating structure. The wrapping mechanism 4 then performs precise wrapping, and finally, the pressing mechanism 5 compacts the wrapped strip material. The entire process is highly automated, easy to operate, and greatly reduces the need for manual intervention, thus improving production efficiency. The column 12 divides the workbench 11 into a feeding area and a wrapping area. This separation ensures that the conveying and wrapping processes of the electric busbar do not interfere with each other, improving work safety.

[0045] The feeding mechanism 2 includes a feeding module 21 and a feeding straightening module 22. The feeding module 21 feeds the coiled EBM into the feeding straightening module 22, and the feeding straightening module 22 straightens the EBM before feeding it into the feeding mechanism 3. The feeding straightening module 22 includes a position adjustment module 221, a straightening support frame 222, a horizontal straightening module 223, and a vertical straightening module 224. The position adjustment module 221 is located in the feeding area, the straightening support frame 222 is mounted on the position adjustment module 221, and the horizontal straightening module 223 and the vertical straightening module 224 are sequentially mounted on the straightening support frame 222 for sequentially straightening the EBM horizontally and vertically. In this embodiment, the coordinated operation of the feeding module 21 and the straightening module 22 ensures a smooth transition of the EBM from a coiled state to a straight state. The feeding module 21 is responsible for feeding the coiled EDM to the straightening module 22. This process requires high stability and accuracy to avoid twisting or damage to the EDM in the initial stage. The straightening module 22 further straightens the EDM precisely to ensure its straightness and surface flatness in subsequent processing stages. The position adjustment module 221 is located in the feeding area and can be flexibly adjusted according to actual production needs to adapt to different specifications of EDM, enhancing the versatility and flexibility of the equipment. The straightening support frame 222 serves as the basic structure, providing a stable mounting platform for the horizontal straightening module 223 and the vertical straightening module 224, ensuring the stability of the straightening process. The sequential arrangement of the horizontal straightening module 223 and the vertical straightening module 224 achieves all-round straightening of the EDM, effectively eliminating bending deformation in the horizontal and vertical directions, improving the straightness of the EDM, and thus improving the tightness and uniformity of the wrapping. This reduces stress concentration during the straightening process of the electric busbar, decreases the internal stress of the busbar material, avoids secondary deformation caused by stress release, and ensures the stability and reliability of the electric busbar during the wrapping process.

[0046] The position adjustment module 221 is used to adjust the straightening support frame 222 along the transmission direction of the electric busbar. The horizontal straightening module 223 includes a horizontal adjustment component 2231 and a horizontal straightening roller 2232. The horizontal adjustment component 2231 is used to adjust the position of the horizontal straightening roller 2232 to perform roll straightening of the electric busbar in the horizontal direction. The vertical straightening module 224 includes a vertical adjustment component 2241 and a vertical straightening roller 2242. The vertical adjustment component 2241 is used to adjust the position of the vertical straightening roller 2242 to perform roll straightening of the electric busbar in the vertical direction. In this embodiment, the position adjustment module 221 ensures the stability and positioning accuracy of the electric busbar during transmission by precisely adjusting the straightening support frame 222 along the transmission direction of the electric busbar, effectively avoiding processing errors caused by positional offset. The horizontal adjustment component 2231 and the horizontal straightening roller 2232 in the horizontal straightening module 223 work together to achieve precise roll straightening of the electric busbar in the horizontal direction. The system can correct bending or twisting of the E-bus on a horizontal plane and ensure the flatness of the E-bus surface, thereby improving the fit and aesthetics of subsequent wrapping processes. The position adjustment function of the horizontal straightening roller 2232 allows operators to flexibly adjust it according to actual needs, adapting to the processing requirements of different E-bus specifications, enhancing the equipment's versatility and flexibility. The vertical straightening module 224, through the cooperation of the vertical adjustment component 2241 and the vertical straightening roller 2242, achieves precise straightening of the E-bus in the vertical direction. This helps eliminate deformation of the E-bus in the vertical direction and ensures the overall straightness of the E-bus, providing a more stable substrate for subsequent wrapping processes. The position adjustment function of the vertical straightening roller 2242 also gives the equipment a high degree of adaptability and adjustability, meeting diverse production needs.

[0047] The fixed sleeve 31 is equipped with a fixed support frame 312, and the fixed sleeve 31 is fixed to the frame 1 by the fixed support frame 312. The fixed sleeve 31 passes through the column 12 axially, and the wrapping mechanism 4 is located on the outer periphery of the fixed sleeve 31. In this embodiment, the structure ensures the axial positioning accuracy of the fixed sleeve 31 during operation and effectively avoids displacement caused by vibration or external force, thereby ensuring the accuracy and consistency of the wrapping operation. The axial passage of the fixed sleeve 31 through the column 12 enhances the structural rigidity of the device. The column 12, as a supporting element, works together with the fixed sleeve 31 to form a stable frame system, which can effectively resist various torques and stresses generated during the wrapping process, ensuring the normal operation of the device under high load conditions. The wrapping mechanism 4 is located on the outer periphery of the fixed sleeve 31, making the entire device structure more compact and reasonable. The close cooperation between the wrapping mechanism 4 and the fixed sleeve 31 facilitates efficient wrapping of the electric busbar.

[0048] The first floating seat 32 is provided with a first positioning step 321, and the second floating seat 34 is provided with a second positioning step 341. The elastic element 33 is a spring, with its two ends abutting against the first positioning step 321 and the second positioning step 341, respectively. Specifically, both the first floating seat 32 and the second floating seat 34 are made of Teflon. In this embodiment, the first floating seat 32 and the second floating seat 34 are respectively provided with the first positioning step 321 and the second positioning step 341, ensuring that the two ends of the spring can accurately abut, thereby achieving effective positioning and stable operation of the spring. As an elastic element 33, the spring plays a key role in buffering and regulating in this structure, effectively absorbing the vibration and impact generated during the winding process of the electric busbar, ensuring the smoothness and accuracy of the winding process. The choice of Teflon for both the first floating seat 32 and the second floating seat 34 brings many benefits. Teflon (polytetrafluoroethylene) material is known for its excellent wear resistance, corrosion resistance, and self-lubricating properties, and can maintain good performance stability in high-frequency reciprocating motion.

[0049] See Figure 6 As shown, the wrapping mechanism 4 includes a wrapping drive module 41, a wrapping turntable 42, a wrapping guide arm 43, and a wrapping reel 44. The wrapping drive module 41 drives the wrapping turntable 42 to rotate around the fixed sleeve 31. The wrapping turntable 42 has a receiving cavity, and the wrapping reel 44 is disposed in the receiving cavity and fixedly connected to the fixed sleeve 31. The wrapping guide arm 43 is disposed on one side of the wrapping turntable 42 and rotates with the wrapping turntable 42. The wrapping guide arm 43 is provided with multiple wrapping guide rollers 431, which are used to guide the strip material toward the electric busbar. When the wrapping turntable 42 rotates, the wrapping reel 44 guides the material toward the electric busbar through the guide rollers and wraps the material around the outer circumference of the electric busbar during the rotation. In this embodiment, the precise control capability of the wrapping drive module 41 ensures that the wrapping turntable 42 rotates stably around the fixed sleeve 31, improving the stability of the wrapping process and effectively avoiding uneven material wrapping caused by uneven rotation. The receiving cavity structure on the wrapping turntable 42 houses the wrapping reel 44 and is fixedly connected to the fixed sleeve 31, achieving orderly material supply and further improving the continuity and reliability of the wrapping operation. The setting of the wrapping guide arm 43 and its characteristic of rotating synchronously with the wrapping turntable 42 ensures that the strip material maintains the correct path and tension state during the guiding process. The configuration of multiple wrapping guide rollers 431 not only effectively guides the strip material towards the electric busbar but also allows for fine-tuning during material transport, ensuring precise winding around the outer circumference of the electric busbar. This reduces the possibility of material deviation or slippage, thereby ensuring the consistency and high standard of wrapping quality. Because the material is continuously and stably guided during the winding process, its distribution around the outer circumference of the electric busbar is more uniform, enhancing the mechanical and electrical properties of the electric busbar and extending its service life.

[0050] The pressing mechanism 5 includes an XY adjustment module 51, a pressing connecting bracket 52, a horizontal pressing module 53, and a vertical pressing module 54. The XY adjustment module 51 is located behind the wrapping mechanism 4. The pressing connecting bracket 52 is mounted on the XY adjustment module 51. The horizontal pressing module 53 and the vertical pressing module 54 are sequentially mounted on the XY adjustment module 51. The horizontal pressing module 53 is equipped with multiple horizontal pressing rollers 531, and the vertical pressing module 54 is equipped with multiple vertical pressing rollers 541, for pressing the wrapped strip material tightly onto the busbar. In this embodiment, the XY adjustment module 51 is located behind the wrapping mechanism 4, providing a stable base for subsequent pressing operations. The XY adjustment module 51 allows for precise adjustment of the horizontal pressing module 53 and the vertical pressing module 54 in a two-dimensional plane, thereby adapting to the needs of busbars of different specifications and shapes, greatly enhancing the flexibility and applicability of the device. The pressing connection bracket 52, acting as a connector, securely fixes the horizontal pressing module 53 and the vertical pressing module 54 to the XY adjustment module 51, forming a unified whole. This ensures coordinated operation between the components, prevents displacement caused by vibration or external forces, and guarantees the stability and consistency of the pressing process. The horizontal pressing module 53 is equipped with multiple horizontal pressing rollers 531, which can apply uniform horizontal pressure to the strip material, making it tightly adhere to the surface of the busbar. The vertical pressing module 54, through multiple vertical pressing rollers 541, further strengthens the vertical pressure on the strip material, ensuring its firm adhesion to the busbar. This dual pressing mechanism not only increases the contact area between the strip material and the busbar but also effectively eliminates any potential air gaps, improving the overall electrical performance and mechanical strength.

[0051] A method for wrapping electric busbars is implemented using a floating wrapping device for electric busbars in new energy vehicles. The feeding mechanism 3, wrapping mechanism 4, and pressing mechanism 5 are each provided in two sets. The front feeding mechanism 3, wrapping mechanism 4, and pressing mechanism 5 constitute a forward wrapping system, and the rear feeding mechanism 3, wrapping mechanism 4, and pressing mechanism 5 constitute a reverse wrapping system; so that bidirectional strip materials are wrapped around the outer diameter of the electric busbar.

[0052] The wrapping method includes the following steps:

[0053] Step S1: The coiled electric arc discharge sheet is fed by the feeding mechanism 2 and straightened in both directions by the straightening module 22: horizontal straightening: 5~15MPa roller pressure is applied in the width direction of the electric arc discharge sheet by the horizontal straightening roller 2232 to eliminate horizontal bending; vertical straightening: 3~10MPa roller pressure is applied in the thickness direction of the electric arc discharge sheet by the vertical straightening roller 2242 to eliminate vertical bending.

[0054] Step S2: The straightened electric busbar is conveyed to the feeding mechanism 3. The feeding mechanism 3 compensates for the radial displacement during wrapping through a floating structure: the electric busbar passes through the feeding groove of the fixed sleeve 31, and the first floating seat 32 and the second floating seat 34 supported by the spring elastic element 33 allow the electric busbar to float radially by 0.5~2mm.

[0055] Step S3, forward wrapping of mica tape: the wrapping turntable 42 of the forward wrapping system rotates clockwise at a speed of 200~600r / min, driving the wrapping guide arm 43 to wrap the mica tape at a wrapping angle of 55°~65° to the outer diameter of the electric busbar; the overlap rate of the mica tape is controlled at 0.1%~10%, forming the first insulation layer;

[0056] Step S4, reverse wrapping of mica tape: The wrapping turntable 42 of the reverse wrapping system rotates counterclockwise at the same speed, wrapping the mica tape at a reverse wrapping angle of 55°~65°, with the overlap rate controlled synchronously at 0.1%~10%, forming a second insulating layer that intersects with the first layer;

[0057] Step S5, bidirectional pressing and curing: After each wrapping, the pressing mechanism 5 performs multi-directional pressing on the mica tape: the horizontal pressing roller 531 applies 8~12MPa pressure to eliminate interlayer air bubbles; the vertical pressing roller 541 applies 6~10MPa pressure to ensure that the adhesion between the mica tape and the electric busbar surface is ≥95%; the pressing temperature is maintained at 80~120℃ to activate the adhesiveness of the mica tape resin;

[0058] Step S6: The distance between the forward wrapping system and the reverse wrapping system is 1.2 to 1.5 times the width of the electrical busbar, ensuring no interference between the bidirectional wrapping layers. In this embodiment, the rolled electrical busbar is fed by the feeding mechanism 2 and bidirectionally straightened using the straightening module 22. The horizontal straightening roller 2232 applies a roller pressure of 5 to 15 MPa in the width direction of the electrical busbar, effectively eliminating horizontal bending; the vertical straightening roller 2242 applies a roller pressure of 3 to 10 MPa in the thickness direction of the electrical busbar, eliminating vertical bending. The bidirectional straightening method can comprehensively correct the deformation of the electrical busbar, ensuring its straightness and surface flatness, providing high-quality base material for subsequent wrapping processes. The straightened electrical busbar has high straightness, reducing material waste and uneven wrapping caused by the bending of the electrical busbar itself during the wrapping process, and improving the stability and reliability of the finished product. The feeding mechanism 3 compensates for radial displacement during wrapping through a floating structure. The electric busbar passes through the feeding groove of the fixed sleeve 31, and the first floating seat 32 and the second floating seat 34, supported by the spring elastic element 33, allow the electric busbar to float radially by 0.5~2mm. This solves the problem of radial displacement caused by uneven force or mechanical vibration during the wrapping process, ensuring the stability and consistency of the electric busbar during the wrapping process. The introduction of the floating structure not only improves the wrapping accuracy but also enhances the adaptability and robustness of the equipment, reducing the failure rate and maintenance costs in the production process. The coordinated work of the forward wrapping system and the reverse wrapping system enables bidirectional wrapping of strip material on the outer diameter of the electric busbar. The wrapping turntable 42 of the forward wrapping system rotates clockwise at a speed of 200~600r / min, driving the wrapping guide arm 43 to wrap the mica tape to the outer diameter of the electric busbar at a wrapping angle of 65°. The overlap rate of the mica tape is controlled at 0.1%~10%, forming the first insulating layer. Subsequently, the wrapping turntable 42 of the reverse wrapping system rotates counterclockwise at the same speed, wrapping the mica tape at a 65° reverse wrapping angle, with the overlap rate simultaneously controlled at 0.1%~10%, forming a second insulation layer that intersects with the first layer. This bidirectional wrapping method not only improves the density and uniformity of the insulation layer but also enhances its mechanical strength and electrical properties, effectively preventing partial discharge and insulation breakdown that may occur during the use of the busbar. The pressing mechanism 5 performs multidirectional compaction of the mica tape, maintaining the pressing temperature at 80~120℃, activating the viscosity of the mica tape resin, further enhancing the bonding strength and integrity of the insulation layer. Multidirectional pressing and curing not only improves the density and stability of the insulation layer but also effectively avoids the generation of interlayer bubbles and voids, improving the busbar's withstand voltage performance and service life. The spacing between the forward and reverse wrapping systems is designed to be 1.2~1.5 times the width of the busbar, ensuring no interference between the bidirectional wrapping layers. The dimensions of the busbar and the requirements of the wrapping process were fully considered, avoiding mutual influence and interference between the forward and reverse wrapping layers, and ensuring the independence and integrity of each layer of insulation material.

[0059] 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 vehicle conductive row winding floating device, characterized in that: The system includes a frame, a feeding mechanism, a conveying mechanism, a wrapping mechanism, and a pressing mechanism. The frame has a worktable with a column on it. The conveying mechanism is mounted on the column, which divides the frame into a feeding area and a wrapping area. The feeding mechanism is located in the feeding area, and the wrapping mechanism is located in the wrapping area and around the periphery of the conveying mechanism. The feeding mechanism conveys the electric busbar towards the conveying mechanism. The conveying mechanism includes a fixed sleeve, a first floating seat, an elastic element, a second floating seat, and a fixed ring. The fixed sleeve is fixedly mounted on the column and has a floating cavity. The first floating seat, the elastic element, and the second floating seat are sequentially arranged within the floating cavity. The fixed ring is located at the port of the floating cavity to restrict the movement of the second floating cavity within it. The outer diameters of the first and second floating seats are... A gap is provided between the inner diameter of the floating cavity and the first floating seat and the second floating seat to allow the first floating seat and the second floating seat to move within the floating cavity; the floating cavity, the first floating seat and the second floating seat are concentrically provided with a feeding groove for feeding the electric busbar; the wrapping mechanism is used to wrap the electric busbar with strip material passing through the feeding mechanism, and the electric busbar is allowed to float radially during wrapping through the first floating seat and the second floating seat; the pressing mechanism is located behind the wrapping mechanism to compact the wrapped strip material; the wrapping mechanism includes a wrapping drive module, a wrapping turntable, a wrapping guide arm and a wrapping disc, the wrapping drive module is used to drive the wrapping turntable to rotate around the fixed sleeve as the axis, the wrapping turntable is provided with a receiving cavity, the wrapping disc is disposed in the receiving cavity and fixedly connected to the fixed sleeve, and the wrapping guide arm is disposed on one side of the wrapping turntable and rotates with the wrapping turntable.

2. The winding and floating device for the conductive bar of a new energy vehicle according to claim 1, characterized in that: The feeding mechanism includes a feeding module and a feeding straightening module. The feeding module is used to feed the coiled electric discharge to the feeding straightening module, and the feeding straightening module is used to straighten the electric discharge and then feed it into the feeding mechanism.

3. The winding and floating device for the conductive bar of a new energy vehicle according to claim 2, characterized in that: The feeding and straightening module includes a position adjustment module, a straightening support frame, a horizontal straightening module, and a vertical straightening module. The position adjustment module is located in the feeding area, the straightening support frame is located on the position adjustment module, and the horizontal and vertical straightening modules are sequentially located on the straightening support frame for sequentially straightening the electric busbar horizontally and vertically.

4. The winding and floating device of the new energy vehicle conductive row according to claim 3, characterized in that: The position adjustment module is used to adjust the straightening support frame along the transmission direction of the electric busbar. The horizontal straightening module includes a horizontal adjustment component and a horizontal straightening roller. The horizontal adjustment component is used to adjust the position of the horizontal straightening roller to perform roll straightening of the electric busbar in the horizontal direction. The vertical straightening module includes a vertical adjustment component and a vertical straightening roller. The vertical adjustment component is used to adjust the position of the vertical straightening roller to perform roll straightening of the electric busbar in the vertical direction.

5. The winding and floating device for the conductive bar of a new energy vehicle according to claim 1, characterized in that: The fixed sleeve is provided with a fixed support frame, and the fixed sleeve is fixed to the frame by the fixed support frame. The fixed sleeve passes through the column axially, and the wrapping mechanism is arranged on the outer periphery of the fixed sleeve.

6. The winding and floating device for the conductive bar of a new energy vehicle according to claim 1, characterized in that: The first floating seat is provided with a first positioning step, the second floating seat is provided with a second positioning step, and the elastic element is a spring, with the two ends of the spring abutting against the first positioning step and the second positioning step respectively.

7. The winding and floating device of the new energy vehicle conductive row according to claim 6, characterized in that: Both the first and second floating seats are formed from Teflon.

8. The winding and floating device for the conductive bar of a new energy vehicle according to claim 1, characterized in that: The wrapping guide arm is equipped with multiple wrapping guide rollers to guide the strip material toward the electric busbar. When the wrapping turntable rotates, the wrapping disc guides the material toward the electric busbar through the guide rollers and wraps the material around the outer circumference of the electric busbar during the rotation process.

9. The winding and floating device for the conductive bar of a new energy vehicle according to claim 1, characterized in that: The pressing mechanism includes an XY adjustment module, a pressing connecting bracket, a horizontal pressing module, and a vertical pressing module. The XY adjustment module is located behind the wrapping mechanism. The pressing connecting bracket is mounted on the XY adjustment module. The horizontal pressing module and the vertical pressing module are sequentially mounted on the XY adjustment module. The horizontal pressing module is equipped with multiple horizontal pressing rollers, and the vertical pressing module is equipped with multiple vertical pressing rollers for pressing the wrapped strip material tightly onto the electric busbar.

Images