A crimping device for high-voltage wiring harness of electric vehicle

Abstract

This utility model relates to the field of wire harness crimping technology and discloses a crimping device for high-voltage wire harnesses for electric vehicles. The device includes a base, two support columns fixedly connected to the top of the base, a middle plate fixedly connected between the two support columns, a mounting seat fixedly connected to the top of the middle plate, mounting plates fixedly connected to both sides of the mounting seat, a cylinder fixedly connected between the two mounting plates, a cylinder push rod slidably connected to the inner side of the cylinder, one end of the cylinder push rod penetrating and extending below the middle plate, a movable plate fixedly connected to the bottom end of the cylinder push rod, and two fixed rods fixedly connected to the bottom end of the movable plate. This utility model, by setting a detachable connection between the bottom mold and the base, means that different specifications of bottom molds can be quickly replaced to adapt to different types of terminals and wire diameters. One crimping device can meet the production needs of multiple product varieties, greatly improving equipment utilization and production flexibility.

Description

Technical Field

[0001] This utility model relates to the field of wire harness crimping technology, specifically a crimping device for high-voltage wire harnesses used in electric vehicles. Background Technology

[0002] In the field of electric vehicle manufacturing, high-voltage wiring harnesses are key components for transmitting electrical energy, and their connection quality directly affects the performance and safety of electric vehicles. The crimping process is a crucial step in ensuring reliable connections of high-voltage wiring harnesses. By crimping the conductors of the wiring harness to the connection terminals, a stable, low-resistance electrical connection is formed.

[0003] Traditional crimping methods often employ manual operation or simple mechanical crimping equipment. Manual operation is not only inefficient but also difficult to guarantee crimp quality. Issues such as weak crimps and inconsistent dimensions can arise due to operator skill levels and fatigue, affecting the electrical performance and mechanical strength of high-voltage wiring harnesses and posing safety hazards to electric vehicles. While existing simple mechanical crimping equipment improves crimping efficiency to some extent, its mold replacement is inconvenient, making it difficult to adapt to the crimping requirements of different high-voltage wiring harness specifications, thus reducing the equipment's versatility and production flexibility.

[0004] Therefore, in order to meet the higher requirements of the electric vehicle manufacturing industry for the quality and efficiency of high-voltage wiring harness crimping, it is necessary to develop a high-voltage wiring harness crimping device for electric vehicles with reasonable structure, high crimping accuracy, good stability and strong versatility. Utility Model Content

[0005] (a) Technical problems to be solved The purpose of this invention is to address the problem that while existing simple mechanical crimping equipment improves crimping efficiency to some extent, its bottom mold is inconvenient to replace, making it difficult to adapt to the crimping requirements of high-voltage wire harnesses of different specifications, thus reducing the equipment's versatility and production flexibility. Therefore, this invention proposes a crimping device for high-voltage wire harnesses used in electric vehicles.

[0006] (II) Technical Solution The technical solution of this utility model to solve the above-mentioned technical problems is as follows: A crimping device for a high-voltage wiring harness for electric vehicles includes a base. Two support columns are fixedly connected to the top of the base. A middle plate is fixedly connected between the two support columns. A mounting seat is fixedly connected to the top of the middle plate. Mounting plates are fixedly connected to both sides of the mounting seat. A cylinder is fixedly connected between the two mounting plates. A cylinder push rod is slidably connected to the inner side of the cylinder. One end of the cylinder push rod passes through and extends below the middle plate. A movable plate is fixedly connected to the bottom end of the cylinder push rod. Two fixed rods are fixedly connected to the bottom end of the movable plate. The bottom ends of the two fixed rods are fixedly connected to a pressure plate. A bottom mold is detachably connected to the top of the base. A guide mechanism is provided between the middle plate and the movable plate.

[0007] Based on the above technical solution, the present invention can be further improved as follows.

[0008] Preferably, the guiding mechanism includes guide rods, two guide rods are fixedly connected to the top of the movable plate, two column sleeves are fixedly connected to the inner side of the intermediate plate, the two guide rods are slidably connected to the inner side of the two column sleeves respectively, and limit plates are fixedly connected to the top of the two guide rods.

[0009] Preferably, the top of the base is detachably connected to two limiting strips by bolts, the bottom mold is snapped between the two limiting strips, and the top of the base is fixedly connected to two limiting posts for abutting the rear side of the bottom mold.

[0010] Preferably, each of the two limiting strips has a bevel on one side of its opposite side.

[0011] Preferably, a pressure groove is formed at the top of the bottom mold.

[0012] Preferably, a handle is fixedly connected to the top of the bottom mold.

[0013] Preferably, a plurality of rubber posts are fixedly connected to the bottom end of the base.

[0014] (III) Beneficial Effects Compared with the prior art, the technical solution of this application has the following beneficial technical effects: This invention features a detachable connection between the bottom mold and the base, which means that different specifications of bottom molds can be quickly replaced to accommodate different types of terminals and wire diameters. One crimping device can meet the production needs of multiple products, greatly improving equipment utilization and production flexibility. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the overall structure of this utility model; Figure 2 This is a schematic diagram showing the relative positional relationship between the bottom mold and the limiting post of this utility model; Figure 3 This is a schematic diagram showing the relative positional relationship between the limiting strip and the limiting post of this utility model; Figure 4 This is a schematic diagram of the guiding mechanism of this utility model.

[0016] In the diagram: 1. Base; 2. Support column; 3. Intermediate plate; 4. Mounting seat; 5. Mounting plate; 6. Cylinder; 7. Cylinder push rod; 8. Moving plate; 9. Fixed rod; 10. Pressure plate; 11. Bottom mold; 12. Guide mechanism; 121. Guide rod; 122. Column sleeve; 123. Limiting piece; 13. Limiting strip; 14. Limiting post; 15. Bevel; 16. Pressing groove; 17. Handle. Detailed Implementation

[0017] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0018] In the embodiments, by Figure 1-4 A crimping device for a high-voltage wiring harness for electric vehicles is provided, comprising a base 1, two support columns 2 fixedly connected to the top of the base 1, an intermediate plate 3 fixedly connected between the two support columns 2, a mounting seat 4 fixedly connected to the top of the intermediate plate 3, mounting plates 5 fixedly connected to the left and right sides of the mounting seat 4, a cylinder 6 fixedly connected between the two mounting plates 5, a cylinder push rod 7 slidably connected to the inner side of the cylinder 6, one end of the cylinder push rod 7 penetrating and extending to the bottom of the intermediate plate 3, a movable plate 8 fixedly connected to the bottom of the cylinder push rod 7, two fixing rods 9 fixedly connected to the bottom of the movable plate 8, the bottom ends of the two fixing rods 9 being fixedly connected to a pressure plate 10, a bottom mold 11 detachably connected to the top of the base 1, and a guide mechanism 12 provided between the intermediate plate 3 and the movable plate 8.

[0019] Based on the above settings, select a suitable bottom mold 11 and install it on top of the base 1 according to the specifications of the wire harness and terminals to be crimped. Place the wires and terminals to be crimped correctly into the cavity of the bottom mold 11, ensuring proper placement. Start the cylinder 6, which drives the cylinder push rod 7 to extend downwards. The cylinder push rod 7 pushes the fixedly connected moving plate 8 to move stably along the guide direction of the guide mechanism 12. The moving plate 8 transmits force and motion to the pressure plate 10 through two fixed rods 9, causing the pressure plate 10 to move downwards synchronously. The pressure plate 10 contacts the terminal on the bottom mold 11. The cylinder 6 continuously applies significant pressure, and the pressure plate 10 and the bottom mold 11 work together to tightly press the terminal metal sleeve onto the conductor of the wire, causing plastic deformation and forming a strong, low-resistance, and airtight connection. Maintain the pressure briefly to ensure the crimped shape is stable. After crimping, the cylinder 6 reverses direction, and the cylinder push rod 7 begins to retract, driving the moving plate 8 and pressure plate 10 to rise smoothly along the guide mechanism 12, returning to the initial position. Operators or automated equipment remove the crimped high-voltage wire harness assembly from the bottom mold 11. One crimping cycle is completed, and preparation for the next operation begins. The bottom mold 11 and the base 1 are detachably connected, which means that different specifications of the bottom mold 11 can be quickly replaced to accommodate different types of terminals and wire diameters. One crimping device can meet the production needs of multiple product varieties, greatly improving equipment utilization and production flexibility.

[0020] Reference Figure 1-4 The guide mechanism 12 includes guide rods 121. Two guide rods 121 are fixedly connected to the top of the movable plate 8. Two column sleeves 122 are fixedly connected to the inner side of the intermediate plate 3. The two guide rods 121 are slidably connected to the inner side of the two column sleeves 122 respectively. Limiting pieces 123 are fixedly connected to the top of the two guide rods 121. With the above structural arrangement, the moving plate 8 and the pressure plate 10 are in their highest positions. Most of the guide rod 121 is located below the sleeve 122, with only the top portion passing through the sleeve 122 on the intermediate plate 3. The limiting piece 123 is suspended above the sleeve 122, without contact. The cylinder push rod 7 pushes the moving plate 8 downwards. The two guide rods 121, fixedly connected to the moving plate 8, move downwards synchronously. The rods of the guide rods 121 slide precisely into the inner hole of the sleeve 122. Guiding function: The inner wall of the sleeve 122 and the rods of the guide rods 121 form a tight sliding fit. This fit has a very small clearance; it acts like a high-precision track, strictly limiting the movement freedom of the moving plate 8 and the pressure plate 10, allowing them to translate only in the vertical direction (Z-axis), completely avoiding any swaying, tilting, or rotation in the horizontal plane (X-axis and Y-axis). This process continues until the pressure plate 10 contacts and presses the workpiece. When cylinder 6 applies maximum pressure, the enormous reaction force is transmitted to guide mechanism 12 through pressure plate 10, fixed rod 9, and moving plate 8. Guide rod 121 and sleeve 122 not only serve as guides but also act as crucial load-bearing components, jointly bearing this lateral force and bending moment, ensuring the stability and rigidity of the entire pressing frame and preventing deformation due to stress from affecting the pressing quality. Cylinder push rod 7 pulls moving plate 8 upwards. Guide rod 121 then smoothly slides upwards from the inner hole of sleeve 122. When moving plate 8 rises to near its initial position, limiting piece 123 fixed to the top of guide rod 121 contacts and abuts the top of sleeve 122. Limiting function: Limiting piece 123 acts as a mechanical hard stop, precisely defining the upward endpoint position of moving plate 8 and pressure plate 10. This ensures that after each pressing cycle, pressure plate 10 returns to a fixed and known height, providing consistent space for the next workpiece placement and preventing damage that might be caused by excessive upward movement of the mechanism.

[0021] Reference Figure 1-4 The top of the base 1 is detachably connected to two limiting strips 13 by bolts. The bottom mold 11 is snapped between the two limiting strips 13. The top of the base 1 is fixedly connected to two limiting posts 14 for abutting the rear side of the bottom mold 11. With the above structural setup, the operator places the selected bottom mold 11 directly onto the designated area at the top of the base 1. This area is open in front and on both sides. Lateral restraint: The left and right sides of the bottom mold 11 naturally fall into the space between two restraining strips 13. The restraining strips 13 are fixed to the base 1 with bolts. Their width is precisely designed to form a tight sliding fit or a slight clearance fit with the width of the bottom mold 11. This step ensures that the bottom mold 11 is precisely restrained in the left-right direction, preventing lateral movement. Longitudinal restraint: When placing the bottom mold 11, the operator pushes its rear side against the two restraining posts 14. The restraining posts 14 are fixedly connected to the base 1, acting as a robust mechanical stop, precisely determining the position of the bottom mold 11 in the front-back direction. At this point, the bottom mold 11 is completely positioned on the horizontal plane: restrained on the left and right by the restraining strips 13, and restrained on the rear by the restraining posts 14. The bottom mold 11 rests on the base 1 under its own weight, and it is usually unconstrained in the vertical direction (it is fixed by the pressure plate 10 during pressing). A complete "clamping" process, which requires no tools for initial positioning, is completed instantly.

[0022] Reference Figure 1-4 Among them, each of the two limiting strips 13 has a sloping side 15 on its opposite side; With the above structural design, the inclined side 15 forms a funnel-shaped guide opening from top to bottom and from outside to inside. When placing the bottom mold 11, the operator does not need to align it with the narrow gap between the two limiting strips 13 with extreme precision. Even if the placement position is slightly off, the bottom of the bottom mold 11 will first contact the inclined surface of the inclined side 15 during descent, and under the action of gravity, it will automatically slide into the correct limiting space along the inclined surface. This makes mold installation very smooth and simple, further speeding up the changeover process and reducing the requirements for operational precision.

[0023] Reference Figure 1-4 The bottom mold 11 has a pressure groove 16 at its top. Through the above structural design, the shape and size of the crimping groove 16 are precisely machined according to the shape and size of the terminal (metal connector) to be crimped. It is not a flat plane, but a cavity that matches the outer contour of the terminal. Before crimping, the operator precisely places the terminal into the crimping groove 16. This ensures that the terminal is completely confined within the groove during crimping, preventing movement or rolling. This ensures that the downward pressure of the pressure plate 10 acts completely, vertically, and centered on the terminal during crimping, which is a prerequisite for forming a uniform, symmetrical, and high-quality crimped joint. It prevents incomplete crimping, misalignment, or damage caused by terminal displacement.

[0024] Reference Figure 1-4 The bottom mold 11 is fixedly connected to a handle 17 at its top end; With the above structural design, directly grasping the bottom mold 11 by hand can contaminate the mold cavity (pressure groove 16) with sweat, oil, or dust from the hands. The handle 17 separates the hand from the mold body, keeping the critical working area of ​​the mold clean. This prevents contaminants from being brought into the crimping area. If these contaminants are pressed under the terminals during crimping, they may affect conductivity and the long-term reliability of the joint.

[0025] Reference Figure 1-4 Among them, the bottom end of the base 1 is fixedly connected with several rubber column heads 18; With the above structural design, during the crimping process, cylinder 6 generates a huge impact force, which is transmitted to the base 1 through the entire machine body. Rubber is a highly efficient shock-absorbing and damping material. The rubber column head 18 can effectively absorb and buffer the impact force and vibration generated during crimping, preventing this energy from being completely transmitted to the workbench or ground. It protects the internal structure of the equipment: reducing loosening and fatigue damage to various connecting parts of the machine body (such as bolts and guide mechanism 12) caused by long-term vibration, thus extending the service life of the equipment. It reduces noise: significantly reducing the impact noise generated by the crimping operation, improving the working environment.

[0026] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0027] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A crimping device for high-voltage wiring harnesses for electric vehicles, characterized in that, The base (1) includes a base (1), two support columns (2) are fixedly connected to the top of the base (1), an intermediate plate (3) is fixedly connected between the two support columns (2), an mounting seat (4) is fixedly connected to the top of the intermediate plate (3), mounting plates (5) are fixedly connected to the left and right sides of the mounting seat (4), a cylinder (6) is fixedly connected between the two mounting plates (5), a cylinder push rod (7) is slidably connected to the inner side of the cylinder (6), one end of the cylinder push rod (7) passes through and extends to the bottom of the intermediate plate (3), a moving plate (8) is fixedly connected to the bottom end of the cylinder push rod (7), two fixing rods (9) are fixedly connected to the bottom end of the moving plate (8), and the bottom ends of the two fixing rods (9) are fixedly connected to the pressure plate (10). A bottom mold (11) is detachably connected to the top of the base (1), and a guide mechanism (12) is provided between the intermediate plate (3) and the moving plate (8).

2. The crimping device for a high-voltage wiring harness for electric vehicles according to claim 1, characterized in that: The guiding mechanism (12) includes guide rods (121). Two guide rods (121) are fixedly connected to the top of the moving plate (8). Two column sleeves (122) are fixedly connected to the inner side of the intermediate plate (3). The two guide rods (121) are slidably connected to the inner side of the two column sleeves (122). The top of each of the two guide rods (121) is fixedly connected to a limiting piece (123).

3. The crimping device for a high-voltage wiring harness for electric vehicles according to claim 1, characterized in that: The top of the base (1) is detachably connected to two limiting strips (13) by bolts. The bottom mold (11) is snapped between the two limiting strips (13). The top of the base (1) is fixedly connected to two limiting posts (14) for abutting the rear side of the bottom mold (11).

4. The crimping device for a high-voltage wiring harness for electric vehicles according to claim 3, characterized in that: Both of the two limiting bars (13) have a bevel (15) on their opposite sides.

5. The crimping device for a high-voltage wiring harness for electric vehicles according to claim 1, characterized in that: The bottom mold (11) has a pressure groove (16) at its top.

6. The crimping device for a high-voltage wiring harness for electric vehicles according to claim 1, characterized in that: A handle (17) is fixedly connected to the top of the bottom mold (11).

7. The crimping device for a high-voltage wiring harness for electric vehicles according to claim 1, characterized in that: Several rubber columns (18) are fixedly connected to the bottom end of the base (1).

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