Tooling and device suitable for long-size aluminum-copper busbar immersion ultrasonic testing

Abstract

The utility model belongs to nondestructive testing technical field especially relates to a kind of tool and device suitable for long size aluminium copper busbar water immersion ultrasonic detection, including base, frame set on base, frame and base between being provided with sealing ring to form the groove container closed at bottom and around, one end of frame is provided with mounting groove, detachable clamping block is set in mounting groove, clamping block has the groove for the busbar of being threaded, the clamping force of frame and base is used to fix busbar and guarantee sealing property, by the local water immersion cavity body formed by groove container, and in frame end portion configuration detachable clamping block with groove, long size aluminium copper busbar only needs to be detected aluminium copper composite region is placed in groove container, and effective water immersion ultrasonic detection can be realized, break through the limitation of traditional equipment to workpiece overall length, significantly improve detection efficiency and adaptability, especially suitable for new energy and other fields in meter level length busbar high-precision, high-efficiency nondestructive testing demand.

Description

Technical Field

[0001] This utility model belongs to the field of non-destructive testing technology, and in particular relates to a tooling and device suitable for ultrasonic testing of long-sized aluminum-copper manifolds by immersion. Background Technology

[0002] With the rapid development of industries such as new energy vehicles, energy storage systems, and smart grids, aluminum-copper composite busbars are widely used in key components such as power battery modules and high-voltage power distribution systems due to their combination of the excellent conductivity of copper and the lightweight and low cost of aluminum. To ensure their electrical performance and structural reliability during service, high-precision non-destructive testing of their internal bonding quality (such as interface debonding, porosity, cracks, and other defects) is essential. Immersion ultrasonic testing (IUT), with its advantages of stable coupling, high resolution, and automated scanning, has become one of the mainstream methods for testing such composite materials.

[0003] However, most of the water immersion ultrasonic testing devices currently widely used in the market are designed for small and medium-sized parts or short-sized workpieces. The length of the testing chamber is limited, and the structure is relatively simple. They usually use an integrated closed water tank with a fixing fixture to achieve workpiece positioning and sealing. When dealing with long aluminum and copper busbars that exceed 1 meter or even several meters in length (such as busbars for new energy batteries and conductive busbars in power systems), existing equipment is difficult to meet the actual testing needs.

[0004] On the one hand, due to the limited size of the water cavity, long workpieces cannot be fully immersed in water and can only be tested in sections and the data spliced ​​together, which is not only inefficient but also prone to missed detections or misjudgments. On the other hand, existing tooling generally suffers from cumbersome operation and poor adaptability. Most rely on methods such as threaded clamping, manual locking, or elastic pressure plates, which take a long time to clamp and disassemble, making it difficult to meet the efficiency requirements of batch testing. At the same time, these fixtures lack the ability to adaptively adjust to different material sections (such as soft aluminum sections and hard copper sections) in aluminum-copper composite busbars, which can easily cause uneven clamping force, potentially damaging the aluminum material or causing workpiece displacement, thus affecting the detection accuracy. Utility Model Content

[0005] The technical problem to be solved by this application is to provide a tooling and device suitable for ultrasonic testing of long-size aluminum-copper manifolds, so as to solve multiple technical problems such as test coverage, sealing reliability and material compatibility.

[0006] In a first aspect, this application provides a tooling and apparatus suitable for ultrasonic testing of long-length aluminum-copper manifolds, including: Base; A frame is provided on the base, and a sealing ring is provided between the frame and the base to form a groove-shaped container with a closed bottom and sides. One end of the frame has a mounting groove, and a detachable clamping block is provided in the mounting groove. The clamping block has a groove for passing through the non-aluminum-copper composite area of ​​the busbar, so as not to be limited by the length of the busbar. The aluminum-copper composite area of ​​the busbar is in the groove-shaped container. The clamping force between the frame and the base makes the sealing ring and the clamping block fit together to fix the busbar and ensure the airtightness.

[0007] Optionally, the fixture for ultrasonic testing of long aluminum-copper manifolds also includes a positioning element that is detachably disposed in the trough-shaped container and used to position the manifold, the positioning element being matched with the clamping block.

[0008] Optionally, the positioning member has a positioning groove, and the positioning groove and the positioning part of the busbar are in clearance fit to restrict the movement and rotation of the busbar in the horizontal plane.

[0009] Optionally, the clamping block and the positioning element can be replaced with different models according to the different sizes of the busbar.

[0010] Optionally, the positioning element is fixedly connected to the base by bolts.

[0011] Optionally, the clamping block and the frame are slidably and positioned together via guide grooves and guide strips.

[0012] Optionally, the clamping block is an elastomer, or the portion of the clamping block that contacts the busbar is provided with an elastic layer to enhance the sealing between the clamping block and the busbar.

[0013] Optionally, the bottom of the base is provided with a drain hole, and a sealing plug is provided inside the drain hole.

[0014] Optionally, the fixture for ultrasonic testing of long-length aluminum-copper manifolds also includes multiple latches for connecting the base and the frame, wherein the latches generate a clamping force between the base and the frame through a locking tension.

[0015] Optionally, a concave-convex positioning structure is provided between the base and the frame, and the protrusion of the concave-convex positioning structure penetrates the sealing ring.

[0016] Secondly, a water immersion ultrasonic testing device suitable for long-sized aluminum-copper manifolds includes the tooling described above for water immersion ultrasonic testing of long-sized aluminum-copper manifolds.

[0017] The beneficial effects of this application are: The first aspect of this application provides a fixture suitable for ultrasonic immersion testing of long-length aluminum-copper manifolds. By setting a sealing ring between the base and the frame to form a local water immersion cavity, and configuring a detachable clamping block with a groove at the end of the frame, long-length aluminum-copper manifolds can be effectively tested by placing the aluminum-copper composite area to be inspected in the trough-shaped container, breaking through the limitation of traditional equipment on the overall length of the workpiece. The clamping block and the sealing ring are simultaneously pressed and sealed by the clamping force of the frame and the base to fix the manifold, which not only ensures the sealing reliability of the water cavity, but also avoids excessive clamping damage to the soft aluminum section. Therefore, this application does not require an overall closed water tank, supports continuous or segmented rapid clamping, significantly improves testing efficiency and adaptability, and is especially suitable for the high-precision, high-efficiency non-destructive testing needs of meter-length manifolds in the new energy and other fields.

[0018] The second aspect of this application provides a water immersion ultrasonic testing device for long-length aluminum-copper busbars. This device integrates the aforementioned tooling as a core load-bearing and sealing unit. By inserting the aluminum-copper composite area to be inspected into the sealed cavity of the tooling, the device utilizes the clamping blocks, positioning components, and locking mechanisms of the tooling to achieve rapid clamping, precise positioning, and reliable sealing. This allows for continuous and high-precision water immersion ultrasonic testing without requiring the entire workpiece to be submerged. Simultaneously, in conjunction with an automated scanning mechanism, it can achieve efficient and blind-spot-free defect detection for busbars with lengths up to meters, significantly improving the quality control level and production efficiency of key conductive components in fields such as new energy vehicles and energy storage systems. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the tooling used for ultrasonic testing of long-length aluminum-copper manifolds in an embodiment of this application; Figure 2 This is an exploded structural diagram of a tooling suitable for ultrasonic testing of long-length aluminum-copper manifolds. According to an embodiment of this application, this tooling is suitable for ultrasonic testing of long-length aluminum-copper manifolds.

[0020] In the diagram: 1-1, busbar; 110, base; 111, drain hole; 112, protrusion; 120, frame; 121, mounting groove; 122, guide strip; 130, clamping block; 131, groove; 132, guide groove; 140, sealing ring; 150, positioning element; 151, positioning groove; 160, sealing plug; 170, latch. Detailed Implementation

[0021] To make the technical problems, technical solutions, and beneficial effects to be solved by this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and are not intended to limit the scope of this application.

[0022] like Figure 1 and Figure 2 As shown, this application provides a tooling suitable for ultrasonic testing of long-length aluminum-copper manifolds, comprising: a base 110 and a frame 120 disposed on the base 110; wherein, a sealing ring 140 is disposed between the frame 120 and the base 110, forming a groove-shaped container with a closed bottom and sides, and an installation groove 121 is provided at one end of the frame 120, and a detachable clamping block 130 is disposed in the installation groove 121. The clamping block 130 has a groove 131 for passing through the non-aluminum-copper composite area of ​​the manifold 1-1, so as not to be limited by the length of the manifold 1-1. The aluminum-copper composite area of ​​the manifold 1-1 is inside the groove-shaped container, and the clamping force of the frame 120 and the base 110 makes the sealing ring 140 and the clamping block 130 fit together to fix the manifold 1-1 and ensure the sealing performance.

[0023] The first aspect of this application provides a fixture suitable for ultrasonic immersion testing of long-length aluminum-copper manifolds. By setting a sealing ring 140 between the base 110 and the frame 120 to form a local water immersion cavity, and configuring a detachable clamping block 130 with a groove 131 at the end of the frame 120, the long-length aluminum-copper manifold 1-1 can be effectively tested by placing the aluminum-copper composite area to be inspected in the trough-shaped container, breaking through the limitation of traditional equipment on the overall length of the workpiece. The clamping block 130 and the sealing ring 140 are simultaneously pressed and sealed by the clamping force of the frame 120 and the base 110 to fix the manifold 1-1, which not only ensures the sealing reliability of the water cavity, but also avoids excessive clamping damage to the soft aluminum section. Therefore, this application does not require an overall closed water tank, supports continuous or segmented rapid clamping, significantly improves the testing efficiency and adaptability, and is especially suitable for the high-precision, high-efficiency non-destructive testing needs of meter-length manifolds 1-1 in the new energy and other fields.

[0024] In one possible implementation, the fixture for ultrasonic testing of long-length aluminum-copper manifolds also includes a positioning element 150 that is detachably disposed within a trough-shaped container and used to position the manifold 1-1, the positioning element 150 being matched with a clamping block 130.

[0025] Specifically, a detachable positioning component 150, matching the clamping block 130, is added inside the trough-shaped container to precisely constrain and guide the position of the manifold 1-1 during water immersion testing. The positioning component 150 can be replaced or adjusted according to the cross-sectional shape and size of different specifications of the manifold 1-1. Its structure usually has a limiting groove or support surface that matches the contour of the non-test section of the manifold 1-1, ensuring that the aluminum-copper composite area is stably centered on the ultrasonic probe scanning path. At the same time, the positioning component 150 and the clamping block 130 work together to restrict the vertical, horizontal, and torsional freedom of the manifold 1-1 during clamping, preventing workpiece displacement caused by water flow disturbance or probe movement, thereby improving test repeatability and defect identification accuracy. In addition, the positioning component 150 adopts a detachable design, which facilitates quick replacement to adapt to different models of products, taking into account both versatility and ease of operation, and further meeting the needs of batch and flexible testing.

[0026] In one possible implementation, the positioning element 150 has a positioning groove 151, which is clearance-fitted with the positioning part of the busbar 1-1 to restrict the movement and rotation of the busbar 1-1 in the horizontal plane.

[0027] Specifically, the positioning groove 151 and the positioning part of the busbar 1-1 adopt a clearance fit design, which effectively restricts the lateral movement of the busbar 1-1 in the horizontal plane and the degree of freedom of rotation around the vertical axis while ensuring smooth installation. This fit method avoids the surface damage or deformation of the aluminum material that may be caused by interference fit, and prevents the workpiece from shaking during the test due to looseness, thereby ensuring the consistency between the ultrasonic probe scanning path and the composite interface of the busbar 1-1. At the same time, the clearance fit facilitates quick loading and unloading, improves the test cycle, and is suitable for long aluminum-copper busbars 1-1 of different batches or similar specifications, taking into account both positioning accuracy and operating efficiency.

[0028] In one possible implementation, the clamping block 130 and the positioning element 150 can be replaced with different models depending on the size of the busbar 1-1.

[0029] Specifically, the clamping block 130 and the positioning component 150 adopt a modular and standardized design. For aluminum-copper busbars 1-1 with different cross-sectional sizes or structural forms, the corresponding model of clamping block 130 and positioning component 150 can be quickly replaced. The groove 131 on the clamping block 130 and the positioning groove 151 on the positioning component 150 respectively match the geometric features of the non-composite area and the positioning part of the busbar 1-1, ensuring stable clamping and reliable sealing. By establishing a series of fixture component libraries, operators can flexibly select and match according to the specifications of the workpiece to be inspected without modifying the entire tooling, which significantly improves the versatility and adaptability of the device and effectively supports the high-efficiency water immersion ultrasonic testing needs of multi-variety, small-batch or variable-specification products.

[0030] In one possible implementation, the positioning element 150 is fixedly connected to the base 110 by bolts.

[0031] Specifically, the positioning component 150 is rigidly connected to the base 110 by bolts, which not only ensures the structural stability of the positioning component 150 when subjected to water flow impact or probe scanning reaction force during water immersion testing, but also facilitates the quick replacement of different models of positioning components 150 according to the specifications of the busbar 1-1; the bolt connection position can be pre-set with multiple sets of standardized mounting holes on the base 110 to adapt to different length or layout requirements, while ensuring high repeatability of the position of the positioning component 150 relative to the ultrasonic probe path after each installation.

[0032] In some embodiments, the positioning member 150 and the base 110 can also be connected by magnetic attraction, snap-fit / elastic snap-fit ​​structure or by high-strength removable adhesive or double-sided adhesive.

[0033] In one possible implementation, the clamp 130 and the frame 120 slide and are positioned together via the guide groove 132 and the guide strip 122.

[0034] Specifically, the side wall of the mounting groove 121 of the frame 120 is provided with a guide strip 122, and the corresponding position of the clamping block 130 is provided with a matching guide groove 132 (or vice versa). The two adopt a sliding pair design with a gap fit, so that the clamping block 130 can slide smoothly into the mounting groove 121 in a preset direction. In this way, not only is the installation and removal operation of the clamping block 130 simplified and the replacement efficiency improved, but the displacement and rotation of the clamping block 130 in the direction perpendicular to the sliding direction can also be effectively restricted, ensuring that it maintains accurate positioning of the busbar 1-1 during the clamping process. At the same time, the guide mating surface can also ensure the uniformity of force when the sealing ring 140 is pressed, avoiding local stress concentration that may lead to sealing failure or damage to the aluminum material, thus taking into account the ease of operation, positioning repeatability accuracy and sealing reliability.

[0035] In one possible implementation, the clamp 130 is an elastic body, or an elastic layer is provided at the part of the clamp 130 that fits against the busbar 1-1 to enhance the sealing between the clamp 130 and the busbar 1-1.

[0036] Specifically, the clamping block 130 is made of an elastic material (such as polyurethane, rubber, silicone or flexible engineering plastic), or an elastic sealing layer (such as rubber pad, fluororubber strip or thermoplastic elastomer) is laminated at the part that contacts and adheres to the busbar 1-1. Utilizing the compressibility and resilience of the material, when the frame 120 and the base 110 are clamped, the elastomer / elastic layer can adaptively conform to the surface contour of the busbar 1-1 and fill the microscopic uneven gaps, thereby significantly improving the interface sealing performance between the clamping block 130 and the busbar 1-1.

[0037] In one possible implementation, the bottom of the base 110 is provided with a drain hole 111, and a sealing plug 160 is provided inside the drain hole 111.

[0038] Specifically, the drain hole 111 and the matching sealing plug 160 are used to quickly drain the water in the trough-shaped container after the test is completed. The sealing plug 160 can be a threaded or press-fit plug to ensure water tightness and prevent leakage during the test. When draining, it can be easily opened by hand or by tool, which significantly improves the efficiency of equipment maintenance and tooling cleaning.

[0039] In one possible implementation, the fixture for ultrasonic testing of long-length aluminum-copper manifold immersion also includes a plurality of latches 170 for connecting the base 110 and the frame 120, the latches 170 generating a clamping force between the base 110 and the frame 120 by a locking pull.

[0040] Specifically, the latch 170 can be a quick clamp, a lever-type latch, or an eccentric locking mechanism. The tooling uses multiple latches 170 between the base 110 and the frame 120. The tension generated when the latches 170 close firmly presses the frame 120 onto the base 110, thus forming a reliable clamping force. This clamping force compresses the sealing ring 140 and the clamping block 130 to ensure the watertightness of the trough-shaped container, and simultaneously presses the manifold 1-1 inserted within it, achieving integrated positioning and sealing. Compared to traditional bolt connections, the latch 170 structure is easier to operate and has a faster locking / unlocking speed, significantly improving clamping efficiency. It is particularly suitable for batch testing scenarios that require frequent replacement of long aluminum-copper manifolds 1-1. Simultaneously, the multiple latches 170 are rationally distributed circumferentially along the frame 120, ensuring uniform clamping force and preventing leakage or workpiece displacement caused by localized warping, thus balancing sealing reliability, ease of operation, and testing stability.

[0041] In one possible implementation, a concave-convex positioning structure is provided between the base 110 and the frame 120, with the protrusion 112 of the concave-convex positioning structure penetrating the sealing ring 140.

[0042] Specifically, the concave-convex positioning structure can be a positioning pin and positioning hole or a boss and a groove, wherein the protrusion 112 extends from one side of the base 110 or the frame 120 and passes through the sealing ring 140 disposed between the two; this solution ensures the effective sealing function of the sealing ring 140 while achieving rapid alignment and precise positioning of the base 110 and the frame 120 during the assembly process through the engagement of the protrusion 112 and the corresponding concave part, preventing relative misalignment or displacement between the two during the locking process; especially after multiple disassemblies and reassemblies, it can still maintain a stable assembly position, ensuring the consistency of the spatial relationship between the clamping block 130, the positioning element 150 and the busbar 1-1, thereby improving the repeatability accuracy of ultrasonic testing; in addition, the protrusion 112 can pass through the sealing ring 140 by using a through-hole clearance fit or partial compression of the sealing ring 140, so as to balance the structural positioning rigidity and assembly reliability without compromising the overall sealing performance.

[0043] Secondly, a water immersion ultrasonic testing device suitable for long-sized aluminum-copper manifolds includes the above-mentioned tooling for water immersion ultrasonic testing of long-sized aluminum-copper manifolds 1-1.

[0044] The second aspect of this application provides a water immersion ultrasonic testing device suitable for long aluminum-copper manifolds, which integrates the aforementioned tooling as a core load-bearing and sealing unit. The overall structure includes: a trough-shaped tooling for accommodating coupling water and forming a local water immersion environment; an ultrasonic probe assembly (usually mounted on a multi-axis motion platform) that can move or scan along the length of the manifold 1-1; a water circulation and filtration system; an ultrasonic signal generation and acquisition module; and a control system.

[0045] This water immersion ultrasonic testing device allows for rapid clamping, precise positioning, and reliable sealing of long aluminum-copper busbars 1-1 by inserting the aluminum-copper composite area to be inspected into the sealed cavity of the tooling. Utilizing the tooling's clamping blocks 130, positioning components 150, and locking latches 170, it enables continuous, high-precision water immersion ultrasonic testing without requiring the entire workpiece to be submerged. Simultaneously, in conjunction with an automated scanning mechanism, it can efficiently and without blind spots detect defects in meter-long busbars 1-1, significantly improving the quality control level and production efficiency of key conductive components in fields such as new energy vehicles and energy storage systems.

[0046] Those skilled in the art should understand that the discussion of any of the above embodiments is merely exemplary and is not intended to imply that the scope of protection of this application is limited to these examples; within the framework of this application, the technical features of the above embodiments or different embodiments can also be combined, the steps can be implemented in any order, and there are many other variations of different aspects of one or more embodiments of this application as described above, which are not provided in detail for the sake of brevity.

[0047] One or more embodiments in this application are intended to cover all such substitutions, modifications, and variations that fall within the broad scope of this application. Therefore, any omissions, modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of one or more embodiments in this application should be included within the protection scope of this application.

Claims

1. A fixture suitable for ultrasonic testing of long-length aluminum-copper manifold drainage, characterized in that, include: Base (110); A frame (120) is provided on the base (110), and a sealing ring (140) is provided between the frame (120) and the base (110) to form a groove-shaped container with the bottom and sides closed. An installation groove (121) is provided at one end of the frame (120), and a detachable clamping block (130) is provided in the installation groove (121). The clamping block (130) has a groove (131) for passing through the non-aluminum-copper composite area of ​​the busbar (1-1) so as not to be limited by the length of the busbar (1-1). The aluminum-copper composite area of ​​the busbar (1-1) is in the groove-shaped container. The clamping force of the frame (120) and the base (110) makes the sealing ring (140) and the clamping block (130) fit and fix the busbar (1-1) and ensure the sealing.

2. The fixture for ultrasonic testing of long-length aluminum-copper manifold drainage as described in claim 1, characterized in that, Also includes: A positioning element (150) is detachably installed inside the trough-shaped container and used to position the busbar (1-1). The positioning element (150) is matched with the clamping block (130).

3. The fixture for ultrasonic testing of long-length aluminum-copper manifold drainage immersion as described in claim 2, characterized in that, The positioning element (150) has a positioning groove (151), and the positioning groove (151) and the positioning part of the busbar (1-1) are in clearance fit to restrict the movement and rotation of the busbar (1-1) in the horizontal plane.

4. The fixture for ultrasonic testing of long-length aluminum-copper manifold drainage as described in claim 3, characterized in that, The clamp (130) and the positioning element (150) can be replaced with different models according to the different sizes of the busbar (1-1).

5. The fixture for ultrasonic testing of long-length aluminum-copper manifold drainage immersion as described in claim 4, characterized in that, The positioning element (150) is fixedly connected to the base (110) by bolts.

6. The fixture for ultrasonic testing of long-length aluminum-copper manifolds under immersion, as described in any one of claims 1-5, is characterized in that... The clamping block (130) and the frame (120) slide and are positioned together by the guide groove (132) and the guide strip (122).

7. The fixture for ultrasonic testing of long-length aluminum-copper manifold drainage as described in claim 6, characterized in that, The clamp (130) is an elastic body, or the part of the clamp (130) that is in contact with the busbar (1-1) is provided with an elastic layer to enhance the sealing between the clamp (130) and the busbar (1-1).

8. The fixture for ultrasonic testing of long-length aluminum-copper manifolds under immersion, as described in any one of claims 1-5, is characterized in that... The bottom of the base (110) is provided with a drain hole (111), and a sealing plug (160) is provided inside the drain hole (111).

9. The fixture for ultrasonic testing of long-length aluminum-copper manifolds under immersion, as described in any one of claims 1-5, is characterized in that... It also includes a plurality of latches (170) for connecting the base (110) and the frame (120), the latches (170) generating a clamping force between the base (110) and the frame (120) by a locking pull; And / or, a concave-convex positioning structure is provided between the base (110) and the frame (120), and the protrusion (112) of the concave-convex positioning structure penetrates the sealing ring (140).

10. A water immersion ultrasonic testing device suitable for long aluminum-copper manifolds, characterized in that, Includes the fixture described in any one of claims 1-9 for ultrasonic testing of long-length aluminum-copper manifolds.

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