WO2023024971A1 - 一种电能传输转接机构、充电插座和机动车辆 - Google Patents
一种电能传输转接机构、充电插座和机动车辆 Download PDFInfo
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- WO2023024971A1 WO2023024971A1 PCT/CN2022/112755 CN2022112755W WO2023024971A1 WO 2023024971 A1 WO2023024971 A1 WO 2023024971A1 CN 2022112755 W CN2022112755 W CN 2022112755W WO 2023024971 A1 WO2023024971 A1 WO 2023024971A1
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- Prior art keywords
- power transmission
- mechanism according
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- welding
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Links
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- H—ELECTRICITY
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- H01R11/01—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts characterised by the form or arrangement of the conductive interconnection between the connecting locations
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
- B60L53/00—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
- B60L53/10—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles characterised by the energy transfer between the charging station and the vehicle
- B60L53/14—Conductive energy transfer
- B60L53/16—Connectors, e.g. plugs or sockets, specially adapted for charging electric vehicles
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- H—ELECTRICITY
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- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
- H01B1/02—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of metals or alloys
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- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
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- H01R13/03—Contact members characterised by the material, e.g. plating, or coating materials
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- H01R24/00—Two-part coupling devices, or either of their cooperating parts, characterised by their overall structure
- H01R24/20—Coupling parts carrying sockets, clips or analogous contacts and secured only to wire or cable
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- H01R31/00—Coupling parts supported only by co-operation with counterpart
- H01R31/06—Intermediate parts for linking two coupling parts, e.g. adapter
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- H—ELECTRICITY
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- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/02—Soldered or welded connections
- H01R4/029—Welded connections
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- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/28—Clamped connections, spring connections
- H01R4/30—Clamped connections, spring connections utilising a screw or nut clamping member
- H01R4/34—Conductive members located under head of screw
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R16/00—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for
- B60R16/02—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for electric constitutive elements
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- H01R11/00—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
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- H01R2201/00—Connectors or connections adapted for particular applications
- H01R2201/26—Connectors or connections adapted for particular applications for vehicles
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
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- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/02—Soldered or welded connections
- H01R4/023—Soldered or welded connections between cables or wires and terminals
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/60—Other road transportation technologies with climate change mitigation effect
- Y02T10/70—Energy storage systems for electromobility, e.g. batteries
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/60—Other road transportation technologies with climate change mitigation effect
- Y02T10/7072—Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T90/00—Enabling technologies or technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02T90/10—Technologies relating to charging of electric vehicles
- Y02T90/14—Plug-in electric vehicles
Definitions
- the invention relates to the technical field of electrical connection, in particular to an electric energy transmission switching mechanism, a charging socket and a motor vehicle.
- the charging system on electric vehicles which is more and more widely used at present, increases the charging current in order to reduce the charging time, so that the effective conductive cross-sectional area of the charging cable and charging terminal reaches 95mm2 to 160mm2, so that the charging socket Or the volume of the charging gun also becomes bulky and heavy, which is inconvenient to use.
- the terminals used for plug-in connection in the electrical device mechanism are not in the same axis as the cables used to transmit electric energy, and cannot be directly connected, or the direction in which the cables are pulled out is in line with the axial direction of the terminals. There is a certain angular deviation in the direction, so a corresponding transfer mechanism is required for connection.
- the terminals that conduct large currents are made of copper materials as the base material, copper has good conductivity, low resistivity, good ductility, and is easy to process and shape. Therefore, copper materials are generally used for turning, forging, stamping, etc. Method processing and molding. When the connection position of the cable is far from the position of the terminal in the mechanism of the electrical device, the terminals are all processed with copper material, which consumes a lot of copper material and is seriously wasted, and the cost of the terminal cannot be reduced.
- connection terminal in the field of power transmission, there is an urgent need for a power transmission transfer mechanism between the connection terminal and the cable, which can realize the non-axial or angled connection between the terminal and the cable, and can save the copper material used by the terminal and reduce the cost of the terminal. .
- the invention provides an electric energy transmission adapter mechanism, a charging socket, and a motor vehicle, which can realize the non-axial or angled connection between the terminal and the cable, and can save the copper material used for the terminal and reduce the cost of the terminal. It can solve the problems that the structure of the electrical device is bulky; the terminal and the cable cannot be connected in an unaxial or angled connection; and the copper material consumption of the terminal is large, and the cost of the terminal cannot be reduced.
- a power transmission adapter mechanism including a power transmission part, an adapter part and a cable
- the power transmission part includes a plug-in end and a connection end connected in sequence
- the cable includes an internal
- the transition part includes a first end, a bending part and a second end connected in sequence, the first end is electrically connected to the connection end, the The second end is electrically connected to the conductor core at one end of the cable, and the bending portion includes at least one bending area.
- the first end is in contact with at least part of the connecting end.
- the first end is at least partially connected to the connecting end by resistance welding, friction welding, ultrasonic welding, arc welding, laser welding, electron beam welding, pressure diffusion welding, magnetic induction welding, screw connection , snap-in, splicing, and crimping in one or several ways to connect.
- the connection end includes a connection surface, and the area of the contact area between the connection surface and the first end accounts for more than 5% of the area of the connection surface.
- the shape of the connecting end is a sheet
- the connecting end includes a first upper surface, a first lower surface and a first side
- the connecting surface is arranged on the first upper surface or the first
- the shape of the first end is a sheet
- the first end includes a second upper surface, a second lower surface and a second side surface, the first upper surface or the first lower surface and the first lower surface
- the second upper surface or the second lower surface is overlapped and then contacted and connected.
- connection end is columnar
- connection end includes a side surface and an end surface
- connection surface is arranged on the end surface
- shape of the first end is a sheet
- first The end includes a second upper surface, a second lower surface and a second side surface, and the end surface is in contact with the second upper surface or the second lower surface.
- the power transmission conversion mechanism further includes bolts, the second upper surface is provided with through holes penetrating through the second lower surface, and the end surface is provided with threaded holes, and the bolts pass through The through hole is screwed into the threaded hole.
- the torque range of the screw connection between the bolt and the threaded hole is 0.1N ⁇ m-30N ⁇ m.
- the shape of the connecting end is cylindrical, the connecting end includes a first inner surface and a first outer surface, and the connecting surface is arranged on the first inner surface or the first outer surface , the shape of the first end is cylindrical, the first end includes a second inner surface and a second outer surface, the first inner surface or the first outer surface and the second outer surface or the second outer surface The second inner surface is overlapped and then contacted and connected.
- the cross-sectional shape of the connecting end or the first end is circular, elliptical, rectangular or polygonal.
- the shape of the second end is a flat plate, a bowl, a U, a V or a cylinder.
- at least part of the guide core is in contact with at least part of the second end.
- At least part of the guide core is at least partly connected to the second end by resistance welding, friction welding, ultrasonic welding, arc welding, laser welding, electron beam welding, pressure diffusion welding, magnetic induction welding, screw connection , snap-in, splicing, and crimping in one or several ways to connect.
- connection end includes a connection surface, at least part of the first end is in contact with the connection surface; the second end includes a wiring surface, and the wiring surface is connected to the connection surface.
- the area of the contact area of the guide core accounts for more than 5% of the area of the wiring surface.
- the transition part is formed by stamping, cutting, bending or machining of a plate.
- the thicknesses of the first end, the bent portion and the second end differ by no more than 35%.
- the angle between two adjacent planes of the bending area is 0°-180°.
- the bending portion of the bending area is arc-shaped, and the inner radius of the bending portion is not less than one-third of the thickness of the transition portion.
- at least one reinforcing rib is provided in the tangential direction of the bending zone, and the reinforcing rib is formed by inwardly recessing the outer material of the bending zone.
- the bending region is twisted, and the included angle between the plane or the longitudinal center plane of symmetry of the first end and the plane or longitudinal center plane of symmetry of the second end is 0°-90° .
- the material of the transfer part contains nickel, cadmium, zirconium, chromium, cobalt, manganese, aluminum, tin, titanium, zinc, copper, silver, gold, phosphorus, tellurium, beryllium, lead one or more.
- the material of the transfer part contains tellurium-copper alloy, and the content of tellurium in the tellurium-copper alloy is 0.1% ⁇ 5%.
- the material of the transfer part contains beryllium-copper alloy, and the content of beryllium in the beryllium-copper alloy is 0.05%-5%.
- the material of the transition part contains phosphor bronze alloy, and the content of phosphorus in the phosphor bronze alloy is 0.01%-1.5%. In a preferred embodiment, the material of the transition part contains lead brass alloy, and the content of lead in the lead brass alloy is 0.1%-5%.
- At least part of the electrical energy transmission part, the guide core and the transfer part is provided with a plating layer.
- the plating layer is not provided on at least part of the connection surfaces.
- at least part of the connecting surface is provided with the plating layer, and the plating layer on the connecting surface is the first plating layer.
- the plating layer is not provided on at least the plane contacting the connecting surface on the first end. In a preferred embodiment, the plating layer is provided on at least the plane contacting the connecting surface on the first end, and the plating layer on at least the plane contacting the connecting surface on the first end is the second Second coating.
- At least part of the wiring surface is not provided with the plating layer.
- At least part of the wiring surface is provided with the plating layer, and the plating layer on the wiring surface is a third plating layer.
- the plating layer is not provided on the guide core. In a preferred embodiment, at least part of the guide core is provided with the plating layer, and the plating layer on the guide core is a fourth plating layer.
- the first coating material, the second coating material, the third coating material are different from the fourth coating material. In a preferred embodiment, the first coating thickness, the second coating thickness, the third coating thickness are different from the fourth coating thickness.
- the coating material contains one of gold, silver, nickel, tin, zinc, tin-lead alloy, silver-antimony alloy, palladium, palladium-nickel alloy, graphite silver, graphene silver, and silver-gold-zirconium alloy. one or more species.
- the coating is provided by means of electroplating, electroless plating, magnetron sputtering or vacuum plating.
- the coating includes a bottom layer and a surface layer.
- the underlying material contains one or more of gold, silver, nickel, tin, tin-lead alloy and zinc; the surface material contains gold, silver, nickel, tin, zinc, tin-lead
- alloys, silver-antimony alloys, palladium, palladium-nickel alloys, graphite silver, graphene silver, and silver-gold-zirconium alloys is one or more of alloys, silver-antimony alloys, palladium, palladium-nickel alloys, graphite silver, graphene silver, and silver-gold-zirconium alloys.
- the material of the guide core contains aluminum.
- the contact resistance between the power transmission part and the transfer part is less than 9m ⁇ . In a preferred embodiment, the contact resistance between the guide core and the transition part is less than 9m ⁇ .
- the present invention also provides a charging socket, which includes the above-mentioned power transmission adapter mechanism.
- the present invention also provides a motor vehicle, which includes the above-mentioned power transmission switching mechanism or the above-mentioned charging socket.
- An electric energy transmission adapter mechanism uses an adapter to connect the electric energy transmission section and the conductor core of the cable respectively, and a bending section is provided on the adapter section to make the electric energy transmission section and the cable Different axial connections can be made, and the electric energy transmission part and the cable can be connected at an angle, thereby reducing the volume of the mechanism of the electric device, and the mechanism of the electric device can be adapted to more use environments.
- the power transmission part and the transfer part provided by the present invention have a variety of connection methods, and the power transmission part and the transfer part can be connected in different crimping, splicing or welding methods according to the usage conditions, so as to realize the power transmission and transfer Good electrical and mechanical properties of the mechanism.
- connection position of the power transmission part and the transfer part provided by the present invention has various shapes, and different shapes can be selected for connection according to the installation environment, providing designers with various design directions.
- the material of the adapter provided by the present invention can be various copper materials, and copper materials of different materials have correspondingly different properties, and can achieve corresponding design purposes in different use environments.
- the coating provided on the power transmission part and the transfer part provided by the present invention can improve the scratch resistance and corrosion resistance of the power transmission part and the transfer part, thereby prolonging the service life of the power transmission transfer mechanism.
- the coating of the power transmission part and the transfer part provided by the present invention has a bottom layer and a surface layer, and a layer of bottom layer is first plated on the surface of the power transmission part and the transfer part to fill the gaps and holes on the surface, and then the surface coating is applied. It will make the bonding between the coating and the base material stronger and smoother, and the surface of the coating will have no gaps and holes, so that the wear resistance, corrosion resistance and electrical performance of the power transmission transfer mechanism will be better, and the power transmission transfer will be greatly extended. service life of the mechanism.
- the cable guide core provided by the present invention contains aluminum, and aluminum cables can be used instead of copper cables to reduce the weight and cost of the cables.
- the present invention also provides a charging socket, using the power transmission transfer mechanism of the present invention, so that the volume of the charging socket is smaller, and the direction of the cable outlet can be set arbitrarily.
- Fig. 1 is a schematic structural diagram of an embodiment of an electric energy transmission switching mechanism in the present invention.
- Fig. 2 is a schematic structural diagram of an embodiment of the power transmission unit in the present invention.
- Fig. 3 is a schematic structural diagram of another embodiment of the power transmission unit in the present invention.
- Fig. 4 is a schematic structural diagram of an embodiment of an adapter in the present invention.
- Fig. 5 is a schematic structural diagram of Fig. 4 in the present invention, in the Y direction.
- Fig. 6 is a schematic view of the structure of Fig. 4 in the X direction of the present invention.
- Fig. 7 is a schematic structural diagram of another embodiment of the power transmission unit in the present invention.
- Fig. 8 is a schematic structural view of an embodiment of the combination of the power transmission part and the transfer part in the present invention.
- Fig. 9 is a schematic structural view of another embodiment of the combination of the power transmission part and the transfer part in the present invention.
- Fig. 10 is a schematic diagram of the structure of the second end of the present invention in which the shape of the second end is bowl-shaped.
- Fig. 11 is a schematic diagram of the structure in which the second end is U-shaped in the present invention.
- Fig. 12 is a schematic structural view of the second end in the present invention in which the shape of the second end is cylindrical.
- Fig. 13 is a structural schematic diagram of a reinforcing rib provided at the transition part in the present invention.
- Fig. 14 is a schematic cross-sectional structure diagram of a charging socket in the present invention.
- 1-power transmission part 11-plug end, 12-connection end, 13-connection surface, 14-first upper surface, 15-first side surface, 16-first lower surface, 17-side surface, 18- End face, 19-threaded hole; 2-transition part, 21-first end, 22-bending part, 23-second end, 24-second upper surface, 25-second side surface, 26-second lower surface , 27-through hole, 28-reinforcing rib; 3-cable, 31-guide core, 32-insulation layer; 4-bolt; 5-charging socket.
- connection should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, a direct connection, or an indirect connection through an intermediary.
- the present invention provides a power transmission adapter mechanism, as shown in Figure 1, including a power transmission part 1, an adapter part 2 and a cable 3, wherein the power transmission part 1 includes a plug-in end 11 and a connecting end connected in sequence 12.
- the cable 3 includes an inner guide core 31 and an insulating layer 32 covering the guide core 31.
- the transition part 2 includes a first end 21, a bent part 22 and a second end 23 connected in sequence. The first end 21 is connected to the The end 12 is electrically connected, the second end 23 is electrically connected to the conductor core 31 at one end of the cable 3 , and the bending portion 22 includes at least one bending area.
- the transfer part 2 is used to respectively connect the power transmission part 1 and the guide core 31 of the cable 3, and the bending part 22 is provided on the transfer part 2, so that the power transmission part 1 and the cable 3 can be out of the same axis. direction, and can make the power transmission part 1 and the cable 3 be connected at an angle, thereby reducing the volume of the electrical device mechanism, and the use of the electrical device mechanism can adapt to more use environments.
- the present invention provides the adapter part 2, so that the extended structure for connecting the cable 3 is not required on the power transmission part 1. While saving the materials used in the power transmission part 1, it also reduces the complexity of the shape of the power transmission part. Due to the processing difficulty of the part 1, the power transmission part 1 can be mass-produced using a simple process, reducing the processing man-hours and improving the production efficiency of the power transmission part 1.
- At least part of the first end 21 is in contact with at least part of the connection end 12 .
- the first end 21 is at least partially connected to the connecting end 12 through resistance welding, friction welding, ultrasonic welding, arc welding, laser welding, electron beam welding, pressure welding, diffusion welding, magnetic induction welding, screw connection, One or more methods of snap-in, splicing, and crimping are used for connection.
- the resistance welding method refers to a method that uses a strong current to pass through the contact point between the electrode and the workpiece, and generates heat from the contact resistance to achieve welding.
- the friction welding method refers to the method of welding by using the heat generated by the friction of the contact surface of the workpiece as the heat source to cause the workpiece to undergo plastic deformation under pressure.
- the ultrasonic welding method is to use high-frequency vibration waves to transmit to the surfaces of two objects to be welded. Under pressure, the surfaces of the two objects are rubbed against each other to form fusion between molecular layers.
- the arc welding method refers to using the arc as a heat source and using the physical phenomenon of air discharge to convert electrical energy into thermal energy and mechanical energy required for welding, so as to achieve the purpose of connecting metals.
- the main methods are electrode arc welding, submerged arc welding, and gas protection. welding etc.
- Laser welding is an efficient and precise welding method that uses a high-energy-density laser beam as a heat source.
- the electron beam welding method refers to the use of accelerated and focused electron beams to bombard the welding surface placed in a vacuum or non-vacuum, so that the workpiece to be welded is melted to achieve welding.
- the pressure welding method is a method of applying pressure to the weldment so that the joint surfaces are in close contact to produce a certain plastic deformation to complete the welding.
- the diffusion welding method refers to a solid-state welding method in which the workpiece is pressurized at high temperature without visible deformation and relative movement.
- the magnetic induction welding method is that two workpieces to be welded are subjected to an instantaneous high-speed collision under the action of a strong pulsed magnetic field. Form a stable metallurgical bond. It is a kind of solid-state cold welding, which can weld conductive metals with similar or dissimilar properties together.
- the threaded connection method refers to a threaded connection, a detachable connection in which the connected parts are integrated with a threaded part (or the threaded part of the connected part). Commonly used threaded joints include bolts, studs, screws and set screws, etc., mostly standard parts.
- the clamping method means that corresponding claws or grooves are provided on the connecting end 12 or the connecting surface 13 respectively, and assembled through the grooves and claws to connect them together.
- the advantage of the card connection method is that the connection is fast and detachable.
- the splicing means that corresponding grooves and protrusions are provided on the connection end 12 or the connection surface 13 respectively, and the grooves and protrusions are assembled by mortise or splicing with each other to make them connected together.
- the advantage of splicing is that the connection is stable and detachable.
- the crimping method, crimping is a production process in which the connecting end 12 and the connecting surface 13 are assembled, and a crimping machine is used to press the two into one.
- the advantage of crimping is mass production. By using an automatic crimping machine, it is possible to quickly manufacture a large number of stable quality products.
- connection method an appropriate connection method or combination of connection methods can be selected according to the actual use environment and the actual state of the connection end 12 and the first end 21, so that the connection end 12 and the first end 21 are stably connected together. To achieve an effective electrical connection.
- connection end 12 includes a connection surface 13 , and the area of the contact area between the connection surface 13 and the first end 21 accounts for more than 5% of the area of the connection surface 13 .
- the contact area between the connection surface 13 and the first end 21 is a key characteristic, the larger the contact area, the greater the contact area between the connection surface 13 and the first end 21 The smaller the voltage drop, the greater the pull-out force.
- the inventor selected 10 groups of the same power transmission part 1 and adapter part 2, and set the same connection surface 13 on the power transmission part 1, and then adopted the same ultrasonic welding method, but The ratio of the area of the contact area of the connection surface 13 and the first end 21 to the area of the connection surface 13 is selected, and then the voltage drop between the connection surface 13 and the first end 21 is tested by passing a current, and the connection surface 13 and the first end are tested.
- the pulling force between 21, the results are recorded in Table 1.
- Voltage drop test method place the connection end 12 and the first end 21 on the voltage drop detection platform, respectively test the voltage values A and B of the connection surface 13 and the first end 21 themselves, and then test the connection surface 13 to the first end 21 voltage value C, and then calculate the value of C-(A+B) as the voltage drop value at the connection point between the connection surface 13 and the first terminal 21 .
- a voltage drop greater than 4mV is unqualified.
- the method for testing the pull-out force is to use a pull-out tester to respectively fix the welded connecting end 12 and the first end 21 on the two end fixtures of the pull-out tester, and then start the pull-out tester to make the two
- the end gripper moves in two opposite directions at a uniform speed, and the pulling force when the first end 21 is separated from the connecting end 12 is recorded.
- a pullout force of less than 1600N is unqualified.
- Table 1 Effect of the ratio of the area of the contact area between the connection surface 13 and the first end 21 to the area of the connection surface 13 on the voltage drop and pull-out force
- the shape of the connection end 12 is a sheet
- the connection end 12 includes a first upper surface 14, a first lower surface 16 and a first side surface 15, and the connection surface 13 is arranged on
- the shape of the first end 21 is a sheet
- the first end 21 includes a second upper surface 24, a second lower surface 26 and a second side 25, and the first upper surface 14
- the first lower surface 16 is overlapped with the second upper surface 24 or the second lower surface 26 and then contacted and connected.
- Both the connecting end 12 and the first end 21 are sheet-shaped, easy to process, and convenient to overlap and connect, which is beneficial to the manufacture of equipment fixtures and welding molds, and facilitates automatic production, improves production efficiency, and reduces production costs.
- connection end 12 is columnar
- connection end 12 includes a side surface 17 and an end surface 18
- connection surface 13 is arranged on the end surface 18, and the shape of the first end 21 is a sheet.
- the first end 21 includes a second upper surface 24 , a second lower surface 26 and a second side surface 25 , and the end surface 18 is in contact with the second upper surface 24 or the second lower surface 26 .
- the end of the power transmission part 1 is not processed into a sheet structure, but directly processed into an end face 18, which can reduce the processing steps, reduce the processing time, and can shorten the length of the power transmission part 1, simplify the volume of the power transmission adapter mechanism, and The processing material of the power transmission part 1 can be saved, and the cost of the power transmission part 1 can be reduced.
- the end face 18 of the connection end 12 and the first end 21 can be connected together by welding, screwing, clamping or splicing.
- the power transmission adapter mechanism further includes a bolt 4 , the second upper surface 24 is provided with a through hole 27 penetrating through the second lower surface 26 , and the end surface 18 is provided with a threaded hole 19 , the bolt 4 passes through the through hole 27 and is screwed into the threaded hole 19 .
- the power transmission part 1 and the adapter part 2 can be quickly connected together by means of threaded connection, and can be detachable, and can be easily disassembled and replaced in subsequent maintenance and repairs.
- the torque range of the screw connection between the bolt 4 and the threaded hole 19 is 0.1N ⁇ m-30N ⁇ m.
- the method of testing the contact resistance between the bolt 4 and the threaded hole 19 is to use a micro-resistance measuring instrument, place one end of the measuring end of the micro-resistance measuring instrument on the power transmission part 1, and place the other end on the transfer part 2. The same position, and then read the contact resistance reading on the micro-resistance meter.
- a contact resistance greater than 1 m ⁇ is unqualified.
- the vibration test is to place the connected sample on the vibration test bench. After 300 vibration cycles, each cycle requires vibration in 6 directions, the frequency is 100Hz, and the acceleration in one direction is 40m/s2. Then observe the bolt 4 and Whether the threaded hole 19 is loose. In this embodiment, the looseness of the bolt 4 and the threaded hole 19 is unqualified.
- Table 2 Effects of different bolt 4 and threaded hole 19 torques on the electrical connection and mechanical connection performance of the power transmission part 1 and the transfer part 2
- the inventors set the minimum value of the torque range for the screw connection of the bolt 4 and the threaded hole 19 to 0.1 N ⁇ m.
- the torque value of the bolt 4 and the threaded hole 19 is more than 30N ⁇ m, the contact resistance between the power transmission part 1 and the transfer part 2 cannot be further reduced.
- the range is determined to be 0.1N ⁇ m-30N ⁇ m.
- the shape of the connection end 12 is cylindrical, the connection end 12 includes a first inner surface and a first outer surface, the connection surface 13 is arranged on the first inner surface or the first outer surface, and the first end 21
- the shape is cylindrical, and the first end 21 includes a second inner surface and a second outer surface, and the first inner surface or the first outer surface overlaps with the second outer surface or the second inner surface and then contacts and connects.
- Both the connecting end 12 and the first end 21 are cylindrical, and can be overlapped together by socketing, and then connected by the above-mentioned connection method.
- This overlapping socket connection method has a large contact area between the connecting end 12 and the first end 21, which can effectively reduce the contact resistance between the connecting end 12 and the first end 21, and improve the electrical performance of the power transmission transfer mechanism.
- the cross-sectional shape of the connecting end 12 or the first end 21 is circular, oval, rectangular or polygonal.
- the cylindrical structure of the connecting end 12 or the first end 21 can have many cross-sections, and different cross-sectional shapes can be selected according to the specific use environment of the connecting end 12 or the first end 21 and its own processing technology, so that The purpose of effectively electrically connecting the connecting end 12 and the first end 21 is achieved.
- the shape of the second end 23 is a flat plate, a bowl, a U, a V or a cylinder.
- the second end 23 is the position where the transfer part 2 is connected to the guide core 31 of the cable 3, and the shape of the second end 23 can be selected according to the shape of the guide core 31 of the cable 3 and the specific use environment.
- the plate shape and bowl shape are generally used for welding with the guide core 31
- the U shape and V shape are generally used for crimping with the guide core 31
- the cylindrical shape can be used for crimping or welding with the guide core 31 .
- At least part of the guide core 31 is in contact with at least part of the second end 23 .
- At least part of the guide core 31 and at least part of the second end 23 are welded by resistance welding, friction welding, ultrasonic welding, arc welding, laser welding, electron beam welding, pressure diffusion welding, magnetic induction welding, screw connection, One or more methods of snap-in, splicing, and crimping are used for connection.
- connection method according to the actual use environment, and the actual state of the guide core 31 and the second end 23 of the cable 3, an appropriate connection method or combination of connection methods can be selected, and at least part of the guide core 31 of the cable 3 It is connected with at least part of the second end 23 stably to realize an effective electrical connection.
- the connecting end 12 includes a connecting surface 13, at least part of the first end 21 is in contact with the connecting surface 13; the second end 23 includes a wiring surface, and the contact area between the wiring surface and the guide core 31 Occupies more than 5% of the wiring surface area.
- the contact area between the wiring surface and the conductor core 31 is a key characteristic. The larger the contact area, the lower the voltage drop between the wiring surface and the conductor core 31. The smaller it will be, the greater the pull-out force will be.
- the inventor selected 10 sets of the same adapters 2 and cables 3, and provided the same wiring surface on the second end 23, and then adopted the same ultrasonic welding method, but selected the wiring surface and the guide core 31 Different contact areas account for the ratio of the wiring surface area, and then the voltage drop between the wiring surface and the conductor core 31 is tested by current, and the pull-out force between the wiring surface and the conductor core 31 is tested, and the results are recorded in Table 3. middle.
- Voltage drop test method place the adapter 2 and the cable 3 on the voltage drop detection table, test the voltage values A and B of the wiring surface and the conductor core 31 itself, and then test the voltage value from the wiring surface to the conductor core 31 C, and then calculate the value of C-(A+B) as the voltage drop value at the connection point between the wiring surface and the conductor core 31 .
- a voltage drop greater than 4mV is unqualified.
- the method of testing the pull-out force is to use a pull-out tester to respectively fix the welded wiring surface and the guide core 31 on the clamps at both ends of the pull-out tester, and then start the pull-out tester to make the clamps at both ends Move in two opposite directions at a uniform speed, and record the pulling force when the guide core 31 is detached from the wiring surface.
- a pullout force of less than 1600N is unqualified.
- Table 3 Effect of the ratio of the area of the contact area between the wiring surface and the conductor core 31 to the area of the wiring surface on the voltage drop and pull-out force between the wiring surface and the conductor core 31
- the inventor sets the contact area between the wiring surface and the guide core 31 to account for 10% of the wiring surface area. 5% or more.
- the connecting portion 2 is formed by stamping, cutting, bending or machining of a plate.
- plate processing to form is a relatively simple and mature process in the current metal processing technology, and plate is also one of the materials that are easy to obtain. If the shape of the transfer part 2 is not complicated, the waste generated by using the plate processing process is relatively simple compared to turning, Processing processes such as milling produce much less waste, and are one of the production processes with higher material utilization. Utilizing the mature plate stamping process and stamping dies, it is possible to quickly and mass-produce the formed transfer part 2. In addition, advanced processing techniques such as laser cutting and water cutting can also be used to blank the plate first, and then adopt the bending process. Forming, or processing the plate in the form of machining can also reduce production costs and improve the production efficiency of the adapter part 2 .
- the thickness of the first end 21 , the bent portion 22 and the second end 23 differ by no more than 35%.
- the thickness of the sheet material is the best, and the material is common, and when stamping or cutting and bending are used, the processing parameters can also be very stable, but due to the various shapes of the connecting end 12 or the guide core 31, The space and use environment of the power transmission adapter mechanism are also various. In some cases, it is necessary to use the first end 21 , the bending portion 22 and the second end 23 of different widths.
- the inventor selected a plurality of bending portions 22 with the same length and width. Similarly, test the voltage drop at both ends of the adapter 2 for the adapter 2 samples with different thicknesses of the first end 21 , the bent portion 22 and the second end 23 , and record the test results in Table 4. In this embodiment, a voltage drop greater than 4mV is unqualified.
- the percentage of thickness difference between the first end 21, the bent portion 22 and the second end 23 refers to the value of the maximum thickness/minimum thickness among the first end 21, the bent portion 22 and the second end 23 value x 100%.
- test method of voltage drop adopt the transfer part 2 sample whose thickness is the same as the minimum thickness of the sample, and other sizes and shapes are the same, test the voltage value at both ends on the voltage drop detection platform, and then use the method in this embodiment For the transfer part 2 samples with different thicknesses, test the voltage value E at both ends at the same position, and then calculate the value of E-D as the voltage drop value of the transfer part 2.
- the angle between two adjacent planes in the bending area is 0°-180°.
- the bending angle is within 0°-180°, so as to meet the requirements of different wiring directions of the adapter part 2 conveniently.
- the transition part 2 has two bending areas, and the bending angles are opposite to A°, so that the first end 21 and the second end 23 of the transition part 2 form two substantially parallel planes.
- the transfer part 2 has a bending area with a bending angle of 90°, which can make the outgoing direction of the cable 3 90° from the axial direction of the power transmission part 1, meeting the requirements for outgoing lines in different directions .
- the angle between two adjacent planes in the bending area may be changed due to the space limitation of the power transmission and switching mechanism, or the requirement of other outgoing directions.
- the bending part of the bending area is arc-shaped, and the inner radius of the bending part is not less than one-third of the thickness of the transition part 2 .
- the bending part of the bending area is generally bent by stamping or using a bending machine. If the inner radius of the bending area is too small or even zero, the outer radius of the bending area will also be very small. Small, resulting in excessive external stretching at the bend, and concentrated stress at the bend. In the subsequent use process, the cable 3 will transmit the external shaking to the bending area of the transfer part 2.
- the inner radius of the bending portion in the bending area is greater than or equal to one-third of the thickness of the transition portion 2 .
- At least one reinforcing rib 28 is provided in the tangential direction of the bending area, and the reinforcing rib 28 is formed by indenting the outer material of the bending area toward the inside.
- stamping is used in the bending area, and at least one rib 28 is processed, which can strengthen the strength of the bending area, increase the maximum force that the transfer part 2 can bear in the bending area, and enable the plate-shaped turning The connection part 2 has a longer service life.
- the bending area is twisted, and the included angle between the plane or longitudinal center plane of symmetry of the first end 21 and the plane or longitudinal center plane of symmetry of the second end 23 is 0°-90°.
- the outgoing direction of the cable 3 is a special angle for the transition part 2
- the angle formed by simply bending the bending area is not satisfactory, the bending area needs to be twisted so that it can realize the second
- the plane of one end 21 and the plane of the second end 23 are no longer parallel, but at a certain angle.
- the longitudinal center of the first end 21 or the second end 23 can be The plane of symmetry serves as the reference plane.
- the outlet angle of the cable 3 forms a certain angle with the axial direction and radial direction of the electric energy transmission part 1 .
- the included angle between the plane of the first end 21 and the plane of the second end 23 is B°.
- the material of the adapter part 2 contains one of nickel, cadmium, zirconium, chromium, cobalt, manganese, aluminum, tin, titanium, zinc, copper, silver, gold, phosphorus, tellurium, beryllium, and lead. or more.
- the inventor used materials of the same size and different materials to make samples of the adapter 2, and tested the conductivity of the adapter 2 respectively.
- the results are shown in Table 5.
- the conductivity of the transition part 2 is greater than 99%, which is an ideal value.
- the electrical conductivity of the transition part 2 made of the selected metal material is within the ideal range.
- phosphorus is a non-metallic material and cannot be directly used as the material of the transition part 2, but it can be added to other metals. Alloys are formed in the metal to improve the electrical conductivity and mechanical properties of the metal itself. Therefore, the inventors set the material of the adapter part 2 to contain one of nickel, cadmium, zirconium, chromium, cobalt, manganese, aluminum, tin, titanium, zinc, copper, silver, gold, phosphorus, tellurium, beryllium, and lead. or more.
- the material of the transfer portion 2 contains tellurium-copper alloy, and the content of tellurium in the tellurium-copper alloy is 0.1% ⁇ 5%.
- the transfer portion 2 has good electrical conductivity and easy cutting performance, ensures electrical performance, and can also improve machinability.
- the inventor selected 10 transfer parts 2 of the same shape for testing, and each transfer part 2 The size is the same, the material of the transfer part 2 is tellurium copper alloy, and the content of tellurium is respectively 0.05%, 0.1%, 0.2%, 0.5%, 0.8%, 1.2%, 2%, 3%, 5%, 6%, 7%. Pass the current through the transfer part 2, and detect the conductivity of the corresponding transfer part 2, and the test results are shown in Table 6. In this embodiment, it is ideal that the conductivity is greater than 99%.
- the material of the adapter part 2 contains beryllium copper alloy, and the content of beryllium in the beryllium copper alloy is 0.05%-5%.
- the content of beryllium in the material of the adapter part 2 is 0.1%-3.5%.
- the beryllium in the transfer part 2 can make the transfer part 2 have high hardness, elastic limit, fatigue limit and wear resistance, and also have good corrosion resistance, thermal conductivity and electrical conductivity, and no sparks will be generated when impacted.
- each transfer part 2 contains beryllium, and the proportion of beryllium content is 0.03%, 0.05%, 0.1%, 0.2%, 1%, 1.8%, 3%, 3.5%, 5%, 6%, respectively.
- the test results are shown in Table 7. In this embodiment, it is ideal that the conductivity is greater than 99%.
- the material of the adapter part 2 contains phosphor bronze alloy, and the content of phosphorus in the phosphor bronze alloy is 0.01%-1.5%.
- the advantage of phosphor bronze is that it has better corrosion resistance and wear resistance, which can ensure good contact and elasticity of the adapter part 2, and has excellent machining performance, which can quickly shorten the processing time of parts.
- transition part 2 In order to test the influence of phosphorus content on the conductivity of the transition part 2, the inventor selected 10 transition parts 2 of the same shape and width for testing. Each transition part 2 contains phosphorus, and the proportion of phosphorus content is 0.001%, 0.005%, 0.01%, 0.05%, 0.1%, 0.5%, 1%, 1.5%, 2%, 2.5%, respectively. The test results are shown in Table 8. In this embodiment, it is ideal that the conductivity is greater than 99%.
- the material of the transfer portion 2 contains lead brass alloy, and the content of lead in the lead brass alloy is 0.1% ⁇ 5%.
- the advantages of lead brass alloy are high strength, dense and uniform structure, good corrosion resistance, and excellent machining performance such as cutting and drilling.
- transition parts 2 In order to test the influence of lead content on the conductivity of the transition part 2, the inventor selected 10 transition parts 2 of the same shape and width for testing. Each transition part 2 contains lead, and the proportion of lead content is 0.05%, 0.1%, 0.5%, 1%, 2%, 3%, 4%, 5%, 6%, 7%, respectively. The test results are shown in Table: 9. In this embodiment, it is ideal that the conductivity is greater than 99%.
- the power transmission part 1, the guide core 31 and the transfer part 2 are at least partially provided with a plating layer to improve the corrosion resistance of the power transfer part 1, the guide core 31 and the transfer part 2, and improve the electrical conductivity. Better prolong the service life of the power transmission adapter mechanism.
- At least part of the connecting surface 13 is not provided with plating.
- the method of not providing a plating layer can be used to make the two connection surfaces directly contact, which can reduce the contact resistance and reduce the contact resistance of the power transmission part 1.
- the voltage drop between the adapter part 2 improves the electrical performance of the power transmission adapter mechanism.
- At least part of the connecting surface 13 is provided with a plating layer, and the plating layer on the connecting surface 13 is the first plating layer.
- a plating layer is required to improve corrosion resistance; or the materials of the power transmission part 1 and the transfer part 2 are different, and a plated metal is required for transition.
- a plating layer needs to be provided on the connecting surface 13 , and in order to distinguish it from other plating layers, the plating layer on the connecting surface 13 is the first plating layer.
- no plated layer is provided on at least the plane of the first end 21 in contact with the connecting surface 13 .
- the method of not providing a plating layer can be used to make the two connection surfaces directly contact, which can reduce the contact resistance and reduce the electric energy.
- the voltage drop between the transmission part 1 and the adapter part 2 improves the electrical performance of the power transmission adapter mechanism.
- the first end 21 is provided with a plating layer at least on the plane contacting the connection surface 13 , and the plating layer on at least the plane contacting the first end 21 contacting the connection surface 13 is the second plating layer.
- a plating layer is required to improve corrosion resistance; or the materials of the power transmission part 1 and the transfer part 2 are different, and a plated metal is required for transition.
- a coating needs to be provided on the first end 21 , and in order to distinguish it from other coatings, the coating on the first end 21 is a second coating.
- connection surface is not provided with a coating.
- the method of not providing a coating can be adopted, so that the two The two surfaces are in direct contact, which can reduce the contact resistance, reduce the voltage drop between the guide core 31 and the adapter part 2, and improve the electrical performance of the power transmission adapter mechanism.
- At least part of the wiring surface is provided with a plating layer, and the plating layer on the wiring surface is the third plating layer.
- the coating on the wiring surface is the third coating.
- no plating layer is provided on the guide core 31.
- the method of not providing a plating layer can be adopted, so that the two The two connection surfaces are in direct contact, which can reduce the contact resistance, reduce the voltage drop between the guide core 31 and the adapter part 2, and improve the electrical performance of the power transmission adapter mechanism.
- At least part of the guide core 31 is provided with the coating layer, and the coating layer on the guide core 31 is the fourth coating layer.
- the coating on the guide core 31 is Fourth coating.
- the first coating material, the second coating material, the third coating material and the fourth coating material are different. That is: in the first coating layer, the second coating layer, the third coating layer and the fourth coating layer, at least one of the materials is different from the others, which can be the material of the first coating layer and the material of the second coating layer, the material of the third coating layer and the The material of the fourth coating layer is different; or the material of the second coating layer is different from the material of the first coating layer, the material of the third coating layer and the material of the fourth coating layer; or the material of the third coating layer is different from the material of the first coating layer, the second coating layer The material of the coating layer is different from that of the fourth coating layer; or the material of the fourth coating layer is different from the material of the first coating layer, the material of the second coating layer and the material of the third coating layer.
- the two materials are the same, but different from the other two materials, it can be that the material of the first coating layer is the same as that of the second coating layer, The material of the third coating layer is the same as that of the fourth coating layer, but the material of the first coating layer is different from that of the third coating layer; or the material of the first coating layer is the same as that of the third coating layer, and the material of the second coating layer is the same as that of the fourth coating layer.
- the material of the first coating layer is the same as that of the second coating layer; or the material of the first coating layer is the same as that of the fourth coating layer, and the material of the second coating layer is the same as that of the third coating layer, but the material of the first coating layer
- the material is not the same as the material of the second plating layer,
- the materials of the three coatings are not the same, and the material of the first coating can be the same as that of the second coating, and the material of the third coating can be the same as that of the third coating.
- the material of the fourth coating layer is different; the material of the first coating layer is the same as that of the third coating layer, the material of the second coating layer and the material of the fourth coating layer; the material of the first coating layer is the same as that of the fourth coating layer, which is the same as that of the second coating layer
- the material of the second coating layer is different from the material of the third coating layer; the material of the second coating layer is the same as that of the third coating layer, which is different from the material of the first coating layer and the material of the fourth coating layer; the material of the second coating layer is different from that of the fourth coating layer
- the material of the third coating layer is the same as that of the first coating layer and the material of the third coating layer; the material of the third coating layer is the same as that of the fourth coating layer, but different from the material of the first coating layer and the material of the second coating layer.
- the thickness of the first coating layer, the thickness of the second coating layer, the thickness of the third coating layer and the thickness of the fourth coating layer are different. That is: among the first coating, the second coating, the third coating and the fourth coating, at least one of them has a thickness different from the others, which can be the thickness of the first coating and the thickness of the second coating, the thickness of the third coating and the thickness of the third coating.
- the thickness of the fourth coating layer is different; or the thickness of the second coating layer is different from the thickness of the first coating layer, the thickness of the third coating layer and the thickness of the fourth coating layer; or the thickness of the third coating layer is different from the thickness of the first coating layer, the thickness of the second coating layer.
- the thickness of the plating layer is different from the thickness of the fourth plating layer; or the thickness of the fourth plating layer is different from the thickness of the first plating layer, the thickness of the second plating layer and the thickness of the third plating layer.
- the thickness of the first coating layer can be the same as the thickness of the second coating layer, and the thickness of the second coating layer
- the thickness of the third coating is the same as that of the fourth coating, but the thickness of the first coating is different from that of the third coating; or the thickness of the first coating is the same as that of the third coating, and the thickness of the second coating is the same as that of the fourth coating
- the thickness of the first coating is different from the thickness of the second coating; or the thickness of the first coating is the same as the thickness of the fourth coating, the thickness of the second coating is the same as that of the third coating, but the first coating
- the thickness of the second coating is not the same as that of the second coating
- the thickness of three coatings is not the same, it can be that the thickness of the first coating is the same as the thickness of the second coating, and the same as the thickness of the third coating.
- the thickness of the fourth coating is different; the thickness of the first coating is the same as that of the third coating, and the thickness of the second coating is different from the thickness of the fourth coating; the thickness of the first coating is the same as that of the fourth coating,
- the thickness of the second coating layer is different from the thickness of the third coating layer; the thickness of the second coating layer is the same as that of the third coating layer, and is different from the thickness of the first coating layer and the thickness of the fourth coating layer; the thickness of the second coating layer is the same as that of the first coating layer
- the thicknesses of the four coating layers are the same, but different from the thickness of the first coating layer and the thickness of the third coating layer; the thickness of the third coating layer is the same as that of the fourth coating layer, and different from the thickness of the first coating layer and the
- the coating material contains one or more of gold, silver, nickel, tin, zinc, tin-lead alloy, silver-antimony alloy, palladium, palladium-nickel alloy, graphite silver, graphene silver, and silver-gold-zirconium alloy. kind.
- the power transmission part 1 and the transfer part 2 will use copper material.
- As an active metal copper will undergo oxidation reaction with oxygen and water during use, so one or more inactive metals are required as The coating prolongs the service life of the power transmission part 1 and the adapter part 2 .
- the conductivity and stability of the above-mentioned metals are better than copper or copper alloys, which can enable the power transmission part 1 and the transfer part 2 to obtain better electrical performance and longer service life.
- the corrosion resistance time test in Table 10 is to put the samples of the power transmission part 1 and the transfer part 2 into the salt spray test chamber, and spray each position of the samples of the power transfer part 1 and the transfer part 2 Spray salt spray, take out and clean every 20 hours to observe the surface corrosion, that is, a cycle, until the surface corrosion area of the power transmission part 1 and the transfer part 2 sample is greater than 10% of the total area, stop the test, and record the time number of cycles. In this embodiment, the number of cycles less than 80 is considered unqualified.
- the coating material contains the commonly used metals tin, nickel, and zinc, the experimental results are not as good as other selected metals.
- the experimental results of other metals are more than the standard value, and the performance is relatively stable. Therefore, the inventor selects the coating material to contain one or more of gold, silver, nickel, tin, zinc, tin-lead alloy, silver-antimony alloy, palladium, palladium-nickel alloy, graphite silver, graphene silver, and silver-gold-zirconium alloy. .
- the plating layer is provided by means of electroplating, electroless plating, magnetron sputtering or vacuum plating.
- the electroplating method is the process of plating a thin layer of other metals or alloys on the metal surface by using the principle of electrolysis.
- the electroless plating method is a process of metal deposition through a controllable oxidation-reduction reaction under the catalysis of metals.
- the magnetron sputtering method uses the interaction between the magnetic field and the electric field to make the electrons run in a spiral shape near the target surface, thereby increasing the probability that the electrons collide with the argon gas to generate ions, and the generated ions hit the target surface under the action of the electric field.
- the target is sputtered.
- the vacuum plating method is to deposit various metal and non-metal films on the surface of parts by distillation or sputtering under vacuum conditions.
- the plating layer includes a bottom layer and a surface layer.
- the coating adopts the method of multi-layer plating. After the power transmission part 1 and the transfer part 2 are processed, there are still many gaps and holes under the surface microscopic interface. These gaps and holes are the power transmission part 1 and the transfer part 2 during use largest cause of wear and corrosion.
- a layer of bottom layer is firstly plated to fill the gaps and holes on the surface, so that the surface of the power transmission part 1 and the transfer part 2 is smooth and free of holes, and then plated
- the surface layer will be more firmly combined and smoother, and the surface of the coating will have no gaps or holes, so that the wear resistance, corrosion resistance and electrical performance of the power transmission part 1 and the transfer part 2 are better, and the power transmission is greatly extended.
- the underlying material contains one or more of gold, silver, nickel, tin, tin-lead alloy and zinc; the surface material contains gold, silver, nickel, tin, zinc, tin-lead alloy, silver-antimony alloy One or more of , palladium, palladium-nickel alloy, graphite silver, graphene silver and silver-gold-zirconium alloy.
- the thickness of the bottom layer is 0.01 ⁇ m ⁇ 15 ⁇ m, preferably, the thickness of the bottom layer is 0.1 ⁇ m ⁇ 9 ⁇ m.
- the thickness of the surface layer is 0.5 ⁇ m-55 ⁇ m, preferably, the thickness of the surface layer is 1 ⁇ m-35 ⁇ m.
- the temperature rise test is to pass the same current through the connected power transmission part 1 and the adapter part 2 sample, and detect the same position of the power transmission part 1 and the adapter part 2 sample before power-on and after temperature stabilization in a closed environment temperature, and make the difference to take the absolute value.
- a temperature rise greater than 50K is considered unqualified.
- the corrosion resistance time test is to put the power transmission part 1 and the transfer part 2 samples into the salt spray test box, and spray salt spray on each position of the power transmission part 1 and the transfer part 2 samples, Take out and clean every 20 hours to observe the surface corrosion, that is, a cycle, until the surface corrosion area of the power transmission part 1 and the transfer part 2 sample is greater than 10% of the total area, stop the test, and record the number of cycles at that time. In this embodiment, the number of cycles less than 80 is considered unqualified.
- Table 11 Effects of different bottom coating thicknesses on the temperature rise and corrosion resistance of the power transmission part 1 and the transfer part 2
- the thickness of the bottom layer of nickel plating is greater than 12 ⁇ m, because the bottom layer is thicker, the heat generated by the power transmission part 1 and the transfer part 2 samples cannot be dissipated, so that the temperature of the power transmission part 1 and the transfer part 2 samples It is unqualified, and the coating is thicker, but it is easy to fall off from the surface of the power transmission part 1 and the transfer part 2, resulting in a decrease in the number of cycles of corrosion resistance. Therefore, the inventors choose the thickness of the bottom plating layer to be 0.01 ⁇ m ⁇ 12 ⁇ m.
- the inventors found that when the thickness of the underlying coating is 0.1 ⁇ m to 9 ⁇ m, the comprehensive effect of the temperature rise and corrosion resistance of the power transmission part 1 and the transfer part 2 is better. Therefore, in order to further improve the safety of the product itself Performance, reliability and practicability, preferably the thickness of the underlying coating is 0.1 ⁇ m to 9 ⁇ m.
- the inventor used the power transmission part 1 and the transfer part with the same specifications and materials, the same thickness of the nickel-plated bottom layer, and different thicknesses of the silver-plated surface layer. Part 2 samples were tested for a series of temperature rise and corrosion resistance time. The experimental method was the same as the above-mentioned experimental method. The experimental results are shown in Table 12.
- Table 12 Effects of different surface coating thicknesses on the temperature rise and corrosion resistance of the power transmission part 1 and the transfer part 2
- the thickness of the surface silver coating is greater than 50 ⁇ m, due to the thick surface coating, the heat generated by the terminal cannot be dissipated, which makes the temperature rise unqualified, and the thick coating is easy to fall off from the surface of the power transmission part 1 and the transfer part 2. , resulting in a decrease in the number of cycles of corrosion resistance. Moreover, since the surface coating metal is more expensive, the use of a thicker coating does not improve performance, and there is no use value. Therefore, the inventors selected the thickness of the surface silver plating layer to be 0.1 ⁇ m ⁇ 50 ⁇ m.
- the inventors found that when the thickness of the surface coating is 1 ⁇ m to 35 ⁇ m, the comprehensive effect of the temperature rise and corrosion resistance of the power transmission part 1 and the transfer part 2 samples is better. Therefore, in order to further improve the safety and reliability of the product itself In terms of performance and practicability, the thickness of the surface coating is preferably 1 ⁇ m to 35 ⁇ m.
- the material of the guide core 31 contains aluminum.
- copper wires are used to conduct current. Copper has high conductivity and good ductility. However, as the price of copper increases day by day, the material cost of using copper as a wire will become higher and higher. For this reason, people begin to look for the substitute of metallic copper to reduce cost.
- the content of metal aluminum in the earth's crust is about 7.73%. After the refining technology is optimized, the price is relatively low. Compared with copper, aluminum is lighter in weight and its conductivity is second only to copper. Aluminum can replace part of copper in the field of electrical connections. Therefore, it is a development trend to replace copper with aluminum in the field of automotive electrical connections.
- the material of the guide core 31 when the material of the guide core 31 contains aluminum, the material of the transition part 2 also contains aluminum.
- the connection between the guide core 31 and the transition part 2 can be transitioned without using a spacer metal, and can be directly The connection is made by crimping or welding or clamping or splicing or screwing, but it is necessary to set a spacer metal between the transfer part 2 and the power transmission part 1 for transition to prevent electrochemical corrosion between copper and aluminum.
- the contact resistance between the power transmission part 1 and the transfer part 2 is less than 9m ⁇ .
- a large current needs to be conducted between the power transmission part 1 and the adapter part 2.
- the contact resistance between the power transmission part 1 and the adapter part 2 is greater than 9m ⁇ , a large temperature will be generated at the contact position. As the time increases, the temperature will become higher and higher. The temperature between the power transmission part 1 and the transfer part 2 is too high. , The thermal expansion rate is different, resulting in asynchronous mechanical deformation, resulting in internal stress between the power transmission part 1 and the adapter part 2, and in severe cases, the plating layer will fall off, and the protection function cannot be realized.
- the second is that the excessive temperature of the power transmission part 1 and the transfer part 2 will be conducted to the insulating layer 32 of the cable 3 connected to the transfer part 2, causing the corresponding insulating layer 32 to melt, which cannot play the role of insulation protection, seriously Sometimes it will lead to short circuit of the line, damage to the connection structure, and even safety accidents such as burning. Therefore, the inventors set the contact resistance between the power transmission part 1 and the transfer part 2 to be less than 9m ⁇ .
- the inventor selected samples of the power transfer part 1 and the transfer part 2 with the same shape, and set them as Different contact resistance, and conduct conductivity and temperature rise test,
- the conductivity test is to connect the power transmission part 1 to the adapter part 2, and then power on the power transmission adapter mechanism to detect the conductivity of the corresponding connection.
- the conductivity is greater than 99%, which is an ideal value.
- the temperature rise test is to pass the same current to the power transmission adapter mechanism, and detect the temperature of the same position of the power transmission part 1 and the transfer part 2 samples before power on and after the temperature is stabilized in a closed environment, and make a difference to get the absolute value. value.
- a temperature rise greater than 50K is considered unqualified.
- Table 13 Effects of contact resistance between different power transmission parts 1 and transition parts 2 on conductivity and temperature rise
- the contact resistance between the guide core 31 and the transition part 2 is less than 9m ⁇ .
- a relatively large current needs to be conducted between the guide core 31 and the transition part 2. If the contact resistance between the guide core 31 and the transition part 2 is greater than 9m ⁇ , a large temperature rise will occur at the contact position. And with the increase of time, the temperature will be higher and higher, the temperature between the guide core 31 and the transfer part 2 is too high, one will cause the difference in thermal expansion rate between the guide core 31 and the transfer part 2 due to different materials , resulting in asynchronous mechanical deformation, resulting in internal stress between the guide core 31 and the adapter part 2, and in severe cases, the plating layer of the adapter part 2 will fall off, and the protective effect cannot be realized.
- the second is that the high temperature of the guide core 31 and the adapter part 2 will be conducted to the insulation layer 32 of the cable 3, causing the corresponding insulation layer 32 to melt, which cannot play the role of insulation protection. In severe cases, it will cause a short circuit and cause a connection. Structural damage, or even safety accidents such as burning. Therefore, the inventors set the contact resistance between the guide core 31 and the transition part 2 to be less than 9 m ⁇ .
- the inventor selected the guide core 31 and the adapter part 2 samples of the same shape, and set them as different Contact resistance, and test the conductivity and temperature rise.
- the conductivity test is to connect the guide core 31 to the adapter part 2, and then energize the power transmission adapter mechanism to detect the conductivity of the corresponding connection.
- the conductivity greater than 99% is the ideal value.
- the temperature rise test is to pass the same current to the power transmission transfer mechanism, and detect the temperature of the same position of the guide core 31 and the transfer part 2 sample before power-on and after the temperature is stabilized in a closed environment, and make a difference to get the absolute value .
- a temperature rise greater than 50K is considered unqualified.
- Table 14 Effects of contact resistance between different guide cores 31 and transition part 2 on conductivity and temperature rise
- the present invention also provides a charging socket 5.
- the charging socket 5 includes the above-mentioned power transmission and switching mechanism.
- the outlet direction of the cable 3 can be set to any direction at the rear end of the charging socket 5, and at the same time, the charging terminal of the charging socket 5 and the situation that the cable 3 is not coaxial can also be realized, which can provide designers More design options are provided, different outlet directions can be designed according to the installation environment of the charging stand, and the volume of the charging socket 5 can be reduced as much as possible, which can save installation space.
- the present invention also provides a motor vehicle, which includes the above-mentioned power transmission adapter mechanism or the above-mentioned charging socket 5 .
- the installation space of the charging socket 5 can be reduced, which provides convenience for the installation and arrangement of other electrical appliances.
- Arbitrary outgoing lines can be set, and the shortest length of the cable 3 can be used to connect with the battery system, saving the material of the cable 3 and reducing the cost of the motor vehicle.
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Abstract
Description
Claims (45)
- 一种电能传输转接机构,包括电能传输部、转接部和线缆,其特征在于:所述电能传输部包括依次连接的插拔端和连接端,所述线缆包括内部的导芯和包裹所述导芯的绝缘层,所述转接部包括依次连接的第一端、弯折部和第二端,所述第一端与所述连接端电性连接,所述第二端与所述线缆一端的所述导芯电性连接,所述弯折部包含至少一个弯折区。
- 根据权利要求1所述的电能传输转接机构,其特征在于,所述第一端的至少部分与所述连接端的至少部分接触连接。
- 根据权利要求2所述的电能传输转接机构,其特征在于,所述第一端的至少部分与所述连接端的至少部分通过电阻焊接、摩擦焊接、超声波焊接、弧焊、激光焊接、电子束焊接、压力扩散焊接、磁感应焊接、螺接、卡接、拼接、压接的一种或几种方式进行连接。
- 根据权利要求1所述的电能传输转接机构,其特征在于,所述连接端上包含连接面,所述连接面与所述第一端的接触区域面积占所述连接面面积的5%以上。
- 根据权利要求4所述的电能传输转接机构,其特征在于,所述连接端的形状为片状,所述连接端包括第一上表面、第一下表面和第一侧面,所述连接面设置在所述第一上表面或所述第一下表面,所述第一端的形状为片状,所述第一端包括第二上表面、第二下表面和第二侧面,所述第一上表面或所述第一下表面与所述第二上表面或所述第二下表面重叠后接触连接。
- 根据权利要求4所述的电能传输转接机构,其特征在于,所述连接端的形状为柱状,所述连接端包括侧面和端面,所述连接面设置在所述端面上,所述第一端的形状为片状,所述第一端包括第二上表面、第二下表面和第二侧面,所述端面与所述第二上表面或所述第二下表面接触连接。
- 根据权利要求6所述的电能传输转接机构,其特征在于,所述电能传输转接机构还包括螺栓,所述第二上表面设置贯穿到所述第二下表面的通孔,所述端面上设置螺纹孔,所述螺栓穿过所述通孔与所述螺纹孔螺接。
- 根据权利要求7所述的电能传输转接机构,其特征在于,所述螺栓与所述螺纹孔螺接的扭矩范围为0.1N·m-30N·m。
- 根据权利要求4所述的电能传输转接机构,其特征在于,所述连接端的形状为筒状,所述连接端包括第一内表面和第一外表面,所述连接面设置在所述第一内表面或所 述第一外表面,所述第一端的形状为筒状,所述第一端包括第二内表面和第二外表面,所述第一内表面或所述第一外表面与所述第二外表面或所述第二内表面重叠后接触连接。
- 根据权利要求9所述的电能传输转接机构,其特征在于,所述连接端或所述第一端的横截面形状为圆形、椭圆形、矩形或多边形。
- 根据权利要求1所述的电能传输转接机构,其特征在于,所述第二端的形状为平板形、碗形、U形、V形或筒形。
- 根据权利要求1所述的电能传输转接机构,其特征在于,所述导芯的至少部分与所述第二端的至少部分接触连接。
- 根据权利要求12所述的电能传输转接机构,其特征在于,所述导芯的至少部分与所述第二端的至少部分通过电阻焊接、摩擦焊接、超声波焊接、弧焊、激光焊接、电子束焊接、压力扩散焊接、磁感应焊接、螺接、卡接、拼接、压接的一种或几种方式进行连接。
- 根据权利要求1所述的电能传输转接机构,其特征在于,所述连接端上包含连接面,所述第一端的至少部分与所述连接面至少部分接触连接;所述第二端上包含接线面,所述接线面与所述导芯的接触区域面积占所述接线面面积的5%以上。
- 根据权利要求1所述的电能传输转接机构,其特征在于,所述转接部利用板材冲压或切割折弯或机加工而成。
- 根据权利要求1所述的电能传输转接机构,其特征在于,所述第一端、弯折部和第二端的厚度,相差不超过35%。
- 根据权利要求1所述的电能传输转接机构,其特征在于,所述弯折区相邻两个平面的夹角为0°-180°。
- 根据权利要求1所述的电能传输转接机构,其特征在于,所述弯折区的弯折处为圆弧状,所述弯折处的内部半径,不小于所述转接部厚度的三分之一。
- 根据权利要求1所述的电能传输转接机构,其特征在于,在所述弯折区切线方向上设置至少一个加强筋,所述加强筋为所述弯折区外部材料向内部凹陷形成。
- 根据权利要求1所述的电能传输转接机构,其特征在于,所述弯折区为扭曲状,所述第一端的平面或纵向中心对称面,与所述第二端的平面或纵向中心对称面的夹角为0°-90°。
- 根据权利要求1所述的电能传输转接机构,其特征在于,所述转接部的材质含有 镍、镉、锆、铬、钴、锰、铝、锡、钛、锌、铜、银、金、磷、碲、铍、铅中的一种或多种。
- 根据权利要求1所述的电能传输转接机构,其特征在于,所述转接部材质中含有碲铜合金,所述碲铜合金中碲的含量为0.1%~5%。
- 根据权利要求1所述的电能传输转接机构,其特征在于,所述转接部材质中含有铍铜合金,所述铍铜合金中铍的含量为0.05%~5%。
- 根据权利要求1所述的电能传输转接机构,其特征在于,所述转接部材质中含有磷青铜合金,所述磷青铜合金中磷的含量为0.01%~1.5%。
- 根据权利要求1所述的电能传输转接机构,其特征在于,所述转接部材质中含有铅黄铜合金,所述铅黄铜合金加中铅的含量为0.1%~5%。
- 根据权利要求14所述的电能传输转接机构,其特征在于,所述电能传输部、所述导芯和所述转接部上至少部分设置镀层。
- 根据权利要求26所述的电能传输转接机构,其特征在于,至少部分所述连接面上不设置所述镀层。
- 根据权利要求26所述的电能传输转接机构,其特征在于,至少部分所述连接面上设置所述镀层,所述连接面上的所述镀层为第一镀层。
- 根据权利要求26所述的电能传输转接机构,其特征在于,所述第一端上至少与所述连接面接触的平面上不设置所述镀层。
- 根据权利要求28所述的电能传输转接机构,其特征在于,所述第一端上至少与所述连接面接触的平面上设置所述镀层,所述第一端上至少与所述连接面接触的平面上的所述镀层为第二镀层。
- 根据权利要求26所述的电能传输转接机构,其特征在于,至少部分所述接线面不设置所述镀层。
- 根据权利要求30所述的电能传输转接机构,其特征在于,至少部分所述接线面上设置所述镀层,所述接线面上的所述镀层为第三镀层。
- 根据权利要求26所述的电能传输转接机构,其特征在于,所述导芯上不设置所述镀层。
- 根据权利要求32所述的电能传输转接机构,其特征在于,至少部分所述导芯上设置所述镀层,所述导芯上的所述镀层为第四镀层。
- 根据权利要求34所述的电能传输转接机构,其特征在于,所述第一镀层材质、 所述第二镀层材质、所述第三镀层材质与所述第四镀层材质不相同。
- 根据权利要求34所述的电能传输转接机构,其特征在于,所述第一镀层厚度、所述第二镀层厚度、所述第三镀层厚度与所述第四镀层厚度不相同。
- 根据权利要求26所述的电能传输转接机构,其特征在于,所述镀层材质含有金、银、镍、锡、锌、锡铅合金、银锑合金、钯、钯镍合金、石墨银、石墨烯银和银金锆合金中的一种或多种。
- 根据权利要求26所述的电能传输转接机构,其特征在于,所述镀层采用电镀、化学镀、磁控溅射或者真空镀的方式设置。
- 根据权利要求26所述的电能传输转接机构,其特征在于,所述镀层包括底层和表层。
- 根据权利要求39所述的电能传输转接机构,其特征在于,所述底层材质含有金、银、镍、锡、锡铅合金和锌中的一种或多种;所述表层材质含有金、银、镍、锡、锌、锡铅合金、银锑合金、钯、钯镍合金、石墨银、石墨烯银和银金锆合金中的一种或多种。
- 根据权利要求1所述的电能传输转接机构,其特征在于,所述导芯的材质中含有铝。
- 根据权利要求1所述的电能传输转接机构,其特征在于,所述电能传输部与所述转接部之间的接触电阻小于9mΩ。
- 根据权利要求1所述的电能传输转接机构,其特征在于,所述导芯与所述转接部之间的接触电阻小于9mΩ。
- 一种充电插座,其特征在于,所述充电插座包括权利要求1-43任一项所述电能传输转接机构。
- 一种机动车辆,其特征在于,所述机动车辆包括权利要求1-43任一项所述电能传输转接机构或包括权利要求44所述充电插座。
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CN216698973U (zh) * | 2021-12-30 | 2022-06-07 | 长春捷翼汽车零部件有限公司 | 便于更换的充电座及汽车 |
CN114709667A (zh) * | 2022-03-14 | 2022-07-05 | 吉林省中赢高科技有限公司 | 一种连接器柔性连接结构及一种车辆 |
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