CN111863313A - Bus converging method - Google Patents
Bus converging method Download PDFInfo
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- CN111863313A CN111863313A CN202010686426.2A CN202010686426A CN111863313A CN 111863313 A CN111863313 A CN 111863313A CN 202010686426 A CN202010686426 A CN 202010686426A CN 111863313 A CN111863313 A CN 111863313A
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- 238000000034 method Methods 0.000 title claims abstract description 29
- 238000003466 welding Methods 0.000 claims abstract description 74
- 239000000758 substrate Substances 0.000 claims abstract description 8
- 238000009413 insulation Methods 0.000 claims description 7
- 238000010438 heat treatment Methods 0.000 claims description 6
- 229910000679 solder Inorganic materials 0.000 claims description 4
- 238000009434 installation Methods 0.000 description 9
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 8
- 238000005476 soldering Methods 0.000 description 6
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- 238000000576 coating method Methods 0.000 description 4
- 238000013461 design Methods 0.000 description 4
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- 238000005304 joining Methods 0.000 description 3
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- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- -1 phenolic aldehyde Chemical class 0.000 description 2
- 238000007747 plating Methods 0.000 description 2
- 229910052709 silver Inorganic materials 0.000 description 2
- 239000004332 silver Substances 0.000 description 2
- RSWGJHLUYNHPMX-UHFFFAOYSA-N Abietic-Saeure Natural products C12CCC(C(C)C)=CC2=CCC2C1(C)CCCC2(C)C(O)=O RSWGJHLUYNHPMX-UHFFFAOYSA-N 0.000 description 1
- 229910001369 Brass Inorganic materials 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
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- 241001604129 Polydactylus Species 0.000 description 1
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- KHPCPRHQVVSZAH-HUOMCSJISA-N Rosin Natural products O(C/C=C/c1ccccc1)[C@H]1[C@H](O)[C@@H](O)[C@@H](O)[C@@H](CO)O1 KHPCPRHQVVSZAH-HUOMCSJISA-N 0.000 description 1
- 238000009825 accumulation Methods 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 239000010951 brass Substances 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
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- 238000011161 development Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
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Images
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B5/00—Non-insulated conductors or conductive bodies characterised by their form
- H01B5/02—Single bars, rods, wires, or strips
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/033—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for wrapping or unwrapping wire connections
Abstract
The invention discloses a bus converging method, which belongs to the technical field of bus bars for spaceflight and comprises the following steps: s1, performing classification calculation on the multiple beams of wires, designing welding grooves suitable for different wires, welding a plurality of wires in parallel in each groove, and designing a corresponding insulating device to be mounted with the structure in an insulating way; s2, selecting wires with different wire diameters according to rated overcurrent capacity and task input, wherein the wire diameters of the wires do not include an insulating skin, and then calculating and determining the size of a clamping groove of a welding wire of the confluence device; s3, welding the cable with the conductive base body, then embedding and installing the conductive base body into the insulating base, and enabling the cable insulating skin to be in contact with the protruding part of the edge of the insulating base; and S4, removing the insulating sheath on the head of the cable, welding the head of the cable with the conductive substrate, and embedding and installing the head of the cable into the insulating layer together. The invention can meet the performance requirements of space power supply products and even single machines of common electronic equipment, can reduce the volume and the weight of the bus bar, reduces the welding times and the workload, and reduces the welding difficulty.
Description
Technical Field
The invention belongs to the technical field of bus bars for spaceflight, and particularly relates to a bus bar converging method.
Background
In an electronic single machine, a large number of wires are required to be welded to different specifications of wires to connect different types of components to realize various functions, and the current flowing through the wires is usually large. With the development of aerospace technology, the requirements for switching power supplies are more and more strict, and the requirements for switching large current and environmental requirements such as small size and space are met, so that the impedance of a connecting conductor is required to be small, the volume is small, and the connection is required to be reliable. The bus bar can complete large current transmission in a single machine, has the advantages of low impedance, low inductive reactance, good anti-interference high-frequency filtering effect, high reliability, space saving, simple assembly and the like compared with a common wire cable bundle, and is widely applied to aerospace power supply and distribution systems.
At present, bus bars for aerospace mainly have two forms, one is a mode that the bus bars are screwed with line pressing terminals; the other mode is a mode of directly welding the split cables by punching round holes or kidney-shaped holes on the bus bars.
Although the bolt joint busbar is high in reliability, the installation mode that the terminal and the busbar are fastened by the screw after the lead is in compression joint with the compression joint terminal occupies a large space, the weight of the busbar is large, and the contact surface has an oxidation risk.
The beam splitting welding type busbar mechanical processing degree of difficulty is great, and is with high costs, and the heat dissipation is fast difficult welding, and the welding process is after heating many times, and the oxidation of silvered film is with higher speed, need heat for a long time and fixed wire during the operation, and the operation degree of difficulty is big, produces the busbar branch root electric current and collects the position and generate heat and stress concentration scheduling problem easily when passing through the heavy current.
Disclosure of Invention
The bus converging method provided by the invention can meet the performance requirements of space power supply products and even single machines of common electronic equipment, can reduce the volume and weight of the bus bar, reduce the welding times and workload, reduce the welding difficulty, improve the reliability, ensure the power supply safety and reduce the short circuit risk.
The invention aims to provide a bus converging method, which comprises the following steps:
s1, performing classification calculation on the multiple beams of wires, designing welding grooves suitable for different wires, welding a plurality of wires in parallel in each groove, and designing a corresponding insulating device to be mounted with the structure in an insulating way;
s2, selecting wires with different wire diameters according to rated overcurrent capacity and task input, wherein the wire diameters of the wires do not include an insulating skin, and then calculating and determining the size of a clamping groove of a welding wire of the confluence device;
s3, welding the cable with the conductive base body, and then embedding and installing the conductive base body into the insulating base, wherein: the cable insulation skin is contacted with the protruding part of the edge of the insulation base;
and S4, removing the insulating sheath on the head of the cable, welding the head of the cable with the conductive substrate, and embedding and installing the head of the cable into the insulating layer together.
Preferably, the number of cables accommodated in each welding wire clamping groove ranges from 1 to 6, and the size of each welding wire clamping groove is equal to the sum of the diameter of the bare wire core and the thickness of the soldering tin.
Preferably, when the bus device needs to be connected with various electronic components, the insulating base and the special welding wire clamping groove for the component lead are designed to be matched in size.
Preferably, the welding is performed by heating to 150 ℃ or higher on a hot stage.
Preferably, when the welding object is a temperature sensitive device, a welding hole or a welding column is designed at the corresponding installation position of the lead clamping groove welding of the device, and after the to-be-welded base body is cooled, a normal temperature welding mode is adopted for welding.
Preferably, the normal temperature welding mode is hook welding, and the component lead is welded on the conductive base body.
Preferably, when the bus bar device needs to be installed in a plurality of stacked layers, the hole positions and the sizes of the installation holes of the insulating layers are consistent.
The invention has the advantages and positive effects that:
through adopting above-mentioned technical scheme, this send under the condition that does not reduce the ability of overflowing, reduced the volume, alleviateed weight, reduced the welding degree of difficulty, but make full use of structure space can plan the inside line of walking of unit when the unit design, increases the inside rationality of walking the line of unit. The insulating design of busbar is also simpler, reduces the processing cost, and the face that needs the protection after the welding is accomplished also significantly reduces, improves the unit reliability. Can be combined and welded with various electronic components, and has great expanded applicability. The advantages of the bolt connection type bus bar and the welding type bus bar are integrated, and the bus bar is more suitable for application of a space power distribution single machine.
The invention can meet the performance requirements of space power supply products and even single machines of common electronic equipment, reduce the volume and the weight of the bus bar, reduce the welding times and the workload, reduce the welding difficulty, improve the reliability, ensure the power supply safety and reduce the short circuit risk.
Drawings
FIG. 1 is a schematic view of an exemplary bus bar joining method of the present invention;
FIG. 2 is a schematic view of an insulating layer of the bus bar bus device of the present invention;
FIG. 3 is a schematic view of an exemplary bus bar merging method of the present invention;
FIG. 4 is a schematic view of a bus bar bussing method according to the present invention illustrating bussing apparatus stack installation;
FIG. 5 is a schematic view of a bus bar joining method according to an exemplary embodiment of the present invention and a welding and joining apparatus for different electronic original devices;
FIG. 6 is a schematic view of an assembly sequence of an embodiment of the bus bar merging method of the present invention;
FIG. 7 is a schematic view of a conventional bolted bus bar for aerospace use;
FIG. 8 is a schematic view of a conventional beam splitting welded bus bar for aerospace use;
the reference numerals in the figures are respectively: 1-a conductive substrate; 2-welding a lead clamping groove; 3-an insulating base; 4-an insulating upper cover; 5-wire inlet end cable bundle; 6-cable bundle at the outlet end; 7-mounting the housing structure; 8-a screw; 9-a nut; 10-electronic components.
Detailed Description
In order to further understand the contents, features and effects of the present invention, the following embodiments are illustrated and described in detail with reference to the accompanying drawings:
as shown in fig. 1 to 8, the technical solution of the present invention is:
a bus converging method is suitable for transmitting large current among various bus bars with different shapes in electric product equipment.
The bus bar is composed of a conductive base body and an insulating layer. The conductive base body is machined by high-quality conductive materials with copper or aluminum as a matrix, the surface is plated with silver, and the insulating layer is machined by epoxy phenolic aldehyde laminated glass cloth plates or insulating materials such as polyimide, nylon and the like.
The convergence device designed by the method can be designed in a plurality of laminated layers, the space in the height direction is fully utilized, the arrangement of the wire harnesses in the single machine is greatly facilitated, the utilization rate of the space in the single machine is improved, and the new requirements of high voltage, high power, small volume and high reliability of space power supply products are met.
The confluence device designed by the method can be used in combination welding with various components such as fuses, sampling resistors and the like. Compared with the mode that components are directly welded on a circuit board and are connected for multiple times through a wire, the mode greatly improves the space utilization rate, lightens the weight of a single machine, is simple and quick to assemble, and has great expansion application value.
The specific idea of the confluence device designed by the method is that,
the method is characterized in that a welding mode is adopted, a plurality of bundles of wires are classified and calculated according to wire diameters and rated overcurrent capacity, welding grooves which are suitable for different wires and have different sizes are designed, a plurality of wires are welded in each groove in parallel, an insulating device matched with the welding grooves in size is designed according to the sizes of the welding grooves, and the insulating device and the structure are installed in an insulating mode.
After different wires are selected according to requirements, the size of a clamping groove of a welding wire of the confluence device is determined by calculating the wire diameter, the rated overcurrent capacity and the like of the wires without insulation skins.
Considering the operability of the welding process and the machining, the number of cables which can be accommodated in a single welding wire clamping groove is 1 to 6 based on the machining and the process implementation, and the size of the clamping groove can be determined according to the process standard of the diameter of the bare wire core and the proper thickness of the soldering tin.
The insulating layer can be integrally processed and molded according to specific assembly conditions or be divided into an insulating base and an insulating upper cover which are respectively installed and then assembled by fastening screws. After the welding of the cable and the conductive base body is finished, the conductive base body is embedded and installed in the insulating base, wherein the cable insulating skin is in contact with the protruding part of the edge of the insulating base.
The part of the cable head part, which is removed from the insulating sheath, is integrated with the conductive substrate by welding and is embedded into the insulating layer together, so that the insulating layer of the welding surface can be fully covered and fully protected, the risks of welding surface oxidation, metal redundancy lap joint and the like are avoided, and the reliability is improved. Meanwhile, the installation is simple and quick, and the complete insulation of the installation machine shell structure 7, the installation screws 8, the nuts 9 and other fasteners and the confluence device can be ensured.
If the confluence device needs to be connected with various electronic components 10, the special insulation base with special matching size and the special clamping groove for component lead wire can be respectively designed for welding. Because the conductive matrix dissipates heat quickly, has large heat capacity, and compared with the beam splitting welding type bus bar, the contact area between the bare wire core and the soldering tin and the conductive matrix is larger, the welding of the lead needs to be carried out on a heating table by heating to more than 150 ℃. In this case, the influence of the heating temperature on the components is considered. If the welding object is a temperature sensitive device, a welding hole or a welding column is designed at the corresponding installation position welded in the lead clamping groove of the device, after the to-be-welded base body is completely cooled, the lead of the device is welded on the conductive base body by adopting a normal-temperature common welding mode such as hook welding, and meanwhile, the insulating layer is designed to be correspondingly shaped to ensure the insulating installation.
If the confluence device needs a plurality of laminated layers, the hole positions and the sizes of the mounting holes of the insulating layers are ensured to be consistent, and the internal conductive matrix can be overlapped in the same form or different forms according to the specific design of specific conditions. During assembly, the fastening screws are changed to corresponding lengths, the reasonability of wiring design inside the single machine can be guaranteed, and the space utilization rate is improved.
The bus bar needs to meet the requirements of 17 wires with 20# at the wire inlet end, namely 17 wires with 20# at the wire inlet end, 5 wires with 18# and 14 wires with 22# at the wire outlet end, namely the wire outlet end 6. The core diameters of bare wires of the three wires are measured to be 1mm of No. 20 wire, 1.25mm of No. 18 wire and 0.8mm of No. 22 wire respectively. Considering factors such as a tin coating process, a thickness of a soldering tin layer, rated overcurrent capacity and the like, the sizes of the conductive substrate 1 and the soldering lead clamping groove 2 are designed to be symmetrical structures for facilitating machining, as shown in fig. 6. A4 mm (width) multiplied by 8mm (length) welding lead clamping groove can be used for welding 2 18# wires, 3 20# wires, 4 22# wires or leads with approximately equal wire diameters. The conductive substrate is processed by brass material, the surface is plated with protective weldable coating silver, and the thickness of the plating is 5-10 μm. An insulating layer is designed again on the basis of the conductive matrix, and the insulating base and the insulating upper cover are conveniently assembled and used by processing an epoxy resin phenolic aldehyde laminated glass cloth plate material. The bare wire core is embedded and installed in the insulating base after being subjected to tin-coating welding, the wire core insulating layer is contacted with the corrugated concave part at the edge of the insulating base, after the insulating upper cover is arranged above the bare wire core insulating layer, the welding contact surface is ensured to be completely insulated and protected, risks such as oxidation and metal redundancy lapping are avoided, and the reliability is greatly improved compared with the rest confluence mode. The dimensional diagrams of the insulating base and the insulating upper cover are shown in fig. 7 and 8 in consideration of machining tolerance and assembly accuracy.
In the welding process, the insulating layer of the wire is firstly removed by using a hot stripper, the length is 7mm, the core wires are exposed, and the multi-strand core wires are not required to be scattered for tin coating. The solder should melt sufficiently to saturate the interstices between the core wires, wet the surface of the core wires, and should slightly outline the core wires, with as little cross-over as possible between the wires. And (4) the bus bar device is welded in the wire clamping groove and is also tin-plated, and the wire after tin plating is aligned and pressed into the clamping groove for welding. The soldering tin occupies the clamping groove, and has no accumulation, no burr, no pull tip, no bridging, no rosin joint, no pinhole and no bubble, the distance between the insulating layer of the lead and the welding point is 0.5-0.8 mm, the insulating layer can not be embedded into the welding point, and the lead has no extrusion, no stress and no deflection. And the requirement is met after the welding is finished and the tensile test proves. And selecting screws with proper length specifications in the fastening and assembling process, and sequentially assembling the shell structure, the embedded insulating base 3, the bus bar and the insulating upper cover 4 together.
The above description is only for the preferred embodiment of the present invention, and is not intended to limit the present invention in any way, and all simple modifications, equivalent changes and modifications made to the above embodiment according to the technical spirit of the present invention are within the scope of the technical solution of the present invention.
Claims (7)
1. A bus bar converging method is characterized by comprising the following steps:
s1, performing classification calculation on the multiple beams of wires, designing welding grooves suitable for different wires, welding a plurality of wires in parallel in each groove, and designing a corresponding insulating device to be mounted with the structure in an insulating way;
s2, selecting wires with different wire diameters according to rated overcurrent capacity and task input, wherein the wire diameters of the wires do not include an insulating skin, and then calculating and determining the size of a clamping groove of a welding wire of the confluence device;
s3, welding the cable with the conductive base body, and then embedding and installing the conductive base body into the insulating base, wherein: the cable insulation skin is contacted with the protruding part of the edge of the insulation base;
and S4, removing the insulating sheath on the head of the cable, welding the head of the cable with the conductive substrate, and embedding and installing the head of the cable into the insulating layer together.
2. The method of claim 1, wherein each solder wire receptacle is capable of receiving a number of cables in a range of 1 to 6, the size of the solder wire receptacle being equal to the sum of the diameter of the bare wire core and the solder thickness.
3. The bus bar converging method according to claim 1 or 2, wherein when the converging device is connected with a plurality of electronic components, the insulating base and the special welding wire clamping groove for the component lead are respectively designed to be matched in size.
4. The method according to claim 1, wherein the welding is performed by heating to 150 ℃ or higher on a hot stage.
5. The bus bar converging method according to claim 1, wherein when the object to be welded is a temperature sensitive device, a welding hole or a welding column is designed at a corresponding position for mounting a lead clamping groove of the device, and after a to-be-welded base body is cooled, welding is performed by adopting a normal temperature welding mode.
6. The method of claim 5, wherein the normal temperature bonding is hook bonding and the component leads are bonded to the conductive substrate.
7. The bus bar merging method according to claim 1, wherein the insulating layer mounting holes are formed in a uniform size when the bus bar apparatus is mounted in a plurality of stacked layers.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202010686426.2A CN111863313A (en) | 2020-07-16 | 2020-07-16 | Bus converging method |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202010686426.2A CN111863313A (en) | 2020-07-16 | 2020-07-16 | Bus converging method |
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| Publication Number | Publication Date |
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| CN111863313A true CN111863313A (en) | 2020-10-30 |
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| CN202010686426.2A Pending CN111863313A (en) | 2020-07-16 | 2020-07-16 | Bus converging method |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113078487A (en) * | 2021-03-22 | 2021-07-06 | 中国电子科技集团公司第十八研究所 | Multi-path bus bar and forming process thereof |
Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| KR20100083413A (en) * | 2009-01-13 | 2010-07-22 | 한국단자공업 주식회사 | Bus-bar assembly |
| CN202333356U (en) * | 2011-10-26 | 2012-07-11 | 贵州航天电器股份有限公司 | Current-collecting combination device |
| CN107611625A (en) * | 2017-08-22 | 2018-01-19 | 成都宏明电子股份有限公司 | A kind of high current wire connection device connected simultaneously for multiple conducting wires |
| CN110994301A (en) * | 2019-11-11 | 2020-04-10 | 上海空间电源研究所 | Hook-type power collecting device for aerospace power product |
-
2020
- 2020-07-16 CN CN202010686426.2A patent/CN111863313A/en active Pending
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| KR20100083413A (en) * | 2009-01-13 | 2010-07-22 | 한국단자공업 주식회사 | Bus-bar assembly |
| CN202333356U (en) * | 2011-10-26 | 2012-07-11 | 贵州航天电器股份有限公司 | Current-collecting combination device |
| CN107611625A (en) * | 2017-08-22 | 2018-01-19 | 成都宏明电子股份有限公司 | A kind of high current wire connection device connected simultaneously for multiple conducting wires |
| CN110994301A (en) * | 2019-11-11 | 2020-04-10 | 上海空间电源研究所 | Hook-type power collecting device for aerospace power product |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113078487A (en) * | 2021-03-22 | 2021-07-06 | 中国电子科技集团公司第十八研究所 | Multi-path bus bar and forming process thereof |
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