CN114709009A - Power transmission line bundle and method for forming the same - Google Patents
Power transmission line bundle and method for forming the same Download PDFInfo
- Publication number
- CN114709009A CN114709009A CN202111601796.2A CN202111601796A CN114709009A CN 114709009 A CN114709009 A CN 114709009A CN 202111601796 A CN202111601796 A CN 202111601796A CN 114709009 A CN114709009 A CN 114709009A
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- China
- Prior art keywords
- power transmission
- transmission line
- insulating layer
- line bundle
- forming
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Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/02—Disposition of insulation
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/06—Insulating conductors or cables
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- 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
- H01R11/11—End pieces or tapping pieces for wires, supported by the wire and for facilitating electrical connection to some other wire, terminal or conductive member
- H01R11/12—End pieces terminating in an eye, hook, or fork
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- 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
- H01R43/16—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for manufacturing contact members, e.g. by punching and by bending
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- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Insulated Conductors (AREA)
Abstract
The present invention provides a power transmission line bundle, comprising: a conductive rod body; an insulating layer formed on the conductive rod main body; and a connection terminal formed at an end of the collector bar body.
Description
Technical Field
The invention relates to a power transmission harness and a method of forming the same.
Background
A power transmission harness is a type of harness used for transmitting power and/or connecting electrical lines. It is widely used in various devices or apparatuses to support the operation or functioning of the device or apparatus. An existing power transmission harness (e.g., a high-voltage harness for transmitting high voltage) is generally constituted by a shielded wire, a connector, a cover and a fixing clip, a bracket, and the like.
Along with the development of the technology, increasingly stringent requirements are continuously put on the power transmission line bundle. As an example, in the field of new energy vehicles, as the mileage of the vehicle is continuously increased with the development of new energy vehicles, the wire diameter of the power transmission wire harness used in the power supply system in the vehicle is also increased, so that the wire harness becomes "hard" (in other words, it is more difficult to wire), and even if the wire harness is routed using a wire slot for fixing the wire harness, the installation is still difficult.
Secondly, because the structures of the connectors on the market are different, different production processes need to be designed for different connectors to deal with, different molds and parameters need to be developed for different types of terminals, and long-time verification is carried out.
Disclosure of Invention
Technical problem to be solved by the invention
The present invention has been made in view of the above-mentioned technical problems, and it is an object of the present invention to provide an improved power transmission harness, which can avoid complicated manufacturing processes and expensive manufacturing costs of conventional power transmission harnesses, and in addition, can improve the conductive performance and wiring of the power transmission harness without designing a wire groove.
Technical scheme for solving technical problem
In one embodiment of the present invention which solves the above problems, there is provided a power transmission line bundle characterized by comprising: a conductive rod body; a connection terminal formed at an end of the collector bar body; and an insulating layer formed on the collector bar body.
In an embodiment of the invention, the conductive rod body comprises one or more bending parts.
In an embodiment of the invention, the power transmission line bundle further includes a shielding layer covering the insulating layer.
In an embodiment of the invention, the shielding layer is fixed on the insulating layer by a snap.
In an embodiment of the invention, the insulating layer is formed by extrusion.
In an embodiment of the present invention, the connection terminal is a ring terminal formed by punching an end portion of the conductor bar main body.
In one embodiment of the present invention to solve the above problems, there is provided a method of forming a power transmission wiring harness, characterized by comprising: providing a conductive rod main body; forming a connection terminal at an end of the conductive rod body; and forming an insulating layer on the conductor bar body.
In an embodiment of the invention, the method further comprises: one or more bent portions are formed by bending the conductor bar main body based on a wiring pattern for wiring of the power transmission line bundle.
In one embodiment of the present invention, the forming of the insulating layer on the collector bar body includes: the insulating layer is extruded on the collector bar body by an extrusion process.
In an embodiment of the present invention, the method further comprises: a shielding layer covers the insulating layer, the shielding layer providing electromagnetic shielding.
In an embodiment of the present invention, forming the connection terminal at the end of the collector bar body includes: forming an end of the collector bar body into the connection terminal through a punching process.
Effects of the invention
According to the invention, the manufacturing process of the power transmission line bundle can be improved.
Further, according to the present invention, wiring and mounting of the power transmission line bundle can be facilitated.
In addition, according to the present invention, the resistance possessed by the loop including the power transmission line bundle can be reduced.
Furthermore, according to the present invention, a wire duct for fixing a power transmission line bundle can be reduced or omitted.
Drawings
So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings, where like reference numerals have been used, where possible, to designate like elements that are common to the figures. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments, wherein:
fig. 1 is a schematic view of a power transmission harness according to the present invention.
Fig. 2 is a partial sectional view of a power transmission harness according to the present invention.
Fig. 3 is a flowchart of a method of forming a power transmission line bundle according to the present invention.
It is contemplated that elements of one embodiment of the present invention may be beneficially utilized on other embodiments without further recitation.
Detailed Description
Other advantages and technical effects of the present invention will be apparent to those skilled in the art from the disclosure of the present specification, which is described in the following with reference to specific embodiments. The present invention is not limited to the embodiments described below, and various other embodiments may be implemented or applied, and various modifications and changes may be made to the details in the present specification without departing from the spirit of the present invention.
Hereinafter, specific embodiments of the present invention will be described in detail based on the drawings. The drawings are for simplicity and clarity and are not intended to be drawn to scale, reflecting the actual dimensions of the structures described. To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. The figures are not drawn to scale and may be simplified for clarity. Elements and features of one embodiment may be beneficially incorporated in other embodiments without further recitation.
Hereinafter, a power transmission line harness 100 according to the present invention will be described with reference to fig. 1 and 2. Wherein fig. 2 is a schematic illustration of a cross-section of power transmission line bundle 100 taken along the a-a plane on fig. 1 (i.e., a plane perpendicular to the paper plane).
As an example, the power transmission line bundle 100 may include a collector bar body 110, a connection terminal 120, and an insulation layer 130. Optionally, power transmission line bundle 100 can further include a shield 130.
The collector bar body 110 may be formed of a conductive material. The conductive material includes, for example, metal, conductive plastic, conductive rubber, or a combination thereof. Suitable metals for forming the collector bar body 110 may include: one or more of copper (Cu), silver (Ag), gold (Au), aluminum (Al), sodium (Na), molybdenum (Mo), tungsten (W), zinc (Zn), nickel (Ni), iron (Fe), platinum (Pt), tin (Sn), lead (Pb), and an alloy thereof, or a composite metal formed of one or more thereof, and the like.
The cross-sectional shape of the collector bar body 110 is not limited to the circular shape shown in fig. 2, and may be various shapes such as a rectangle, a square, an ellipse, a ring, a polygon, and the like, which can be designed according to actual needs.
The overall shape of the conductor bar body 110 is not limited to the bar shape shown in fig. 1, and may be various shapes such as a screw shape, a spindle shape, a prism shape, and the like, which may be designed according to actual needs.
Optionally, the collector bar body 110 may include one or more bends 111. The bent portion 111 may have any angle. The bending angle and the setting position of the bent portion 111 may be determined according to actual requirements (for example, wiring requirements of the power transmission line bundle 100). For example, the bending angle and the setting position of the bent portion 111 are determined so that a desired orientation of the collector bar main body 110 is achieved by the bent portion 111 to obtain a desired wiring of the power transmission line bundle 100. The bent portion 111 may be formed through various molding processes or machining processes. As an example, the desired routing of the power transmission line bundle 100 may be achieved by a robot bending the conductor bar body 110 according to a 3D modeling of the desired routing of the power transmission line bundle 100 to form one or more bends 111 to facilitate installation of the power transmission line bundle 100, for example. Additionally, since the desired routing or routing can be achieved by the bend 111, there is no need for a different raceway for securing a wiring harness to facilitate routing as is required for conventional power transmission harnesses for the power transmission harness 100 of the present invention.
The connection terminal 120 may be formed through various processes. For example, the connection terminal 120 may be formed by punching an end of the conductor bar body 110, as shown in fig. 1. For example, the connection terminal 120 may be formed using the same or different material as that of the conductor bar body 110, and connected to the end of the conductor bar body 110 through a bonding process such as welding. The process of forming the connection terminal 120 may be determined according to actual requirements.
The connection terminal 120 may have any suitable shape according to the actual application, for example, a ring shape, a rectangular shape, a circular shape, etc.
The insulating layer 130 may be made of any suitable insulating material, such as an inorganic insulating material (glass, etc.), an organic insulating material (resin, rubber, etc.), or a hybrid insulating material, and the like. The insulating layer 130 may electrically and physically isolate the collector bar body 110 from the external environment to avoid leakage or interference or damage from the external environment.
An insulating layer 130 may be formed on the collector bar body 110. Preferably, the insulating layer 130 may substantially completely cover the surface of the collector bar body 110. Preferably, the insulating layer 130 may be closely (i.e., substantially without gaps) affixed to the surface of the collector bar body 110. For example, the insulation layer 130 may be extruded onto the collector bar body 110 by an extrusion process. For example, the insulating layer 130 may be deposited on the collector bar body 110 by a deposition process. The process of forming the insulating layer 130 may be determined according to actual requirements.
The shielding layer 140 may cover the insulating layer 130. Preferably, the shielding layer 140 may substantially completely cover the surface of the insulating layer 130. Preferably, the shielding layer 140 may be closely (i.e., substantially without a gap) affixed to the surface of the insulating layer 130. The shield layer 140 may be covered on the insulating layer 130 by any suitable method or process. As a non-limiting example of a method of covering the shielding layer 140 on the insulating layer 130, the shielding layer 140 may be clamped by a snap 150 as shown in fig. 1, thereby fixing the shielding layer 140 on the insulating layer 130.
Hereinafter, a method 300 for forming a power transmission line bundle according to the present invention will be described with reference to fig. 3.
At step 301, a collector bar body is provided. The collector bar body may be formed of a conductive material. The conductive material includes, for example, metal, conductive plastic, conductive rubber, or a combination thereof. Suitable metals for forming the collector bar body 110 may include: one or more of copper (Cu), silver (Ag), gold (Au), aluminum (Al), sodium (Na), molybdenum (Mo), tungsten (W), zinc (Zn), nickel (Ni), iron (Fe), platinum (Pt), tin (Sn), lead (Pb), and an alloy thereof, or a composite metal formed of one or more thereof, and the like. The collector bar body may be provided by various forming methods. The bulk conductive material is cut, for example, by a cutting process, to form a conductive rod body. For example, the bulk conductive material is stretched into a rod shape by a stretching process, thereby forming a conductive rod body. For example, by a molding method, thereby forming the collector bar body. According to actual requirements, the sectional shape of the conductor bar body may be formed in a circular, rectangular, square, oval, annular, polygonal, or the like suitable shape, and the overall shape of the conductor bar body may be formed in a rod shape, screw shape, spindle shape, prism shape, or the like suitable shape.
At step 302, connection terminals are formed at ends (e.g., both or either ends) of the conductor bar body. The connection terminal may be formed through various processes. For example, the connection terminal may be formed by pressing the end of the conductive rod main body. For example, the connection terminal may be formed using the same or different material as that of the conductor bar main body, and connected to the end of the conductor bar main body by a bonding process such as welding.
Optionally, at step 303, one or more bends are formed by bending the conductor bar body for routing of the power transmission line bundle based on the wiring pattern. The wiring pattern can be determined according to actual requirements by referring to an existing design drawing or a built wiring harness 3D digital model. Bending the conductive rod main body may be performed by a bending robot based on the wiring pattern.
At step 304, an insulating layer is formed on the conductor bar body. The insulating layer may be formed of any suitable insulating material that may be used to provide protection to the stub body and/or to electrically, physically, etc. isolate it from the external environment. The insulating layer may be formed by various processes. As a non-limiting example, the insulating layer may be formed by extruding the insulating layer on the body of the collector bar through an extrusion process.
Optionally, at step 305, a shielding layer is covered on the insulating layer, the shielding layer providing electromagnetic shielding. The shield layer may be formed of any suitable material. The shielding layer may be, for example, a conductive cloth, a conductive rubber, a conductive paint, or the like. The shield layer may be overlaid on the insulating layer by any suitable method or process. As an example, the shield layer may be fixed on the insulating layer by a snap.
In certain embodiments, the operations included in method 300 may occur simultaneously, substantially simultaneously, or in a different order than shown in the figures.
In some embodiments, all or part of the operations included in the methods in the above embodiments may optionally be performed automatically by a program. In one example, the present invention may be implemented as a program product stored on a computer-readable storage medium for use with a computer system. The program(s) of the program product comprise functions of the embodiments (including the methods described herein). Illustrative computer-readable storage media include, but are not limited to: (i) non-writable storage media (e.g., read-only memory devices within a computer such as CD-ROM disks readable by a CD-ROM machine, flash memory, ROM chips or any type of solid-state non-volatile semiconductor memory) on which information is permanently stored; and (ii) writable storage media (e.g., disk storage or hard disk drives or any type of solid-state random-access semiconductor memory) on which alterable information is stored. Such computer-readable storage media, when carrying computer-readable instructions that direct the functions of the methods described herein, are embodiments of the present invention.
The power transmission line bundle 100 and the method 300 of forming a power transmission line bundle according to the present application have at least the following benefits:
(1) reducing the loop resistance: for example, the end of the conductive rod main body is directly punched into a ring-shaped connecting terminal which is convenient to mount, so that the compression joint and welding resistance of a loop can be reduced, and the overall loop resistance can be reduced.
(2) The production process is simplified: the conventional production process of the power transmission line bundle needs to calculate the head stripping length of the insulating layer of the power transmission line bundle according to different connectors, and the trimming and head stripping lengths of the shielding layer need to design, develop and verify crimping/welding dies and parameters according to different connecting terminals. According to the method, the production process of the power transmission line bundle is greatly simplified, the conventional process development flow can be replaced only by forming the connecting terminal, forming the insulating layer and bending the copper rod, the production process is simplified, and therefore the production efficiency is improved.
(3) The development of wire grooves is reduced: because the large-square power transmission line bundle is hard, in order to facilitate wiring, different wire grooves are required to be designed for fixing the power transmission line bundle. This application accessible bending robot carries out accurate bending to the bar copper, according to the accurate wiring of 3D data, has reduced the design development work of eliminating the wire casing even.
(4) The installation of pencil of being convenient for: conventional large square power transmission line bundles are hard and difficult to bend, thereby causing difficulty in installation, and can generate stress action, so that accurate and convenient wiring cannot be ensured. This application can use the robot of bending to carry out accurate bending to the bar copper according to the trend of 3D digifax, strictly according to the accurate wiring of 3D data, the installation of the pencil of being convenient for in the system.
Alternative embodiments of the present application are described in detail above. It will be appreciated that various embodiments and modifications may be made thereto without departing from the broader spirit and scope of the application. Many modifications and variations will be apparent to those of ordinary skill in the art in light of the teachings of this application without undue experimentation. As a non-limiting example, one skilled in the art may omit one or more of the various components of the above-described system or structure, add one or more components to the above-described system or structure, or replace some or all of the various structures or systems involved in the present embodiment with other components having the same or similar functions. Therefore, the technical solutions available to those skilled in the art through logic analysis, reasoning and limited experiments based on the concepts of the present application shall fall within the scope of protection defined by the claims of the present application.
Claims (11)
1. A power transmission line bundle, comprising:
a conductive rod body;
a connection terminal formed at an end of the collector bar body; and
an insulating layer formed on the conductive rod main body.
2. A power transmission line bundle according to claim 1, wherein said collector bar body comprises one or more bends.
3. A power transmission line bundle according to claim 1, further comprising a shielding layer overlying said insulating layer.
4. The power transmission wiring harness of claim 3 wherein the shield is secured to the insulation layer by a snap fit.
5. A power transmission line bundle according to claim 1, characterized in that said insulating layer is formed by extrusion.
6. An electrical transmission line bundle according to claim 1, wherein said connection terminal is a ring-shaped terminal formed by punching an end portion of said rod body.
7. A method of forming a power transmission wiring harness, comprising:
providing a conductive rod main body;
forming a connection terminal at an end of the conductive rod body; and
an insulating layer is formed on the collector bar body.
8. The method of claim 7, further comprising: one or more bent portions are formed by bending the conductor bar main body based on a wiring pattern for wiring of the power transmission line bundle.
9. The method of claim 7, wherein forming an insulating layer on the collector bar body comprises: the insulating layer is extruded on the collector bar body by an extrusion process.
10. The method of claim 7, further comprising: a shielding layer covers the insulating layer, the shielding layer providing electromagnetic shielding.
11. The method of claim 7, forming a connection terminal at an end of the collector bar body comprises: forming an end of the collector bar body into the connection terminal through a punching process.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202111601796.2A CN114709009A (en) | 2021-12-24 | 2021-12-24 | Power transmission line bundle and method for forming the same |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202111601796.2A CN114709009A (en) | 2021-12-24 | 2021-12-24 | Power transmission line bundle and method for forming the same |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN114709009A true CN114709009A (en) | 2022-07-05 |
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Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202111601796.2A Pending CN114709009A (en) | 2021-12-24 | 2021-12-24 | Power transmission line bundle and method for forming the same |
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| Country | Link |
|---|---|
| CN (1) | CN114709009A (en) |
Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN213905764U (en) * | 2020-12-31 | 2021-08-06 | 芜湖通和汽车管路系统有限公司 | New energy automobile distribution bus structure |
-
2021
- 2021-12-24 CN CN202111601796.2A patent/CN114709009A/en active Pending
Patent Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN213905764U (en) * | 2020-12-31 | 2021-08-06 | 芜湖通和汽车管路系统有限公司 | New energy automobile distribution bus structure |
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