CN117140008A - Flash welding butt-joint process for copper-aluminum busbar of automobile - Google Patents
Flash welding butt-joint process for copper-aluminum busbar of automobile Download PDFInfo
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- CN117140008A CN117140008A CN202311338984.XA CN202311338984A CN117140008A CN 117140008 A CN117140008 A CN 117140008A CN 202311338984 A CN202311338984 A CN 202311338984A CN 117140008 A CN117140008 A CN 117140008A
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- copper
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- aluminum
- bar
- busbar
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- 238000003466 welding Methods 0.000 title claims abstract description 163
- JRBRVDCKNXZZGH-UHFFFAOYSA-N alumane;copper Chemical compound [AlH3].[Cu] JRBRVDCKNXZZGH-UHFFFAOYSA-N 0.000 title claims abstract description 57
- 238000000034 method Methods 0.000 title claims abstract description 46
- 229910052802 copper Inorganic materials 0.000 claims abstract description 96
- 239000010949 copper Substances 0.000 claims abstract description 96
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims abstract description 94
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 87
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 86
- 238000005498 polishing Methods 0.000 claims abstract description 18
- 210000001503 joint Anatomy 0.000 claims abstract description 16
- 239000000463 material Substances 0.000 claims abstract description 12
- 238000009413 insulation Methods 0.000 claims abstract description 9
- 238000009713 electroplating Methods 0.000 claims abstract description 8
- 238000012545 processing Methods 0.000 claims abstract description 8
- 238000000227 grinding Methods 0.000 claims abstract description 6
- 238000007599 discharging Methods 0.000 claims abstract description 5
- 238000001125 extrusion Methods 0.000 claims abstract description 5
- 239000011241 protective layer Substances 0.000 claims abstract description 5
- 238000005496 tempering Methods 0.000 claims description 16
- 238000012360 testing method Methods 0.000 claims description 12
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical group [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 10
- 125000004122 cyclic group Chemical group 0.000 claims description 6
- 239000010410 layer Substances 0.000 claims description 6
- 238000004806 packaging method and process Methods 0.000 claims description 6
- 229910052759 nickel Inorganic materials 0.000 claims description 5
- 238000011056 performance test Methods 0.000 claims description 5
- 238000005452 bending Methods 0.000 abstract description 5
- 238000010008 shearing Methods 0.000 abstract description 4
- 239000002699 waste material Substances 0.000 abstract description 3
- 230000001276 controlling effect Effects 0.000 description 5
- 238000003756 stirring Methods 0.000 description 5
- 230000001105 regulatory effect Effects 0.000 description 4
- 239000004411 aluminium Substances 0.000 description 3
- 238000005219 brazing Methods 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 230000007547 defect Effects 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000007689 inspection Methods 0.000 description 2
- 239000002893 slag Substances 0.000 description 2
- 229920000742 Cotton Polymers 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 239000004020 conductor Substances 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 238000005485 electric heating Methods 0.000 description 1
- 238000006056 electrooxidation reaction Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000009661 fatigue test Methods 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 230000002452 interceptive effect Effects 0.000 description 1
- 229910001338 liquidmetal Inorganic materials 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/04—Flash butt welding
- B23K11/046—Apparatus therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/30—Features relating to electrodes
- B23K11/31—Electrode holders and actuating devices therefor
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Arc Welding In General (AREA)
Abstract
The application discloses a butt joint process for flash welding of a copper-aluminum busbar of an automobile, which comprises the following steps: processing a welding end face: respectively processing the welding end surfaces of the copper bar and the aluminum bar into V-shaped or convex-concave or plane shapes which are mutually matched, and polishing and deburring the welding end surfaces of the copper bar and the aluminum bar; copper bar electroplating: electroplating a protective layer on the surface of the copper bar; flash butt welding: discharging the copper bar and aluminum into a flash butt welding machine for flash butt welding to obtain a copper-aluminum busbar; and (5) polishing and grinding a welded junction: polishing the welded junction position of the copper aluminum busbar to remove redundant welding extrusion residue materials on the periphery; insulation treatment: the thermal shrinkage insulating pipe is sleeved outside the welded junction position of the polished copper-aluminum busbar, the copper-aluminum butt welding time is effectively reduced, the welding efficiency is improved, the auxiliary material arc striking plate in the welding process is eliminated, the material waste is reduced, and the welding drawing force, the shearing force, the bending and other performance parameters of the copper-aluminum busbar are improved.
Description
Technical Field
The application belongs to the technical field of welding processes, and particularly relates to a flash welding butt joint process of an automobile copper-aluminum busbar.
Background
At present, a copper-aluminum bar or a T2 pure copper bar is generally adopted for the bus bar of the automobile. The pure copper bar is heavy and does not meet the light weight aim of an automobile. At present, the butt welding of copper and aluminum bars in the automobile busbar industry adopts a friction stir welding process, and arc striking plates are required to be added on two sides of a butt welding position. The friction stir welding has low processing efficiency; the arc striking plate is added in the welding process, so that the material consumption is increased, and auxiliary materials are wasted in the process; the friction stir welding product has poorer bending and shearing force performance; the defects of slag inclusion and the like are easy to generate in the friction stir welding seam; the friction stir welding can only be performed with equal width and straight plane butt joint, the welding area cannot be larger than the minimum sectional area of the product, and the current carrying of the sectional area of the conductor is insufficient due to the occurrence of welding defects, so that the temperature rise and the resistance performance are unqualified.
Disclosure of Invention
The application aims to solve the problems in the background technology and provides a butt joint process for flash welding of an automobile copper-aluminum busbar.
In order to achieve the above purpose, the application provides a flash welding butt joint process of an automobile copper-aluminum busbar, which comprises the following steps:
processing a welding end face: respectively processing the welding end surfaces of the copper bar and the aluminum bar into V-shaped or convex-concave or plane shapes which are mutually matched, and polishing and deburring the welding end surfaces of the copper bar and the aluminum bar;
copper bar electroplating: electroplating a protective layer on the surface of the copper bar;
flash butt welding: the method comprises the following steps of discharging copper bars and aluminum into a flash butt welding machine for flash butt welding to obtain copper-aluminum busbar, wherein the welding process of flash butt welding specifically comprises the following steps: a preheating stage, in which a cyclic voltage pulse wave is applied to the fixed electrode to preheat the copper bar and the aluminum bar; in the flash welding stage, current is applied to the copper bar and the aluminum bar to heat and melt the welding end surfaces of the copper bar and the aluminum bar, the movable electrode moves synchronously, and the movable electrode is kept in contact with the welding end surfaces of the copper bar and the aluminum bar corresponding to the same side; in the upsetting stage, upsetting force is applied to the copper bar or the aluminum bar to enable the welding end surfaces of the copper bar and the aluminum bar to be mutually fused together, and upsetting current is applied to enable the copper bar and the aluminum bar to be thermally fused; in the tempering stage, applying a cyclic voltage pulse wave to slowly cool the welding end surfaces of the copper bars and the aluminum bars;
the welding process comprises the following parameters: the voltage is 1.0V-1.3V, the heat conduction time is 1 s-1.3 s, the heat break time is 0.08 s-0.12 s, the heat times are 4-6 times, and the heat interval is 0.18 s-0.23 s when the electrodes are electrified and preheated; the movable plate moves to upsett the welding ports of the copper bars and the aluminum bars, the applied voltage is 2.40V-2.70V, the duration time is 0.23 s-0.27 s, and the upsetting time delay is 0.08 s-0.12 s; upsetting the welding ports of the copper bars and the aluminum bars, tempering, wherein the voltage applied to the electrodes is 1.40V-1.70V, the tempering time is 0.3 s-0.5 s, the tempering breaking time is 0.08 s-0.12 s, and the tempering times are 4-6 times; the electrode applied voltage is 3.50V-4.00V, the descending speed and the returning speed of the movable electrode are 75 mm/s-85 mm/s and 95 mm/s-100 mm/s respectively in the welding process, and the advancing speed of the movable plate is 75 mm/s-85 mm/s respectively in the welding process;
and (5) polishing and grinding a welded junction: polishing the welded junction position of the copper aluminum busbar to remove redundant welding extrusion residue materials on the periphery;
insulation treatment: and a heat-shrinkable insulating tube is sleeved outside the welded junction position of the polished copper-aluminum busbar.
The following functions are applied to each stage of the welding process of flash butt welding: the preheating stage is used for preventing the temperature of the copper aluminum bar from suddenly changing to influence the material and welding quality of the copper aluminum bar; the flash welding stage is to apply a larger current to the welding piece to heat and melt the butt joint part so as to facilitate the subsequent upsetting fusion; the upsetting stage is used for enabling the welding end surfaces of the copper bars and the aluminum bars to be fully contacted and fused; the tempering stage is to prevent the weld from cooling too quickly to affect the toughness of the weld.
Preferably, the welding end face gap between the copper bar and the aluminum bar in the flash butt welding step is smaller than 5mm.
Preferably, the thicknesses of the copper bars and the aluminum bars are 2-8 mm, and the widths of the copper bars and the aluminum bars are 5-50 mm.
Preferably, the protective layer is a nickel layer, and the thickness of the nickel layer is 5 μm to 8 μm.
Preferably, the length of the copper aluminum busbar is not less than 500mm.
Preferably, the thickness width of the welding position of the copper-aluminum busbar in the step of polishing and grinding the welded junction is controlled within 0.5mm with the width and thickness deviation of the copper busbar and the aluminum busbar.
Preferably, the butt joint process of the copper-aluminum busbar flash welding of the automobile further comprises the following steps: and (5) checking and packaging, namely performing performance size test on the copper-aluminum busbar subjected to the insulation treatment, and packaging after the test is qualified.
Preferably, the performance size test includes an equal electrical performance test for withstand voltage insulation of a product and a product size inspection test.
Preferably, the flash butt welding machine includes:
the machine body is provided with openings for the aluminum bars and the copper bars to pass through at two sides;
the fixed plate is arranged on the machine body, a first lifting control device and a first fixed electrode are arranged at the front end of the fixed plate, the first lifting control device is connected with the first movable electrode and drives the first movable electrode to move up and down, the first fixed electrode is aligned with the first movable electrode, and a copper bar or an aluminum bar is arranged above the first fixed electrode;
the movable plate is slidably arranged on the machine body, a second lifting control device and a second fixed electrode are arranged at the front end of the movable plate, the second lifting control device is connected with the second movable electrode and drives the second movable electrode to move up and down, the second fixed electrode is aligned with the second movable electrode, and a copper bar or an aluminum bar is arranged above the second fixed electrode;
the linear driving device is arranged on the machine body, is connected with the movable plate and drives and controls the movable plate to be close to or far away from the fixed plate, and when the movable plate is close to the fixed plate, the copper bars and the aluminum bars are mutually close to each other and are extruded, and a welding joint is formed at the joint of the copper bars and the aluminum bars during welding;
and the power supply is arranged inside the machine body and is electrically connected with the first fixed electrode and the second fixed electrode.
Preferably, the machine body is provided with a display screen, a controller and a plurality of control buttons, wherein the controller is respectively and electrically connected with the power supply, the display screen, the control buttons, the first lifting control device, the second lifting control device and the linear driving device, and controls the working states of the first lifting control device, the second lifting control device and the linear driving device.
The application has the beneficial effects that: according to the welding method, the flash butt welding machine is adopted for welding, under the condition of specific welding parameters, copper-aluminum butt welding time can be effectively reduced, welding efficiency is improved, auxiliary material arc striking plates in the welding process are eliminated, material waste is reduced, and performance parameters such as welding drawing force, shearing force and bending of copper-aluminum bus bars are improved.
The features and advantages of the present application will be described in detail by way of example with reference to the accompanying drawings.
Drawings
FIG. 1 is a process flow diagram of an embodiment of the present application.
Fig. 2 is a schematic view of a flash butt welding machine according to an embodiment of the present application.
Fig. 3 is a schematic view of the structure of the welded surface of the aluminum welding and the copper welding according to the embodiment of the present application.
Fig. 4 is a schematic diagram of the working principle of the flash butt welding machine according to the embodiment of the application.
In the figure: 1-fuselage, 2-fixed plate, 3-fly leaf, 4-first lift controlling means, 5-second lift controlling means, 6-linear drive, 7-aluminium row, 8-copper row, 9-transformer, 10-transverse rail, 11-opening, 41-first mounting panel, 42-first movable electrode, 43-first fixed electrode, 51-third mounting panel, 52-second movable electrode, 53-second fixed electrode.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present application more clear, the technical solutions of the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present application. It will be apparent that the described embodiments are some, but not all, embodiments of the application. The components of the embodiments of the present application generally described and illustrated in the figures herein may be arranged and designed in a wide variety of different configurations. In the description of the present application, it should be noted that, the azimuth or positional relationship indicated by the terms "inner", "outer", etc. are based on the azimuth or positional relationship shown in the drawings, or the azimuth or positional relationship that is commonly put in use of the product of this application, are merely for convenience of describing the present application and simplifying the description, and do not indicate or imply that the device or element to be referred to must have a specific azimuth, be configured and operated in a specific azimuth, and therefore should not be construed as limiting the present application. Furthermore, the terms "first," "second," and the like, are used merely to distinguish between descriptions and should not be construed as indicating or implying relative importance.
In the description of the present application, it should also be noted that, unless explicitly specified and limited otherwise, the terms "disposed", "connected" and "connected" are to be construed broadly, and may be, for example, fixedly connected, detachably connected or integrally connected; can be directly connected or indirectly connected through an intermediate medium, and can be communication between two elements. The specific meaning of the above terms in the present application will be understood in specific cases by those of ordinary skill in the art.
The present application will be described in detail with reference to the accompanying drawings.
Referring to fig. 1 to 4, the present embodiment provides a butt-joint process of flash welding of an automotive copper-aluminum busbar, which comprises the following steps:
s01, processing a welding end face: discharging the copper bar and aluminum into a stamping die for stamping, cutting and blanking, stamping the welding end surfaces of the copper bar and the aluminum bar into V-shaped or convex-concave or plane shapes which are mutually matched so as to ensure that the effective area of subsequent welding is not smaller than the sectional area of a product, polishing and deburring the welding end surfaces of the copper bar and the aluminum bar by using a polishing machine and a cotton blanket wheel, wherein the copper bar and the aluminum bar can be cut off for blanking after stamping and bending treatment so as to better meet the production requirement of the copper-aluminum busbar with specific shape and size;
s02, copper bar electroplating: electroplating a nickel layer with the thickness of 5-8 mu m on the surface of the copper bar, wherein other metal protection layers can be welded on the surface of the copper bar on the premise of meeting the problem of preventing electrochemical corrosion of a copper-aluminum welding end;
s03, flash butt welding: the method comprises the following steps of discharging copper bars and aluminum into a flash butt welding machine for flash butt welding to obtain copper-aluminum busbar, wherein the welding process of flash butt welding specifically comprises the following steps: a preheating stage, in which a cyclic voltage pulse wave is applied to the fixed electrode to preheat the copper bar and the aluminum bar; in the flash welding stage, current is applied to the copper bar and the aluminum bar to heat and melt the welding end surfaces of the copper bar and the aluminum bar, the movable electrode moves synchronously, and the movable electrode is kept in contact with the welding end surfaces of the copper bar and the aluminum bar corresponding to the same side; in the upsetting stage, upsetting force is applied to the copper bar or the aluminum bar to enable the welding end surfaces of the copper bar and the aluminum bar to be mutually fused together, and upsetting current is applied to enable the copper bar and the aluminum bar to be thermally fused; in the tempering stage, applying a cyclic voltage pulse wave to slowly cool the welding end surfaces of the copper bars and the aluminum bars;
the welding process comprises the following parameters: the voltage applied during the electrifying and preheating between the electrodes is 1.1V, the heat-on time is 1.2s, the heat-off time is 0.10s, the heat times are 5 times, and the heat interval is 0.20s; the movable plate moves to upsett the welding ports of the copper bars and the aluminum bars, the applied voltage is 2.60V, the duration time is 0.25s, and the upsetting time delay is 0.10s; upsetting the welding ports of the copper bars and the aluminum bars, tempering, wherein the voltage applied to the electrodes is 1.6V, the tempering time is 0.4s, the tempering breaking time is 0.1s, and the tempering times are 5 times; the electrode applied voltage is 3.80V during flash welding, the descending speed and the returning speed of the movable electrode during welding are respectively 80mm/s and 99mm/s, and the advancing speed of the movable plate during welding is respectively 80mm/s;
s04, polishing and grinding a welded junction: removing redundant welding extrusion surplus materials at the periphery by manually polishing or automatically polishing the weld junction position of the copper-aluminum busbar by using a polishing machine and a polishing belt, and ensuring that the thickness width of the welding position of the copper-aluminum busbar is controlled within 0.5mm with the width and thickness deviation of the copper busbar and the aluminum busbar, for example, the thickness width of the welding position of the copper-aluminum busbar is equal to the width and thickness of the copper busbar and the aluminum busbar, or the width thickness is greater than the width and thickness of the copper busbar and the aluminum busbar but the size deviation is controlled within 0.5 mm;
s05, insulating treatment: sleeving a heat-shrinkable insulating tube on the outer side of a welded junction position of the polished copper-aluminum busbar so as to ensure that the pressure-resistant insulating electrical performance index of the product is met;
s06, checking and packaging: and performing performance tests including electrical performance tests such as voltage withstand insulation and product size inspection tests on the copper-aluminum busbar after the insulation treatment, and packaging after the test is qualified.
Wherein, in the flash butt welding step, when the copper bar and the aluminum bar are placed in the flash butt welding machine, the welding end face clearance of the copper bar and the aluminum bar is less than 5mm, the thicknesses of the copper bar and the aluminum bar are 2 mm-8 mm, the widths of the copper bar and the aluminum bar are 5 mm-50 mm, and the length of the copper aluminum busbar is not less than 500mm.
Performance testing was performed on copper-aluminum bus bars with 25 x 3.5mm cross-sectional area prepared by the above process, and some of the performance test data were as follows: 70 times/min of welding fatigue test, 1mm amplitude test 20000 times, no cracking at the welded junction position of the copper-aluminum busbar; resistivity of copper-aluminum busbar is 0.033 Ω.mm 2 M; copper aluminum butt welding tensile strength 7213.6N; and under the conditions that the ambient temperature is 60 ℃ and 200A current is loaded and the current flows for 60min, the temperature of the copper-aluminum busbar is constant, and the temperature rise of the welded junction position of the copper-aluminum busbar is 9.41K. The welding drawing force, shearing force, bending and other performance indexes of the copper-aluminum busbar manufactured by adopting the flash welding butt joint process of the copper-aluminum busbar of the automobile are relatively better.
Referring to fig. 2 to 4, the flash butt welding machine in the above process includes:
a machine body 1, wherein openings 11 for the aluminum bars 7 and the copper bars 8 to pass through are arranged on the left side and the right side of the machine body 1;
the fixed plate 2 is arranged on the machine body 1, a first lifting control device 4 and a first fixed electrode 43 are arranged at the front end of the fixed plate 2, the first lifting control device 4 is connected with the first movable electrode 42 and drives the first movable electrode 42 to move up and down, the first fixed electrode 43 is aligned with the first movable electrode 42, and a copper bar 8 or an aluminum bar 7 is arranged above the first fixed electrode 43;
the movable plate 3 is slidably arranged on the machine body 1, a second lifting control device 5 and a second fixed electrode 53 are arranged at the front end of the movable plate 3, the second lifting control device 5 is connected with the second movable electrode 52 and drives the second movable electrode 52 to move up and down, the second fixed electrode 53 is aligned with the second movable electrode 52, and a copper bar 8 or an aluminum bar 7 is arranged above the second fixed electrode 53;
a linear driving device 6, the linear driving device 6 is installed on the machine body 1, the linear driving device 6 is connected with the movable plate 3 and drives and controls the movable plate 3 to be close to or far away from the fixed plate 2, when the movable plate 3 is close to the fixed plate 2, the copper bar 8 and the aluminum bar 7 are close to each other to be extruded, and a welding joint is formed at the joint of the two when welding;
and a power supply installed inside the body 1 and electrically connected to the first and second fixed electrodes 43 and 53.
During actual use, the front end of the machine body 1 is internally provided with a cavity communicated with the opening 11, the fixed plate 2, the movable plate 3 and the linear driving device 6 are all positioned in the cavity, in order to improve the operation safety of the device, the front end of the machine body 1 is provided with a movable protective door to prevent metal from splashing in the welding process, the position of the opening 11 is higher than or flush with the upper ends of the first fixed electrode 43 and the second fixed electrode 53, the machine body 1 is provided with a transverse guide rail 10, and the rear end of the movable plate 3 is slidably arranged on the transverse guide rail 10. A scrap cleaning hole is arranged on the machine body so as to collect and clean welding slag. The welding end surfaces of the copper bar 8 and the aluminum bar 7 are mutually matched, and the welding surfaces of the copper bar 8 and the aluminum bar 7 comprise, but are not limited to, V-shaped, concave-convex and plane surfaces. The power supply is connected with the transformer 9, the transformer 9 is electrically connected with the first fixed electrode 43 and the second fixed electrode 53, and the width and the thickness of the welding surface of the copper bar 8 and the aluminum bar 7 can be equal in width and thickness or different in width and thickness according to welding requirements. In FIG. 3, F j The first lifting control device 4 and the second lifting control device 5 respectively drive the first movable electrode 42 and the second movable electrode 52 to apply clamping force to the welding part when pressing down, F up The upsetting force applied to the welding member when the linear driving device 6 drives the movable plate 3 to move is V f The flash speed of the weldment is driven by the linear driving device 6 when the movable plate 3 moves.
The movable plate is controlled to move through the linear driving device so as to control the extrusion condition of the brazing piece and the aluminum welding piece, the first lifting control device and the second lifting control device respectively control the first movable electrode and the second movable electrode to move downwards to clamp the brazing piece and the aluminum welding piece and simultaneously be communicated with the corresponding first fixed electrode and second fixed electrode, and the arc striking plate is not required to reduce the waste of auxiliary materials during flash welding, so that the welding device is applicable to welding of the brazing piece and the aluminum welding piece with the same or different cross-sectional shapes, improves the welding efficiency, reduces the rejection rate, and has lighter cost and weight relative to an all-copper busbar after welding.
Further, the machine body 1 is provided with a display screen, a controller and a plurality of control buttons, the controller is respectively and electrically connected with the power supply, the display screen, the control buttons, the first lifting control device 4, the second lifting control device 5 and the linear driving device 6, and controls the working states of the first lifting control device 4, the second lifting control device 5 and the linear driving device 6, and the working parameters displayed by the display screen include, but are not limited to, a feeding speed, a pressure value and a current value.
Further, the control button includes shift knob, scram button, pressure regulating button, feed speed regulating button, shift knob is used for controlling the switch of power, scram button is used for controlling the scram of car copper aluminium busbar flash light welding interfacing apparatus, pressure regulating button is used for controlling the pressure value that the back copper bar 8 and aluminium bar 7 extrudeed each other behind the movable plate 3 of linear drive device 6 drive, feed speed regulating button control linear drive device 6 drive movable plate 3 removal's speed, pressure value, speed value are detected through the pressure sensor that sets up between movable plate 3 and fixed plate 2, speed sensor.
Further, the front end of the fixed plate 2 is slidably provided with a first mounting plate 41, two ends of the first mounting plate 41 are respectively connected with a first movable electrode 42 and the first lifting control device 4, and the first movable electrode 42 is fixed or detachably mounted at the lower end of the first mounting plate 41.
Further, the front end of the fixed plate 2 is mounted with a first rail on which the first mounting plate 41 is slidably mounted.
Further, the front end of the fixing plate 2 is provided with a second mounting plate, the first fixing electrode 43 is detachably mounted on the second mounting plate, and the connection mode between the first fixing electrode 43 and the second mounting plate includes but is not limited to bolt connection and pin connection.
Further, the front end of the movable plate 3 is slidably provided with a third mounting plate 51, two ends of the third mounting plate 51 are respectively connected with a second movable electrode 52 and the second lifting control device 5, and the second movable electrode 52 is fixedly or detachably mounted at the lower end of the third mounting plate 51.
Further, the front end of the movable plate 3 is mounted with a second guide rail, and the third mounting plate 51 is slidably mounted on the second guide rail.
Further, the front end of the movable plate 3 is provided with a fourth mounting plate, the second fixed electrode 53 is detachably mounted on the fourth mounting plate, and the connection mode between the second fixed electrode 53 and the fourth mounting plate includes but is not limited to bolt connection and pin connection.
Further, the first lifting control device 4, the second lifting control device 5 and the linear driving device 3 are pneumatic linear control devices or hydraulic linear control devices, the pneumatic linear control devices comprise air cylinders, the hydraulic linear control devices comprise hydraulic cylinders, and the air cylinders of the first lifting control device 4 and the second lifting control device 5 or the piston rod ends of the hydraulic cylinders are connected with corresponding first mounting plates and third mounting plates.
The working process of the flash butt welding machine comprises the following steps: one end of the copper bar 8 passes through the opening 11 on the left side of the machine body 1 and is placed above the first fixed electrode 43, one end of the aluminum bar 7 passes through the opening 11 on the right side of the machine body 1 and is placed above the second fixed electrode 53, the first lifting control device 4 and the second lifting control device 5 respectively control the first movable electrode 42 and the second movable electrode 52 to be pressed down until the copper bar 8 and the aluminum bar 7 are pressed down, the power supply is connected, the linear driving device 6 controls the movable plate 3 to move, when the end surfaces of the two weldments are contacted, the electric heating is carried out, the contact points are heated to form a liquid metal 'lintel' and burst, spark spraying is carried out, a flash is formed, the connecting end surfaces of the two weldments are heated when the flash is carried out, when the welding temperature is reached, the movable plate 3 is suddenly accelerated, the connecting end surfaces of the two weldments are mutually extruded by a large upsetting force, the welding area is subjected to strong plastic deformation, and interactive crystals are formed on the bonding surfaces when molten metal is extruded, and a firm welding joint is formed.
The above embodiments are illustrative of the present application, and not limiting, and any simple modifications of the present application fall within the scope of the present application.
Claims (10)
1. The flash welding butt-joint process of the copper-aluminum busbar of the automobile is characterized by comprising the following steps of:
processing a welding end face: respectively processing the welding end surfaces of the copper bar and the aluminum bar into V-shaped or convex-concave or plane shapes which are mutually matched, and polishing and deburring the welding end surfaces of the copper bar and the aluminum bar;
copper bar electroplating: electroplating a protective layer on the surface of the copper bar;
flash butt welding: the method comprises the following steps of discharging copper bars and aluminum into a flash butt welding machine for flash butt welding to obtain copper-aluminum busbar, wherein the welding process of flash butt welding specifically comprises the following steps: a preheating stage, in which a cyclic voltage pulse wave is applied to the fixed electrode to preheat the copper bar and the aluminum bar; in the flash welding stage, current is applied to the copper bar and the aluminum bar to heat and melt the welding end surfaces of the copper bar and the aluminum bar, the movable electrode moves synchronously, and the movable electrode is kept in contact with the welding end surfaces of the copper bar and the aluminum bar corresponding to the same side; in the upsetting stage, upsetting force is applied to the copper bar or the aluminum bar to enable the welding end surfaces of the copper bar and the aluminum bar to be mutually fused together, and upsetting current is applied to enable the copper bar and the aluminum bar to be thermally fused; in the tempering stage, applying a cyclic voltage pulse wave to slowly cool the welding end surfaces of the copper bars and the aluminum bars;
the welding process comprises the following parameters: the voltage is 1.0V-1.3V, the heat conduction time is 1 s-1.3 s, the heat break time is 0.08 s-0.12 s, the heat times are 4-6 times, and the heat interval is 0.18 s-0.23 s when the electrodes are electrified and preheated; the movable plate moves to upsett the welding ports of the copper bars and the aluminum bars, the applied voltage is 2.40V-2.70V, the duration time is 0.23 s-0.27 s, and the upsetting time delay is 0.08 s-0.12 s; upsetting the welding ports of the copper bars and the aluminum bars, tempering, wherein the voltage applied to the electrodes is 1.40V-1.70V, the tempering time is 0.3 s-0.5 s, the tempering breaking time is 0.08 s-0.12 s, and the tempering times are 4-6 times; the electrode applied voltage is 3.50V-4.00V, the descending speed and the returning speed of the movable electrode are 75 mm/s-85 mm/s and 95 mm/s-100 mm/s respectively in the welding process, and the advancing speed of the movable plate is 75 mm/s-85 mm/s respectively in the welding process;
and (5) polishing and grinding a welded junction: polishing the welded junction position of the copper aluminum busbar to remove redundant welding extrusion residue materials on the periphery;
insulation treatment: and a heat-shrinkable insulating tube is sleeved outside the welded junction position of the polished copper-aluminum busbar.
2. The automotive copper aluminum busbar flash welding butt joint process according to claim 1, wherein: and in the flash butt welding step, the welding end face gap between the copper bar and the aluminum bar is smaller than 5mm.
3. The automotive copper aluminum busbar flash welding butt joint process according to claim 1, wherein: the thicknesses of the copper bars and the aluminum bars are 2-8 mm, and the widths of the copper bars and the aluminum bars are 5-50 mm.
4. The automotive copper aluminum busbar flash welding butt joint process according to claim 1, wherein: the protective layer is a nickel layer, and the thickness of the nickel layer is 5-8 mu m.
5. The automotive copper aluminum busbar flash welding butt joint process according to claim 1, wherein: the length of the copper aluminum busbar is not less than 500mm.
6. The automotive copper aluminum busbar flash welding butt joint process according to claim 1, wherein: and in the step of polishing and grinding the welded junction, the deviation between the thickness width of the welding position of the copper-aluminum busbar and the width and thickness of the copper busbar and the aluminum busbar is controlled within 0.5 mm.
7. The automotive copper aluminum busbar flash welding butt joint process according to claim 1, wherein: the method also comprises the following steps: and (5) checking and packaging, namely performing performance size test on the copper-aluminum busbar subjected to the insulation treatment, and packaging after the test is qualified.
8. The automotive copper aluminum busbar flash welding butt joint process of claim 7, wherein: the performance size test comprises an equal electrical performance test of product voltage withstand insulation and a product size test.
9. The automotive copper aluminum busbar flash butt welding process according to any one of claims 1 to 8, wherein: the flash butt welding machine comprises:
the machine body is provided with openings for the aluminum bars and the copper bars to pass through at two sides;
the fixed plate is arranged on the machine body, a first lifting control device and a first fixed electrode are arranged at the front end of the fixed plate, the first lifting control device is connected with the first movable electrode and drives the first movable electrode to move up and down, the first fixed electrode is aligned with the first movable electrode, and a copper bar or an aluminum bar is arranged above the first fixed electrode;
the movable plate is slidably arranged on the machine body, a second lifting control device and a second fixed electrode are arranged at the front end of the movable plate, the second lifting control device is connected with the second movable electrode and drives the second movable electrode to move up and down, the second fixed electrode is aligned with the second movable electrode, and a copper bar or an aluminum bar is arranged above the second fixed electrode;
the linear driving device is arranged on the machine body, is connected with the movable plate and drives and controls the movable plate to be close to or far away from the fixed plate, and when the movable plate is close to the fixed plate, the copper bars and the aluminum bars are mutually close to each other and are extruded, and a welding joint is formed at the joint of the copper bars and the aluminum bars during welding;
and the power supply is arranged inside the machine body and is electrically connected with the first fixed electrode and the second fixed electrode.
10. The automotive copper aluminum busbar flash welding butt joint process of claim 9, wherein: the machine body is provided with a display screen, a controller and a plurality of control buttons, wherein the controller is respectively and electrically connected with a power supply, the display screen, the control buttons, the first lifting control device, the second lifting control device and the linear driving device, and controls the working states of the first lifting control device, the second lifting control device and the linear driving device.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN117961564A (en) * | 2024-03-20 | 2024-05-03 | 广东合晟新能源科技有限公司 | Full-automatic production system for soft package copper bars |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN117961564A (en) * | 2024-03-20 | 2024-05-03 | 广东合晟新能源科技有限公司 | Full-automatic production system for soft package copper bars |
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