超声波焊接能量对大直径线束-端子接头性能影响  

Effect of ultrasonic welding energy on the performance of large diameter wire-terminal joints

作　　者：许龙 洪宛璐 赵伦 李承旺 雷乐 张溟晨 梁召峰[2] 周光平[2] Md Shafiqul Islam XU Long;HONG Wanlu;ZHAO Lun;LI Chengwang;LEI Le;ZHANG Mingchen;LIANG Shaofeng;ZHOU Guangping;Md Shafiqul Islam(College of Science,China Jiliang University,Hangzhou 310018,China;Institute of Intelligent Manufacturing Technology,Shenzhen Polytechnic,Shenzhen 518055,China;Department of Mechanical Engineering,Blekinge Tekniska Högskola,Karlskrona 37179,Sweden)

机构地区：[1]中国计量大学理学院,杭州310018 [2]深圳职业技术学院智能制造技术研究院,深圳518055 [3]瑞典布京理工学院机械学院,卡尔斯克鲁纳37179

出　　处：《应用声学》2024年第4期799-806,共8页Journal of Applied Acoustics

基　　金：国家自然科学基金项目(12104324,12074354);深圳职业技术大学高层次人才科研启动项目(6022310046K,6024330003K);深职大-新栋力超声波焊接技术研发中心项目(602331009PQ);深圳职业技术大学博士后出站后期资助项目(6023271014K1)。

摘　　要：线束与端子的连接技术在新能源汽车上的需求日益增大。传统连接方式存在耗能高、性能不稳定、产生污染等缺点,因此超声波焊接技术被推广应用到新能源汽车的线束连接上。该文以EVRP5平方屏蔽高压线为研究对象,采用单一变量法对线束进行超声波焊接试验,以焊接能量为变量,通过力学性能测试、微观分析和超声波检测分析超声波的焊接机理。试验结果表明,当焊接能量为5 kJ时,接头抗拉力为2616 N;当焊接能量为11 kJ时,接头抗拉力提高至6650 N。在一定范围内,随着焊接能量的不断增大,接头由靠近工具头处和焊接界面处向内,由未连接状态到点连接、线连接、面连接最终逐渐形成原子间键合。Wire-terminal joining technology is increasingly in demand on new energy vehicles.The traditional connection method has high energy consumption,unstable performance,pollution and other shortcomings,so ultrasonic welding technology is promoted and applied to the connection of the wire harness of new energy vehicles.Although ultrasonic welding technology has been quite mature,but in the field of wiring harness welding is still in the fumbling stage.In this paper,EVRP 50 square shielded high-voltage wire is used as the research object,and the ultrasonic welding test is conducted on the wire harness using the single variable method,and the welding energy is used as the variable to analyze the ultrasonic welding mechanism through mechanical property testing,microscopic analysis and ultrasonic detection.The test results show that when the welding energy is 5 kJ,the joint tensile force is 2616 N;when the welding energy is 11 kJ,the joint tensile force is increased to 6650 N.In a certain range,with the increasing welding energy,the joint from near the tool head and welding interface inward,from the unconnected state to the point connection,line connection,surface connection eventually gradually formed metallurgical bond.

关 键 词：超声波焊接 线束 焊接能量 力学性能 

分 类 号：TB559[理学—物理]