Development and experiment of electromagnetic pulse crimping device for high-voltage wire harness of electric vehicles

Li Chengxiang; Shen Ting; Zhou Yan; Wu Hao; Zhang Bingfei; Mi Yan

doi:10.11884/HPLPB202234.210568

Volume 34 Issue 7

May 2022

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Article Navigation > High Power Laser and Particle Beams > 2022 > 34(7): 079001

Li Chengxiang, Shen Ting, Zhou Yan, et al. Development and experiment of electromagnetic pulse crimping device for high-voltage wire harness of electric vehicles[J]. High Power Laser and Particle Beams, 2022, 34: 079001. doi: 10.11884/HPLPB202234.210568

Citation:

Li Chengxiang, Shen Ting, Zhou Yan, et al. Development and experiment of electromagnetic pulse crimping device for high-voltage wire harness of electric vehicles[J]. High Power Laser and Particle Beams, 2022, 34: 079001. doi: 10.11884/HPLPB202234.210568

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Development and experiment of electromagnetic pulse crimping device for high-voltage wire harness of electric vehicles

doi: 10.11884/HPLPB202234.210568

Laboratory of Power Transmission Equipment & System Security and New Technology, Chongqing University, Chongqing 400044, China

Received Date: 2021-12-02
Accepted Date: 2022-05-12
Rev Recd Date: 2022-04-29

Available Online: 2022-05-13

Publish Date: 2022-05-12

Abstract

Abstract

The use of aluminum alloy high-voltage wire harnesses instead of copper wire harnesses can reduce the weight of electric vehicles, increase battery endurance, and reduce cost. Aiming at the difficulty of reliable and effective connection between aluminum alloy high-voltage wire harness and copper alloy terminal, this paper proposes to use electromagnetic pulse crimping technology (EMPC) to connect aluminum alloy high-voltage wire harness and copper alloy terminal. A set of EMPC device suitable for the connection has been developed. The EMPW device has a maximum discharge energy of 28 kJ. During the crimping process, with the increase of the discharge voltage, the temperature of the terminal surface increases. The aluminum alloy high-voltage wire harness and the copper alloy terminal can be connected reliably at 12 kV. An optical microscope was used to analyze the microstructure of the connection interface, and the electrical and mechanical properties of the interface were tested. The analysis shows that the electromagnetic pulse crimping technology can realize metallurgical combination between the aluminum alloy high-voltage wire harness and the terminal as well as the aluminum alloy core wires. The connection interface has a corrugated morphology and a vortex morphology. The test results show that the contact resistance, vibration test and tensile load test of the joint meet the industrial standards of automobile and the national standards of cable joint.
- electric vehicle,
- high-voltage wire harnesses,
- terminal,
- electromagnetic pulse crimping,
- performance test

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References(17)

References

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