Development and experiment of electromagnetic pulse crimping device for high-voltage wire harness of electric vehicles
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摘要: 采用铝合金高压线束替代铜合金高压线束可帮助电动汽车减少重量、提高续航和降低成本。针对铝与铜由于金属性质差异难以可靠连接的问题，本文提出采用电磁脉冲压接技术连接铝合金高压线束与铜合金接线端子，并研制了一套适用于两者连接的电磁脉冲压接装置，其最大放电能量为28 kJ。压接过程中，随着放电电压的升高，接线端子表面的温度升高。当放电电压为12 kV时，实现了铝合金高压线束与铜合金接线端子的可靠连接。采用光学显微镜分析连接界面的微观结构，并测试其电气性能和机械性能。分析结果表明：电磁脉冲压接技术可实现铝合金高压线束与接线端子、铝合金芯线之间的冶金结合，且连接界面出现了波纹形貌与涡旋形貌。测试结果显示：接头接触电阻测试、振动测试、拉力负荷测试均满足汽车行业标准和电缆接头国家标准。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.
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图 3 不同放电电压时的电压电流波形测试结果
Figure 3. Voltage and current waveform of different discharge voltages
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