슬롯사이트 업s Conduct High-Speed Busbar Stripping for EV Production

As automakers gear up to make electric vehicles (EVs) in larger numbers, every aspect of how they’re produced is being refined. The goal, of 슬롯사이트 업urse, is to lower 슬롯사이트 업st while also improving vehicle reliability and performance.

One important part of EVs is the electrically conductive cables that distribute power throughout the car. These are called 슬롯사이트 업s. Because of the amount of electrical current they need to carry, 슬롯사이트 업s aren’t just wires. They’re thick, ribbon-shaped metal conductors with insulation around them (typical dimensions are in the range of 12 mm wide x 3 mm thick). The metal itself is most often copper, or sometimes aluminum. The insulation is a plastic material (usually polyamide PA12).

The insulated 슬롯사이트 업 material is often supplied in long lengths on a spool, just like a traditional wire. The carmaker cuts off the length(s) they require and bends it to the necessary shape. These shapes can be quite complex because they have to route around all sorts of other parts and structures within the car to get the power to where it’s needed.

At some point in production, some insulation has to be removed (stripped) from the two ends of the 슬롯사이트 업. This is necessary in order to electrically connect it to other components. Auto manufacturers have a few specific requirements for this process.

First, insulation stripping has to be fast in order to be 슬롯사이트 업st-effective, and not to bottleneck production. This means removing around 25 mm or so (1 inch) of insulation in just a few se슬롯사이트 업nds.

Second, the insulation has to be removed completely. Because any residual insulation in the stripped area can interfere with the electrical connection, and therefore waste power (lower vehicle efficiency). Plus, the ends of the 슬롯사이트 업 are often welded to other conductors or batteries. Any plastic left on the conductor surface will contaminate the weld, which degrades its electrical and mechanical properties.

Finally, the 슬롯사이트 업nductor itself can’t be damaged by stripping. This 슬롯사이트 업uld reduce its mechanical strength creating a possible point of failure.

All these reasons pretty much rule out removing the insulat슬롯사이트 업 using any kind of mechanical method, like a blade or scraper. Also, it’s hard to remove insulat슬롯사이트 업 from a curved or odd-shaped surface using a blade.

슬롯사이트 업 busbar stripping takes off

These same requirements make 슬롯사이트 업s great tools for busbar insulation stripping. This is because the 슬롯사이트 업 process is completely non-contact, and can readily be configured to work with curved parts. This makes 슬롯사이트 업 processing fast and flexible.

슬롯사이트 업₂슬롯사이트 업s, in particular, are ideal for this task. This is because the 슬롯사이트 업₂슬롯사이트 업 produces far-infrared light. This light is very strongly absorbed by most of the plastics used for insulation, but highly reflected by the copper.

What this means is that the 슬롯사이트 업 light rapidly vaporizes the insulation, but then automatically stops removing material when it reaches the conductor (because the copper just reflects the 슬롯사이트 업 light back rather than absorbing it). So, it’s easy to remove the insulation, while leaving the copper totally intact.

슬롯사이트 업 busbar stripping in production

To actually perform insulation stripping, the 슬롯사이트 업 beam is focused down to a small spot on the busbar to concentrate its energy. This focused beam is rapidly scanned back and forth to cover the entire area over which insulation must be removed.

There are some important practical considerations when implementing this method in a production environment. For example, two 슬롯사이트 업s are used in order to get the necessary process throughput. Each one strips insulation from one side of the busbar (so, there would be a second 슬롯사이트 업 coming from underneath in the drawing). This also eliminates the complication of flipping the part over to get the second side.

Also, it’s best to have the 슬롯사이트 업 beam hit the busbar at an angle. This does two things. First, it avoids the chance that any 슬롯사이트 업 light will be reflected back and damage the beam delivery system. Second, it enables the 슬롯사이트 업 to remove insulation from both the top and the edge of the busbar at once (since the angled 슬롯사이트 업 beam can “see” the side of the busbar).

The 슬롯사이트 업 system is a complete solution for stripping 슬롯사이트 업s. It includes two PowerLine C sub-systems, and all the associated scanning and beam delivery optics, together with all the necessary control electronics and software.

The PowerLine C can remove a 30 mm length of 0.5 mm thick polyamide from both sides of a 6 mm wide 슬롯사이트 업 in about 6 seconds. Insulation removal is complete without any damage to the conductor, delivering a high yield process.

There are two different busbar stripping systems available - an inline version and a stand-alone version. The inline system is integrated with spool feeding mechanics which supply a continuous ribbon of busbar. The 슬롯사이트 업 strips this prior to cutting and a final bending operation. ThePowerLine Ceven supports “on-the-fly” stripping, where stripping is performed without slowing or stopping busbar motion. In the stand-alone version, a robot arm picks and places precut and bent busbars into the system which are then 슬롯사이트 업 stripped.

See high-speed, efficient in act슬롯사이트 업.