Ma nā kahua e ulu wikiwiki nei o New Energy Vehicles, nā ʻōnaehana mālama ikehu, a me ka hāʻawi ʻana i ka mana voli -kiʻekiʻe, ʻo ka maikaʻi o nā pilina busbar keleawe ke ola o ka ʻōnaehana uila holoʻokoʻa. Ke hoʻololi nei nā koi ʻoihana mai ka "hana ʻana i kahi pilina" i ka hōʻoia ʻana i ka "ola lōʻihi, haʻahaʻa haʻahaʻa, a me nā hemahema ʻole," ʻo ka Medium Frequency Direct Current Inverter.Weila makaua puka mai ma ke 'ano he hana ma'amau-ʻoihana. Eia nō naʻe, no ka hoʻohana maoli ʻana i kona hiki, pono ka ʻike hohonu o ke kumu physics a me ka hoʻokele kaʻina hana.
Hāʻawi kēia alakaʻi i ka wehewehe hohonu ʻana o ka ʻenehana MFDC ma ka hoʻoheheʻe ʻana i ka busbar keleawe, e uhi ana i ka physics wela, nā ʻāpana kaʻina piha, ka hoʻohui ʻana i nā mea like ʻole, a ma ka -pilikia pūnaewele.
Koikoʻi Physics: No ke aha e koi ai ʻo Copper Busbar welding i ka MFDC?
Hāʻawi ke keleawe i kahi luʻi kūʻokoʻa i ka hoʻoheheʻe kūʻē ʻana ma muli o kona kiʻekiʻe kiʻekiʻe o ka wela (ma kahi o $400 W/(m\\cdot K)$) a me ka hoʻoili uila. ʻO ia ke ʻano o ka wela i hana ʻia i ka wā wili e hoʻopau koke ʻia i nā mea a puni a me nā electrodes, e paʻakikī ke hana i kahi weld nugget paʻa.
E like me ke Kānāwai o Joule, $Q=I^2Rt$, hilinaʻi nui ka hana ʻana i ka wela ma ke kūpaʻa hoʻopili ʻana ma waena o nā mea hana, no ka mea, haʻahaʻa loa ke kūʻē nui ($R$) o ke keleawe.
Loaʻa i nā mea welder AC kuʻuna (50/60Hz) i ka loli ʻana o kēia manawa a me nā helu -ʻaʻohe, e hana ana i nā pilikia wela no ka manawa pōkole. No ke keleawe hoʻokele kiʻekiʻe, hiki i kēia hoʻomaha pōkole ke pakele i ka wela, pinepine ka hopena i ka uila uila akā ʻaʻole i piha a i ʻole "anu" weld nugget (i kapa ʻia ʻo "shunted weld").
Ua lanakila ka welder MFDC i kēia ma ka hoʻohuli ʻana i ke au i kahi alapine kiʻekiʻe (maʻamau 1000Hz) a me ka hoʻopuka ʻana i kahi ʻano nalu manuahi kokoke loa. ʻO kēia hoʻokomo ikehu paʻa mau e hōʻoia:
- Kaulike Wela Hikiwawe: Hiki i ke alapine kiʻekiʻe ke hoʻomalu i ka pae millisecond-, e hoʻohua i ka wela e hana ai i ka nugget ma mua o ka hiki ʻana o ka hoʻopuehu wela i ka ikehu.
- Hoʻokumu Nugget Kūʻokoʻa: Mālama ka DC maʻemaʻe i ka mahana o ka loko i hoʻoheheʻe ʻia, e hōʻemi ana i ka kipaku ʻana (spatter) a me ka hōʻoia ʻana i kahi ʻaʻahu, weld hohonu.
- Hoʻemi ʻia ka Heat Affected Zone (HAZ): Hoʻopili nui ʻia ka ikehu ma ka weld interface, he mea koʻikoʻi ia no nā ʻeke pākahiko NEV kahi e hiki ai i ka wela nui ke hōʻino i nā cell pili a i ʻole insulation.
Ka Mana Kaʻina Hana piha: Hoʻomaʻamaʻa i ke Kaʻina Welding
No ka loa'a 'ana i ka -ki'eki'e ki'eki'e copper busbar weld e koi 'ia ma mua o ka ho'onohonoho 'ana i ke au; e pili ana i ke kaʻina hana maʻamau, multi{1}}pae.
1. Mamua -Weld Surface Preparation: The Critical First Step
Hoʻokumu koke nā ʻili keleawe i kahi ʻāpana oxide me ke kūpaʻa kiʻekiʻe. ʻO ke kuʻi ʻana ma luna o kēia papa e alakaʻi i ka hana wela paʻa ʻole a me ka spatter nui.
- Hoʻomaʻemaʻe Mechanical: E hoʻohana i ka pulupulu uea a i ʻole ka mea abrasive maikaʻi no ka wehe ʻana i ka papa okisa, me ka ʻimi ʻana i kahi ʻano ʻeleʻele ($Ra$) ma kahi o $1.6\\mu m$.
- Hoʻomaʻemaʻe Kemika: E hoʻomaʻemaʻe i ka wahi wili me ka waiʻona ʻenehana a i ʻole acetone e wehe ai i nā aila a me nā mea haumia hiki ke hoʻokalapona a hoʻoulu i ka porosity i ka weld.
2. Manaʻo ʻia nā ʻōkuhi palena (Laʻana: 3mm+3mm Ke keleawe Maʻemaʻe)
ʻO ka loina maʻamau no ka wili keleawe ʻo "High Current, Short Time, High Force."
| Kaʻina Hana | ʻĀpana | Paipai ʻia | Hana a me ke kumu |
| Kīkini |
Pumi Electrode (Pihi) |
3.5 - 5.5 kN | E hōʻoia i ka pilina pili a hoʻopaʻa i ke kūʻē mua. |
| Weld | ʻĀpana wiliwili (I) | 18 - 25 kA | Pono ke au kiʻekiʻe e lanakila ai i ka conductivity thermal kiʻekiʻe o ke keleawe. |
| Weld | Manawa Weld (t) | 150 - 300 ms | Mālama ʻia ka pōkole e hōʻemi i ka nalowale o ka wela; hāʻawi pinepine ʻia i 2-3 pulses. |
| Paʻa | Manawa Paʻa (Pihi) | 100 - 200 ms | Mālama ʻia ke kaomi i ka wā paʻa nugget e pale i nā haʻahaʻa a me ka haki ʻana. |
3. Electrode Management
- Mea maʻamau: Papa 2 (CuCrZr) a i ʻole Papa 3 (CuBe2) maʻamau. No nā busbar mānoanoa loa, hoʻohana ʻia nā metala refractory e like me Tungsten a i ʻole Molybdenum i kekahi manawa no ka hoʻonui ʻana i ke kūpaʻa hoʻopili ʻana a me ka wela wela.
- Geometry: ʻO kahi kihi radius nui (e laʻa, R50-R100 dome a i ʻole cone i ʻoki ʻia ke alo papaha) no ka mālama ʻana i ka mānoanoa o kēia manawa a e hōʻemi i ka indentation.
ʻO ka hoʻoheheʻe ʻana i nā mea like ʻole: Advanced NEV Applications
ʻOi aku ka maikaʻi o nā welders MFDC i nā hiʻohiʻona hoʻohui paʻakikī i maʻamau i ka hana ʻana i ka pā uila NEV:
- Copper + Aluminum:He mea paʻakikī loa kēia ma muli o ka hoʻokumu wikiwiki ʻana o nā Intermetallic Compounds brittle (IMC). ʻO ka mana pololei o MFDC e hiki ai i kahi weld i hoʻopaʻa ʻia e kaupalena i ka mānoanoa o ka papa IMC i kekahi mau micrometers, e hōʻoia ana i ka ikaika mechanical a me ka hana uila.
- Copper + Nickel/Stainless Steel:No ka mea, ʻoi aku ka nui o ke kūʻē ʻana o Nickel a me Stainless Steel ma mua o ke keleawe, neʻe maoli ke koena wela i ka mea kiʻekiʻe -kūpono. Hoʻohana ka hoʻonā i ka hoʻohana ʻana i nā Electrodes Dissimilar: he electrode -kiʻekiʻe (e laʻa, Molybdenum) ma ka ʻaoʻao keleawe a me kahi electrode CuCrZr maʻamau ma ka ʻaoʻao nickel e hoʻohālikelike ai i ka hana wela.
Ka Loiloi Pono a me nā Kūlana ʻOihana
Pono e hōʻoia ʻia ka maikaʻi o Weld me ka hoʻohana ʻana i nā ʻano hoʻāʻo ʻino a me ka -ʻole, e kuhikuhi pinepine ana i nā kūlana koʻikoʻi e like me IPC-A{-610 (Acceptability of Electronic Assemblies) a me nā maʻamau kaʻa kaʻa e like me QC/T 413.
| Ka helu helu | Koi maʻamau | Hana MFDC |
| Ikaika Mechanical | Hoao Peel: Anawaena Nugget ($D$) $\\ge 5\\sqrt{t}$ | Kūlike kiʻekiʻe; maʻemaʻe "pihi" huki -waho i ke ʻano hemahema. |
| Hana Uila | ʻO ka hoʻāʻo ʻana o ka piʻi ʻana o ka wela (helu ʻia i kēia manawa) | Piʻi ka wela o ka pilina $\\le 5^\\circ C$ ma luna o ka wela o ka busbar. |
|
ʻIke/Hana |
Hohonu Indentation | Pono e $< 15%$ of the thinnest sheet thickness. |
| Metallurgy | Kūlana Nugget | ʻO ke ʻano o ka palaoa kūlike; liʻiliʻi liʻiliʻi a i ʻole micro{0}} māwae. |
Ma ka -Hoʻoponopono pilikia ma ka Pūnaewele: He alakaʻi hoʻomaʻamaʻa no nā pilikia maʻamau
ʻOiai me nā mea hana maikaʻi loa, hiki i nā loli kaʻina hana ke alakaʻi i nā hemahema. Eia ka papaʻaina kūpono no nā ʻenekinia kahua:
| ʻIke ʻia ke kīnā | Hoʻolāʻau kumu kumu | Hoʻoponopono kūpono |
| Electrode Sticking/Adhesion | ʻAʻole lawa ka hoʻolili ʻana a i ʻole ke ʻano nui o kēia manawa. | Increase cooling water flow rate (target $>6L/min$); e hoʻohana i kahi anawaena maka electrode nui aʻe. |
| ʻOi aku ka nui o ka Spatter/Expulsion |
ʻAʻole lawa ka ikaika electrode (kaomi) a i ʻole ka pili ʻana o ka ʻili. |
E hoʻonui i ka Pumi Weld/Pre{0}}Weld Force; e hōʻoia i ka palahalaha a maʻemaʻe nā mea hana. |
| ʻEleʻele/Puna Weld Wahi | ʻO ka oxidation o ka ʻili a i ʻole ka manawa weld nui. | E hoʻomaikaʻi i ka hoʻomaʻemaʻe mua -weld; e hoʻohana i ka manawa weld pōkole me nā pulses he nui; e noʻonoʻo i ka pale kinoea inert. |
| Kaha Weld Kūlike ʻole | ʻO ke kūpaʻa hoʻopili ʻana ma muli o ke aahu electrode. | E hoʻokō i kahi papa hana koʻikoʻi no ka lole electrode (resurfacing) a me ka hoʻololi. |
Ka hopena
Ka pono oMFDC wahi wiliwilino ka mea, ʻaʻole ʻokoʻa wale nā pahu keleawe; hōʻike ia i kahi hoʻololi kumu i ka hiki ke hana. Hoʻoponopono ia i nā pilikia kūlohelohe o ka conductivity kiʻekiʻe o ke keleawe, e hāʻawi ana i kahi weld kiʻekiʻe me ka hilinaʻi kiʻekiʻe (maʻamau 99.9%+ hua), mālama mālama ikehu (a hiki i 30% hoʻemi i hoʻohālikelike ʻia me AC), a me ka traceability piha.
No nā ʻenekinia ma NEV a me nā ʻoihana mana, ʻaʻole koho hou ka ʻenehana MFDC-a ia ka mea e pono ai no ka loaʻa ʻana o nā loulou kiʻekiʻe, -kiʻekiʻe, hilinaʻi i koi ʻia e nā ʻōnaehana hou.
