Cap And Contact For Hybrid Electric Vehicle Fuses
Products Description
Cap and Contact for Hybrid Electric Vehicle Fuses typically consist of the following parts:
Fuse Contact Cap (outer cap)
Fuse Blade Contact (blade structure)
Brass Inner Cap (inner cap)
Copper Conductive Shell (conductive shell)
Riveted Conductive Joint (riveted conductive joint)
Brazed Conductive Assembly (brazed conductive assembly)
Depending on different fuse design requirements, the following structures can be achieved:
Circular Structure
Square Structure
Irregularly Shaped Connection Structure
Double-Layer Conductive Structure
Multi-Point Welding Structure
High-Strength Conductive Connection Structure
Design Advantages: Multi-dimensional decoupling design for automotive-grade reliability
Anti-rotation locking and foolproof mechanical riveting structure
Micro-geometric anti-rotation bumps (interlocking ribs) are designed on the physical contact surface between the brass inner cap and the copper outer cap. Before brazing, precise pre-riveting is performed using several tons of mechanical gravity.
Aerodynamic optimization of venting and sand filling channels
The top of the Outer Cap and Terminal Welded Components is designed with micro-holes, which serve both as stress relief vents during high-temperature welding and perfectly match the high-density quartz sand micro-vibration filling process in the automated fuse production line, ensuring dense and seamless filling of the internal arc-extinguishing medium.
Smooth edge stress release R-angle design
All punched surfaces and end bends are mechanically and chemically polished to form a micron-level large R-angle transition, eliminating the electric field concentration effect and preventing corona or weak flashover at the end under high-voltage energy storage.
Manufacturing Process and Advantages: Extreme Control of Microscopic Defects
Precision Progressive Stamping and Deformation Control
The Outer End Cap and Contact Welded Assembly Set and brass inner cap are formed using high-precision multi-station progressive die stamping. Addressing the work-hardening characteristic of T2Y2 copper, micro-lubrication within the die and a step-annealing structure control the grain flow of the material, ensuring the stamped parts are free of microcracks and lugs, with dimensional tolerances controlled at the micrometer level.
Precision Riveting Pre-assembly
Before welding, an automated precision riveting process mechanically pre-positions and pre-tightens the inner and outer caps. Closed-loop control of the riveting force ensures absolutely uniform welding gaps, eliminating incomplete welds and misaligned welds.
High-Frequency Induction/Resistance Brazing Timing Control
The welding process uses PLC to precisely control the current waveform, energizing time, and applied pressure. High-speed thermal imaging monitors welding temperature in real time, ensuring precise melting and spreading of high-temperature solder at the interface, achieving a metallurgical bond with excellent airtightness and a welding rate far exceeding industry standards.
Ultrasonic C-scan non-destructive testing
Abandoning the traditional method of relying solely on visual inspection and sampling, ultrasonic C-scanning equipment is introduced to provide 100% non-destructive visualization of internal porosity and lack of fusion defects in each batch of welds, reducing the risk of microscopic failure to zero.
Application Advantages: Validated New Energy Scenarios
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We not only provide standardized Copper Contact for Round Type Fuse products, but also offer integrated engineering solutions based on customers' fuse structure, current rating, and automated assembly requirements, from material development and connection process verification to mass production, helping new energy projects achieve more stable and consistent mass production.
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