Sourcing Siab-Kev ntseeg tau hlau qhov chaw rau EV HVDC Contactors thiab Relays

EV HVDC contactor kev ntseeg tau nyob ntawm peb yam kev tswj hwm: hluav taws xob conductivity ntawm txoj kev tooj liab tam sim no, sealing kev ua tau zoo ntawm ceramic - mus rau -hlau sib dhos, thiab kev tiv thaiv kev ruaj ntseg nyob rau hauv ntau dua -voltage switching. Apollo manufactures HVDC contactor hlau qhov chaw siv C1100 ntshiab tooj liab, precision stamping, kuj nyiaj brazing, laser vuam, thiab IATF 16949-tswj txheej txheem rau tsheb thiab lub zog cia daim ntaub ntawv.

 

Kev hloov pauv ntawm 400V mus rau 800V hluav taws xob architectures nce qhov kev xav tau tam sim no, kev ntxhov siab rwb thaiv tsev thiab kev tswj xyuas thermal xav tau hauv cov contactors thiab relays. Kev xaiv cov khoom siv, vuam zoo, plating thickness thiab qhov ntev tswj ncaj qha txiav txim siab kev pab cuam lub neej, hloov kev ntseeg tau thiab tsis ua hauj lwm tus nqi.

 

 

 

800V System Voltage tsim cov kev xav tau siab dua rau cov khoom sib cuag

Cov tsheb hluav taws xob niaj hnub siv 800V roj teeb platforms xav tau HVDC contactors los cuam tshuam thiab nqa siab -voltage DC nyob rau hauv kev ua haujlwm hnyav.

 

Piv nrog rau cov kab ke 400V ib txwm muaj, 800V architectures txo cov nqi them tam sim no rau tib lub zog tso tawm tab sis nce cov cai rau:

 

Arc suppression muaj peev xwm thaum lub sij hawm DC hloov.
Rwb thaiv tsev deb thiab dielectric zog.
Hu rau vuam kuj.
Thermal dissipation ntawm conductive Cheebtsam.
Ntev -lub sij hawm ruaj khov tom qab ntau txhiab lub voj voog hloov.

 

Hom HVDC contactor kev khiav hauj lwm tsis:

Parameter	Engineering Yuav Tsum Tau
Qhov system voltage	450VDC-1000VDC
Nruam tam sim no	200A–600A
Peak tam sim no	800A + nyob ntawm daim ntawv thov
Rwb thaiv tsev tsis kam	Ntau dua lossis sib npaug rau 100MΩ
Dielectric tiv taus voltage	2.5kV-4kV AC
Copper conductivity yuav tsum tau	Ntau dua lossis sib npaug li 97% IACS
Tiv tauj kuj variation	<10μΩ after durability testing

 

Cov khoom siv hlau sab hauv yuav tsum ua kom tsis muaj - txoj kev tiv thaiv thaum muaj sia nyob thermal cycling, kev co, thiab rov hloov hluav taws xob.

 

HVDC Contactor Hlau Yam Khoom Xaiv: C1100 Copper vs C2680 Brass

Tam sim no - nqa cov khoom nyob rau hauv EV relays thiab contactors ib txwm xav tau siab -conductivity tooj liab alloys. Brass feem ntau yog siv rau cov khoom siv tab sis tsis tsim nyog rau siab -tam sim no cov khoom siv hluav taws xob uas yuav tsum tau txo qis.

 

Khoom siv	C1100 ntshiab tooj liab	C2680 tooj dag
Cov ntsiab lus tooj liab	Ntau dua lossis sib npaug li 99.90%	60–65%
Hluav taws xob conductivity	Ntau dua lossis sib npaug rau 100% IACS	26-28% IAB
Thermal conductivity	398 W/m·K	120 W/m·K
Daim ntawv thov	Busbar, davhlau ya nyob twg, tus neeg xyuas pib phaj	Cov khoom vaj tse, cov khoom siv kho tshuab
Corrosion kuj	Siab nrog plating	Nruab nrab
High tam sim no haum	Zoo heev	txwv

 

Apollo xaiv C1100 ntshiab tooj liab rau EV relay tooj liab stamping Cheebtsam uas tsis tshua muaj hluav taws xob poob thiab kev ua haujlwm thermal.

 

Precision EV Relay Copper Stamping Controls rau pawg ntau lawm

HVDC contactor Cheebtsam yuav tsum muaj kev vam meej stamping tshuab kom ua tiav cov khoom tsim tawm ruaj khov.

 

Hom kev tsim khoom parameter:

Khoom thickness: 0.3mm-5.0mm.
Dimensional kam rau ua: ± 0.01mm
Burr qhov siab tswj: Tsawg dua lossis sib npaug li 10% cov khoom tuab.
Flatness tswj: Tsawg dua lossis sib npaug li 0.05mm.
CMM tshuaj xyuas rau qhov loj me.
SPC saib xyuas rau kev tsim khoom tas mus li.

 

Cov txheej txheem tsim khoom muaj xws li:

Progressive tuag stamping.
Daim duab sib sib zog nqus.
CNC thib ob machining.
Hauv - tuag riveting.
Kuj welding.
Laser vuam Cu-Cu thiab Cu-Al pob qij txha.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Thov Kev Ntsuam Xyuas DFM Dawb & Tso Cai

 

 

Ceramic - mus rau -Hloov Sealing Cheebtsam rau High Voltage Isolation

 

HVDC contactors siv ceramic sealing qauv los tswj kev ua haujlwm rwb thaiv tsev ntawm cov khoom siv hluav taws xob sab hauv thiab ib puag ncig sab nraud.

 

Lub rooj sib txoos ceramic yuav tsum tiv taus:

Lub tshuab nqus tsev siab lossis roj sealing yuav tsum.
Thermal expansion sib txawv ntawm ceramic thiab hlau.
Mechanical shock thaum lub tsheb ua haujlwm.
High voltage rwb thaiv tsev kev ntxhov siab.

 

Cov khoom siv:

 

Cheebtsam	Khoom siv	Muaj nuj nqi
Ceramic insulator	Al₂O₃ ceramic 95% -99% purity	Hluav taws xob rwb thaiv tsev
Terminal tus pin	C1100 tooj liab / Kovar alloy	Kev xa tawm tam sim no
Sealing alloy	Active brazing alloy	Ceramic{0}}kev sib txuas hlau
Hu rau tus neeg nqa khoom	Copper alloy	Kev txhawb nqa tshuab

 

Hom Ceramic Sealing Parameters:

 

Cov khoom kuaj	Kev xav tau
Dielectric kev puas tsuaj voltage	>15 kV / hli
Helium leakage tus nqi	Tsawg dua lossis sib npaug li 1 × 10⁻⁹ Pa·m³/s
Thermal cycling	-40℃rau +150 degree
Brazing kub	780 degree-900 degree
Dimensional kam rau ua	± 0.02 hli

 

Apollo siv cov kev tiv thaiv nyiaj brazing thiab lub tshuab nqus tsev vacuum brazing thev naus laus zis rau cov khoom siv ceramic-hlau sib dhos.

 

Copper Busbar thiab Hu Rau Tus Qauv Tsim rau Kev Tswj Thermal

 

Tus neeg xyuas pib tsim hauv HVDC contactors ncaj qha cuam tshuam qhov kub nce.

Copper Cheebtsam yuav tsum optimization ntawm:

Hla - cheeb tsam.
Kev faib tawm ceev tam sim no.
Thaum tshav kub kub hloov txoj kev.
Hu rau interface kuj.

Thermal loss xam raws li nram no:

 

P = I²R

 

qhov twg:

P=tshav kub.
Kuv=kev khiav hauj lwm tam sim no.
R=conductor kuj.

 

Rau txoj kev 500A tam sim no, qhov me me ntawm kev tiv thaiv kev tiv thaiv tuaj yeem tsim cov thermal tsub zuj zuj.

Piv txwv:

 

Tiv tauj Resistance	Tam sim no	Thaum tshav kub kub tiam
10μΩ	500A	2.5W
50μΩ	500A	12.5W
100μΩ	500A	25W

 

Qhov no yog vim li cas nyiaj -plated contact nto thiab precision-welded tooj liab qauv yuav tsum tau.

 

Sib cuag Cov Khoom Ua Haujlwm: Nyiaj Alloy thiab Copper Interface Control

HVDC relay tiv tauj yuav tsum tau tiv thaiv:

Arc yaig.
Oxidation.
Hu rau vuam.
Mechanical hnav.

 

Cov ntaub ntawv sib cuag:

Khoom siv	Daim ntawv thov	Yam ntxwv
AgNi	Kev hloov pauv dav dav	Siab hnav tsis kam
AgSnO₂	DC hloov	Zoo arc kuj
Nyiaj dawb	Kev siv tsis tshua muaj zog	Zoo conductivity
Copper substrate + nyiaj plating	Terminal interface	Tsawg tiv thaiv

 

Cov txheej txheem tsim khoom:

Silver contact riveting.

Hauv - tuag riveting.

Kuj welding.

Molecular diffusion vuam.

Silver brazing.

 

Lub vuam interface yog soj ntsuam los ntawm:

Hla -section metallographic tsom xam.

Kev ntsuam xyuas lub zog tensile.

Kev ntsuas hluav taws xob tiv thaiv.

X-ray tshuaj xyuas thaum xav tau.

 

 

 

Laser Vuam Cu-Cu thiab Cu-Al Joints Raws li Automotive Standards

 

Copper thiab aluminium sib koom yog dav siv hauv EV roj teeb thiab lub zog hluav taws xob sib dhos vim qhov yuav tsum tau txo qhov hnyav.

Txawm li cas los xij, tooj liab- aluminium welding ntsib teeb meem:

Cov ntsiab lus melting sib txawv.
Intermetallic compound tsim.
Thermal expansion mismatch.
Kev tswj porosity.

Apollo siv laser vuam Cu-Al txheej txheem tswj nrog tsis suav nrog:

 

Parameter	Tswj ntau yam
Vuam nkag	Tswj los ntawm laser zog ceev
Porosity tus nqi	<1%
Weld zog	Raws li cov neeg siv khoom specification
Thaum tshav kub kub- thaj tsam cuam tshuam	Tsawg kawg
Kev tshuaj xyuas	Hla -section + tensile test

 

Laser Welding vs Resistance Silver Brazing Sib piv

 

Txheej txheem	Laser Vuam Cu-Al	Resistance Silver Brazing
Kub input	Low localized tshav kub	Nruab nrab / siab thermal input
Kev sib koom ua ke muaj zog	Siab	Siab
Automation	Zoo heev	Zoo heev
Material compatibility	Cu-Al, Cu-Cu	Copper alloys, ceramic los ua ke
Tej daim ntawv thov	Roj teeb terminals, busbars	Tiv tauj cov rooj sib txoos, cov khoom sib khi
Kev tswj tsis raug	Kev saib xyuas porosity	Brazing void soj ntsuam

 

 

Silver Plating Thickness Control rau Kev Tiv Thaiv Kev Tiv Thaiv Kev Tiv Thaiv

 

Silver plating yog siv dav hauv HVDC cov chaw sib tiv tauj vim tias cov nyiaj muab hluav taws xob muaj hluav taws xob zoo thiab kev sib cuag ruaj khov hauv kev hloov pauv ntau zaus.

Plating txheej tiv thaiv:

Tooj liab oxidation.
Nce kev tiv thaiv.
Qhov saum npoo corrosion.
Tiv tauj overheating.

 

Rau EV relay tooj liab stamping Cheebtsam, plating zoo nyob ntawm:

Base khoom huv si.
Nto ua kom cov txheej txheem.
Tam sim no ceev thaum electroplating.
Da dej kub stability.
Thickness uniformity.

 

Hom nyiaj plating specifications:

Parameter	Engineering Yuav Tsum Tau
Cov khoom siv hauv paus	C1100 tooj liab / tooj liab alloy
Nyiaj purity	Ntau dua lossis sib npaug li 99.9%
Plating thickness	3μm–10μm
Thickness kam rau ua	±1μm
Nto roughness Ra	Tsawg dua los yog sib npaug li 0.8μm
Adhesion xeem	ISO 2819 ua raws
ntsev tsuag kuj	Raws li cov neeg siv khoom specification
Tiv tauj tiv thaiv	<10mΩ depending on design

 

Apollo ua cov txheej thickness xyuas los ntawm:

X-ray fluorescence (XRF) ntsuas.
Metallographic cross -section tsom xam.
Kev kuaj adhesion.
Kev kuaj ntsev ntsev.

Tin Plating xaiv rau kev tiv thaiv hluav taws xob thiab kev siv nyiaj kom zoo

Tin plating feem ntau yog xaiv rau cov khoom siv hluav taws xob uas yuav tsum tau muaj kev tiv thaiv thiab oxidation.

Piv nrog nyiaj plating, tin muab:

Cov khoom siv qis dua.
Zoo solder compatibility.
Kev tiv thaiv ruaj khov rau qis - zaus hloov daim ntawv thov.

Txawm li cas los xij, tin muaj qis dua conductivity thiab muaj kev pheej hmoo siab dua ntawm fretting corrosion nyob rau hauv kev co.

 

Feature	Nyiaj Plating	Tin Plating
Hluav taws xob conductivity	Zoo heev	Nruab nrab
Tiv tauj tiv thaiv	Tsawg heev	Nruab nrab
Oxidation kuj	Zoo heev	Zoo
Siab -kev hloov tam sim no	Tsim nyog	txwv
Solderability	Zoo	Zoo heev
EV HVDC hu rau daim ntawv thov	Nyiam	Kev thov nyob ntawm

 

Rau HVDC contactors khiav hauj lwm saum 400A, nyiaj plating feem ntau xaiv rau lub ntsiab conductive interface.

 

Epoxy hmoov txheej thiab rwb thaiv tsev tiv thaiv rau HV Cheebtsam

High- cov khoom siv hluav taws xob xav tau cov tshuab hluav taws xob muaj peev xwm tiv thaiv hluav taws xob tawg, ya raws, thiab kev puas tsuaj rau txhua yam.

Apollo siv epoxy hmoov txheej txheej txheem rau insulated busbars thiab hluav taws xob hlau sib dhos.

 

Cov txheej txheem txheej txheem:

 

Parameter	Tus nqi
Txheej khoom	Epoxy hmoov
Thickness ntau	100μm–300μm
Dielectric zog	>15 kV / hli
nplaim taws ntsuas	UL 94 V-0
Ua haujlwm kub	-40℃rau +150 degree
Adhesion xeem	ASTM D 3359 Cov Lus Qhia Tshwj Xeeb

 

Kev sib piv ntawm epoxy hmoov txheej thiab cua sov shrink rwb thaiv tsev:

 

Parameter	Epoxy hmoov txheej	Thaum tshav kub kub Shrink Tube
Thickness uniformity	Siab	Nruab nrab
Complex geometry npog	Zoo heev	txwv
Dielectric zog	>15 kV / hli	Kev thov nyob ntawm
Mechanical tiv thaiv	Siab	Nruab nrab
Automation haum	Siab	Nruab nrab
Ntev -lub sij hawm vibration resistance	Zoo heev	Zoo

 

 

Automotive Hlau Stamping txheej txheem tswj raws li IATF 16949

Apollo tswj HVDC contactor hlau qhov chaw tsim khoom raws li kev tswj hwm tsheb zoo.

 

Kev tsim khoom flow muaj xws li:

Incoming khoom soj ntsuam.
Progressive stamping.
Precision txoj kev.
Vuam thiab brazing.
Kev kho saum npoo.
Dimensional soj ntsuam.
Kev ntsuas hluav taws xob ua haujlwm.
PPAP cov ntaub ntawv xa tuaj.

 

Quality Control Parameters:

Txheej txheem	Txoj kev tshuaj xyuas	Tswj Lub Hom Phiaj
Khoom siv tooj liab	Cov ntaub ntawv pov thawj + conductivity test	Ntau dua lossis sib npaug li 97% IACS
Stamping dimension	Kev tshuaj xyuas CMM	± 0.01 hli
Flatness	Laser ntsuas	Tsawg dua los yog sib npaug li 0.05mm
Vuam lub zog	Tensile xeem	Cov neeg siv khoom specification
Plating thickness	XRF	±1μm
Rwb thaiv tsev	High voltage xeem	Raws li kev tsim
Kev kuaj pom	Helium leak test	Tsawg dua lossis sib npaug li 1 × 10⁻⁹ Pa·m³/s

 

PPAP Qib 3 Cov Ntaub Ntawv rau Ntiaj Teb EV Supply Chains

Ntiaj teb no automotive cov neeg muas zaub xav tau traceable ntau lawm kev pom zoo cov txheej txheem ua ntej loj ntau lawm.

 

Apollo txhawb PPAP Theem 3 xa mus suav nrog:

Part Submission Warrant (PSW).
Txheej Txheem Flow Diagram.
PFMEA.
Tswj Plan.
Measurement System Analysis (MSA).
Dimensional Reports.
Cov ntaub ntawv xeem cov ntaub ntawv.
Kev Kawm Txuj Ci (Cp/Cpk).
Cov ntaub ntawv pom zoo ua piv txwv.

Yam khoom muaj peev xwm:

 

Yam khoom	Apollo muaj peev xwm
Prototype tooling	20-30 hnub
Qauv xa tuaj	7-15 hnub nyob ntawm qhov nyuaj
Lub sijhawm ua khoom loj	15-20 hnub
Ntau lawm traceability	Batch{0}}qib taug qab
Qhov system zoo	TIAB SA 16949
Environmental system	ISO 14001 Daim Ntawv Pov Thawj

 

Cov cuab yeej tshuaj xyuas Precision rau HVDC Contactor Hlau Qhov

Kev ntseeg siab yuav tsum ntsuas dhau qhov kev tshuaj xyuas qhov muag.

 

Apollo siv:

Coordinate Measuring Machine (CMM).
Optical ntsuas qhov system.
XRF txheej analyzer.
Cov khoom siv ntsuas tensile.
Hluav taws xob tiv thaiv tester.
Cov cuab yeej ntsuas hluav taws xob tawg.
Helium leak detector.

Qhov loj me tseem ceeb yog tswj los ntawm kev tswj xyuas cov txheej txheem txheeb cais (SPC).

 

Hom kam rau ua:

Stamping qhov ntev: ± 0.01mm
Qhov chaw qhov tseeb: ± 0.02mm.
Kev sib cuag kev sib raug zoo: raws li cov neeg siv khoom kos duab.
Nto flatness: Tsawg dua los yog sib npaug rau 0.05mm.

 

Thov Kev Ntsuam Xyuas DFM Dawb & Tso Cai

 

 

Pom zoo Cov Qauv Txheej Txheem rau EV thiab ESS daim ntawv thov

Cov ntawv thov sib txawv xav tau cov khoom sib txawv thiab cov txheej txheem sib xyaw ua ke.

 

Daim ntawv thov	Khoom siv pom zoo	Kev tsim khoom	Kev kho saum npoo
EV lub ntsiab roj teeb contactor	C1100 tooj	Stamping + nyiaj plating	3-10 m
ESS DC relay	Copper alloy	Stamping + vuam	Silver / Tin plating
Charger pawg contactor	tooj liab terminal	CNC + brazing	Anti- oxidation txheej
Roj teeb busbar txuas	Tooj / aluminium	Laser vuam	Rwb thaiv tsev txheej
Ceramic kaw contactor	Tooj + ceramic	Nqus brazing	Silver interface

 

Hom Failure Hom thiab Kev Tiv Thaiv Kev Tiv Thaiv
Tiv tauj Resistance nce

 

Ua rau:

Tsis txaus nyiaj txheej thickness.
Tooj liab oxidation.
Tsis zoo welding interface.
Qhov chaw paug.

 

Kev Tiv Thaiv:

XRF plating tshuaj xyuas.
Clean manufacturing ib puag ncig.
Kev sim tshuaj tiv thaiv.
Tiv tauj rau kev txheeb xyuas qhov tseeb.
Thermal Failure Thaum lub sijhawm ua haujlwm siab tam sim no

 

Ua rau:

Tsis muaj tooj liab hla -section.
Kev sib koom ua ke ntau dhau.
Tsis zoo cua sov dissipation.

 

Kev Tiv Thaiv:

Thermal simulation.
Copper khoom optimization.
Tsawg-tsis kam vuam.
Kev ntsuas kub nce.
Rwb thaiv tsev tawg

 

Ua rau:

Txheej tsis xws luag.
Tsis txaus dielectric thickness.
Ntse ntug hluav taws xob teb concentration.

 

Kev Tiv Thaiv:

Epoxy hmoov txheej tshuaj xyuas.
High -voltage tiv thaiv kev sim.
Ntug radius optimization.

 

 

HVDC contactor kev ua tau zoo nyob ntawm kev tswj kev sib cuam tshuam ntawm tooj liab conductivity, ceramic sealing kev ntseeg tau, kev sib cuag nto engineering, thiab kev tsim khoom sib xws.

 

Apollo manufactures HVDC contactor hlau qhov chaw, EV relay tooj liab stamping Cheebtsam, thiab tshiab zog contactor sib dhos siv:

 

C1100 ntshiab tooj liab cov ntaub ntawv.

Precision nce qib stamping.

Laser vuam Cu-Al technology.

Tsis kam nyiaj brazing.

Silver / Tin plating tswj.

IATF 16949 automotive ntau lawm tswj.

PPAP Qib 3 cov ntaub ntawv txhawb nqa.

 

Rau cov tuam txhab EV, ESS integrators, thiab cov tuam txhab hluav taws xob cov khoom siv hluav taws xob xav tau cov khoom siv ruaj khov ntawm - cov khoom siv hloov tam sim no, kev siv hluav taws xob tsim hluav taws xob yuav tsum pib nrog kev xaiv cov khoom siv, txheej txheem tsim, thiab kev soj ntsuam muaj peev xwm.

 

 

Dab tsi yog PPAP Theem 3 lub sijhawm xa khoom rauEV HVDC contactor hlau qhov chaw?

Apollo feem ntau muab cov ntaub ntawv PPAP Theem 3 tom qab kev pom zoo thiab kev pom zoo ntawm cov txheej txheem tsim khoom. Lub sijhawm ncua sij hawm nyob ntawm cov cuab yeej nyuaj thiab cov neeg siv khoom siv tau cov cai.

 

Dab tsi ntawm qhov ntev ntev tuaj yeem Apollo ua tiav rau EV relay tooj liab stamping qhov chaw?

Apollo tswj qhov tseem ceeb stamping qhov ntev nyob rau hauv ± 0.01mm siv cov kev vam meej tuag, SPC xyuas, thiab CMM tshuaj xyuas cov tshuab.

 

Yuav ua li cas Apollo txheeb xyuas nyiaj plating thickness ntawm HVDC tiv tauj cov khoom?

Silver plating thickness yog ntsuas siv XRF tsom xam thiab metallographic cross-section soj ntsuam, feem ntau tswj tsis pub dhau 3μm-10μm raws li cov neeg siv khoom tshwj xeeb.