汽车部件连接件母排、铜排、铝排自动浸塑流水线是专为汽车电气系统核心部件 —— 连接件母排、铜排、铝排设计的自动化涂层加工设备，核心功能是通过浸塑工艺在三种金属导体排表面形成均匀、耐磨的塑料绝缘涂层（常用材质为 PVC、PE），起到绝缘、防腐蚀、防氧化及抗机械冲击的作用，保障导体排在汽车高振动、高湿度、多粉尘的复杂工况下稳定传导电流，是汽车电气安全与部件耐用性的关键加工设备。

该流水线实现全流程自动化作业，无需大量人工干预，典型工作流程包含八大核心环节：

1. 自动上料与定位：通过伺服驱动的链式输送系统或机械臂，将待加工的汽车部件连接件母排、铜排、铝排精准输送至进料工位，设备搭载视觉识别模块，可自动区分不同材质与规格的导体排，调整输送速度与后续工艺参数；

2. 预处理清洁：依次经过脱脂槽（采用碱性脱脂剂，去除导体排表面冲压油污与指纹）、酸洗槽（针对铜排氧化层用稀硫酸处理，铝排用专用除氧化膜药剂）、三道水洗槽（分别为中和水洗、纯水洗、漂洗，彻底清除残留药剂，避免影响涂层附着力），各槽体温度与处理时间由 PLC 系统自动控制；

3. 热风烘干：清洁后的导体排进入烘干炉，炉内温度控制在 90-110℃，通过热风循环系统实现均匀加热，快速去除表面水分，确保后续浸塑时涂层无气泡；

4. 预热活化：烘干后的导体排进入预热炉，根据材质差异调整温度（铜排 120-140℃，铝排 100-120℃），提升导体排表面活性，增强塑料涂层与金属表面的结合强度；

5. 自动浸塑：预热后的导体排由升降机构匀速浸入塑料涂液槽（涂液浓度与温度实时监测，浓度控制在 25%-35%，温度 40-50℃），浸塑时间与提升速度根据涂层厚度需求（通常 0.2-0.6mm）自动调节，确保涂层均匀覆盖导体排表面及边角；

6. 流平修整：浸塑后的导体排进入流平区，通过可调速输送与微风辅助，使表面多余涂液自然流平，避免出现流挂、积料等缺陷；

7. 高温固化：流平后的导体排进入固化炉，炉温根据塑料材质设定（PVC 材质 160-180℃，PE 材质 180-200℃），固化时间 15-25 分钟，通过热风循环使塑料涂液充分熔融、交联固化，形成致密绝缘膜层；

8. 冷却下料与检测：固化后的导体排进入水冷 + 风冷复合冷却通道，快速降温至常温，随后由输送系统送至下料工位，同时设备搭载激光测厚仪与外观检测相机，自动检测涂层厚度与表面缺陷（如针孔、漏涂），合格产品自动分拣至成品库，不合格品标记并剔除。

该流水线的核心优势体现在以下四方面：

• 材质兼容性强：可同时处理连接件母排、铜排、铝排三种不同材质的导体排，通过智能参数切换，无需更换模具或槽体，适配汽车部件多品种、小批量的生产需求；

• 涂层性能优异：自动化控制全流程工艺参数，涂层厚度误差≤±0.05mm，击穿电压≥28kV/mm，耐盐雾测试可达 500 小时以上，完全满足汽车行业严苛的电气与环境可靠性标准；

• 生产效率高：单条流水线每小时可处理 150-300 根导体排，支持 24 小时连续作业，相比传统半自动设备效率提升 3-4 倍，适配汽车零部件大规模量产需求；

• 环保节能：配备涂液循环回收系统，未附着涂液回收率达 96% 以上，减少原材料浪费；固化炉废气经活性炭吸附 + 催化燃烧处理后达标排放，VOCs 排放浓度≤30mg/m³；同时采用余热回收装置，将固化炉余热用于预热炉，能耗降低 20%-25%。

目前，该流水线广泛应用于新能源汽车（纯电动、混合动力）及传统燃油汽车的电气系统部件加工，如电池包连接件母排、电机控制器铜排、高压配电箱铝排等关键部件的绝缘涂层处理，是汽车电气部件国产化量产的核心设备之一。

The Automatic Dip Coating Line for Connector Busbars, Copper Busbars and Aluminum Busbars of Automotive Components is an automated coating processing equipment specially designed for the core components of automotive electrical systems - connector busbars, copper busbars and aluminum busbars. Its core function is to form a uniform and wear-resistant plastic insulation coating (common materials are PVC and PE) on the surface of the three types of metal conductor bars through the dip coating process. This coating provides insulation, corrosion resistance, oxidation resistance and resistance to mechanical impact, ensuring that the conductor bars can stably conduct current under the complex working conditions of high vibration, high humidity and high dust in automobiles. It is a key processing equipment for automotive electrical safety and component durability.

This production line realizes the whole-process automated operation without a lot of manual intervention, and its typical working process includes eight core links:

1. Automatic Loading and Positioning: Through a servo-driven chain conveyor system or robotic arm, the connector busbars, copper busbars and aluminum busbars of automotive components to be processed are accurately transported to the feeding station. The equipment is equipped with a visual recognition module, which can automatically distinguish conductor bars of different materials and specifications, and adjust the conveying speed and subsequent process parameters;

2. Pretreatment Cleaning: Successively passing through a degreasing tank (using alkaline degreaser to remove stamping oil and fingerprints on the surface of conductor bars), a pickling tank (using dilute sulfuric acid to treat the oxide layer of copper bars, and special oxide film removal agent for aluminum bars), and three water washing tanks (neutralization water washing, pure water washing and rinsing respectively) to completely remove residual chemicals and avoid affecting coating adhesion. The temperature and treatment time of each tank are automatically controlled by the PLC system;

3. Hot Air Drying: The cleaned conductor bars enter the drying furnace, where the temperature is controlled at 90-110℃. Uniform heating is achieved through a hot air circulation system to quickly remove surface moisture and ensure no bubbles in the coating during subsequent dip coating;

4. Preheating Activation: The dried conductor bars enter the preheating furnace, and the temperature is adjusted according to material differences (120-140℃ for copper bars, 100-120℃ for aluminum bars) to improve the surface activity of the conductor bars and enhance the bonding strength between the plastic coating and the metal surface;

5. Automatic Dip Coating: The preheated conductor bars are evenly immersed in the plastic coating tank by a lifting mechanism (the concentration and temperature of the coating solution are monitored in real time, with the concentration controlled at 25%-35% and the temperature at 40-50℃). The dip coating time and lifting speed are automatically adjusted according to the required coating thickness (usually 0.2-0.6mm) to ensure that the coating uniformly covers the surface and edges of the conductor bars;

6. Leveling and Trimming: The dipped conductor bars enter the leveling area, and through adjustable speed conveying and gentle air assistance, the excess coating solution on the surface is naturally leveled to avoid defects such as sagging and material accumulation;

7. High-Temperature Curing: The leveled conductor bars enter the curing furnace, and the furnace temperature is set according to the plastic material (160-180℃ for PVC, 180-200℃ for PE) with a curing time of 15-25 minutes. The plastic coating solution is fully melted, cross-linked and cured through hot air circulation to form a dense insulating film;

8. Cooling, Unloading and Inspection: The cured conductor bars enter a composite cooling channel of water cooling and air cooling to quickly cool down to room temperature. Then they are transported to the unloading station by the conveyor system. At the same time, the equipment is equipped with a laser thickness gauge and an appearance inspection camera to automatically detect the coating thickness and surface defects (such as pinholes and missing coating). Qualified products are automatically sorted to the finished product warehouse, and unqualified products are marked and rejected.

The core advantages of this production line are reflected in the following four aspects:

• Strong Material Compatibility: It can process three types of conductor bars (connector busbars, copper busbars and aluminum busbars) at the same time. Through intelligent parameter switching, there is no need to replace molds or tanks, which adapts to the production needs of multiple varieties and small batches of automotive components;

• Excellent Coating Performance: The whole process parameters are controlled automatically, the coating thickness error is ≤±0.05mm, the breakdown voltage is ≥28kV/mm, and the salt spray resistance test can reach more than 500 hours, which fully meets the strict electrical and environmental reliability standards of the automotive industry;

• High Production Efficiency: A single production line can process 150-300 conductor bars per hour and supports 24-hour continuous operation. Compared with traditional semi-automatic equipment, the efficiency is increased by 3-4 times, which adapts to the large-scale mass production needs of automotive components;

• Environmental Protection and Energy Saving: Equipped with a coating solution recycling system, the recovery rate of unused coating solution is over 96%, reducing raw material waste; the waste gas from the curing furnace is discharged up to the standard after activated carbon adsorption + catalytic combustion treatment, and the VOCs emission concentration is ≤30mg/m³; at the same time, a waste heat recovery device is adopted to use the waste heat of the curing furnace for the preheating furnace, reducing energy consumption by 20%-25%.

At present, this production line is widely used in the processing of electrical system components of new energy vehicles (pure electric, hybrid) and traditional fuel vehicles, such as the insulation coating treatment of key components such as battery pack connector busbars, motor controller copper busbars, and high-voltage distribution box aluminum busbars. It is one of the core equipment for the localized mass production of automotive electrical components.