连接件母排、铝排、铜排全自动 PVC 浸涂生产线是专为电气领域中连接件母排、铝制导体排、铜制导体排设计的高度自动化涂层加工设备，核心功能是通过全自动浸涂工艺在三种导体排表面形成均匀、致密的 PVC 绝缘涂层，起到绝缘、防腐蚀、防氧化及防机械磨损的作用，保障导体排在电力传输、电气连接中的安全性与稳定性，满足高低压电气设备、新能源装置等场景的严苛使用要求。

该生产线的工作流程实现全自动化控制，无需人工干预，主要包含七大核心环节：

1. 自动上料：通过机械臂或链式输送系统将待加工的连接件母排、铝排、铜排批量输送至进料工位，设备可自动识别导体排类型与尺寸，适配不同规格工件；

2. 预处理：依次经过脱脂槽（去除表面油污、杂质）、酸洗 / 除锈槽（针对铜排、铝排表面氧化层进行清理）、多道水洗槽（冲洗残留药剂，避免影响涂层附着力），全程自动化控温与控时，确保工件表面洁净度；

3. 预热烘干：工件进入预热炉，炉内温度精准控制在 80-120℃，通过热风循环系统均匀加热，去除工件表面水分并提升表面温度，为 PVC 涂液附着奠定基础；

4. PVC 浸涂：预热后的工件由伺服电机驱动的输送装置匀速浸入 PVC 涂液槽，涂液浓度、温度及浸涂时间可根据不同导体排材质与涂层厚度需求（通常为 0.1-0.5mm）自动调节，确保涂层均匀覆盖无漏点；

5. 流平固化：浸涂后的工件先进入流平区，使表面多余涂液自然流平，随后进入固化炉，炉温控制在 160-200℃，通过热风循环实现 PVC 涂液熔融、交联固化，形成稳定绝缘膜层；

6. 冷却定型：固化后的工件进入冷却通道，采用风冷与水冷结合的方式快速降温至常温，避免涂层因温差过大出现开裂、脱落；

7. 自动下料与检测：冷却后的工件由输送系统送至下料工位，同时设备搭载视觉检测模块，自动检测涂层厚度、外观缺陷（如气泡、漏涂），合格工件自动分拣至成品区，不合格品标记并剔除。

生产线的核心优势显著：

• 兼容性强：可同时处理连接件母排、铝排、铜排三种不同材质与规格的导体排，无需频繁更换模具或调整设备参数，切换效率高；

• 涂层质量稳定：全自动化控制浸涂、固化等关键参数，涂层厚度误差可控制在 ±0.03mm 内，击穿电压≥25kV/mm，绝缘性能与耐腐蚀性远超行业标准；

• 生产效率高：单条生产线每小时可处理 200-500 根导体排，实现 24 小时连续作业，大幅提升批量生产能力；

• 环保节能：配备 PVC 涂液循环回收系统，未附着涂液回收率达 98% 以上，减少原材料浪费；固化炉废气经活性炭吸附 + UV 光解处理后达标排放，符合国家环保要求；同时采用智能温控系统，相比传统设备能耗降低 15%-20%。

目前，该生产线广泛应用于高低压配电柜、新能源汽车电池包、光伏逆变器、储能设备等领域，为连接件母排、铝排、铜排提供高效、稳定的 PVC 绝缘涂层加工，是电气导体排规模化生产的需要。

The Full-Automatic PVC Dipping Production Line for Connector Busbars, Aluminum Busbars and Copper Busbars is a highly automated coating processing equipment specially designed for connector busbars, aluminum conductor bars and copper conductor bars in the electrical field. Its core function is to form a uniform and dense PVC insulation coating on the surface of the three types of conductor bars through a fully automatic dipping process. This coating provides insulation, corrosion resistance, oxidation resistance and protection against mechanical wear, ensuring the safety and stability of conductor bars in power transmission and electrical connection, and meeting the strict application requirements of high and low voltage electrical equipment, new energy devices and other scenarios.

The working process of this production line is fully automated without manual intervention, mainly including seven core links:

1. Automatic Loading: Batch transport of connector busbars, aluminum busbars and copper busbars to be processed to the feeding station through a robotic arm or chain conveyor system. The equipment can automatically identify the type and size of conductor bars, adapting to workpieces of different specifications;

2. Pretreatment: Successively passing through a degreasing tank (removing surface oil and impurities), a pickling/rust removal tank (cleaning the oxide layer on the surface of copper and aluminum busbars), and multiple water washing tanks (rinsing residual chemicals to avoid affecting coating adhesion). The temperature and time are fully automatically controlled throughout the process to ensure the surface cleanliness of workpieces;

3. Preheating and Drying: Workpieces enter the preheating furnace, where the temperature is precisely controlled at 80-120℃. Uniform heating is achieved through a hot air circulation system to remove surface moisture of workpieces and increase surface temperature, laying a foundation for the adhesion of PVC coating solution;

4. PVC Dipping: The preheated workpieces are immersed in the PVC coating tank at a constant speed by a conveyor driven by a servo motor. The concentration, temperature of the coating solution and dipping time can be automatically adjusted according to the material of different conductor bars and the required coating thickness (usually 0.1-0.5mm), ensuring uniform coating coverage without missing points;

5. Leveling and Curing: The dipped workpieces first enter the leveling area to allow the excess coating solution on the surface to level naturally, then enter the curing furnace. The furnace temperature is controlled at 160-200℃, and the PVC coating solution is melted, cross-linked and cured through hot air circulation to form a stable insulating film;

6. Cooling and Shaping: The cured workpieces enter the cooling channel, and are quickly cooled to room temperature by a combination of air cooling and water cooling, avoiding cracking and peeling of the coating due to excessive temperature difference;

7. Automatic Unloading and Inspection: The cooled workpieces are transported to the unloading station by the conveyor system. At the same time, the equipment is equipped with a visual inspection module to automatically detect the coating thickness and appearance defects (such as bubbles, missing coating). Qualified workpieces are automatically sorted to the finished product area, and unqualified products are marked and rejected.

The core advantages of the production line are significant:

• Strong Compatibility: It can process three types of conductor bars (connector busbars, aluminum busbars and copper busbars) of different materials and specifications at the same time, without frequent mold replacement or equipment parameter adjustment, with high switching efficiency;

• Stable Coating Quality: Fully automatic control of key parameters such as dipping and curing, the coating thickness error can be controlled within ±0.03mm, and the breakdown voltage is ≥25kV/mm, whose insulation performance and corrosion resistance far exceed industry standards;

• High Production Efficiency: A single production line can process 200-500 conductor bars per hour, realizing 24-hour continuous operation and greatly improving the mass production capacity;

• Environmental Protection and Energy Saving: Equipped with a PVC coating solution recycling system, the recovery rate of unused coating solution is over 98%, reducing raw material waste; the waste gas from the curing furnace is discharged up to the standard after activated carbon adsorption + UV photolysis treatment, complying with national environmental protection requirements; at the same time, an intelligent temperature control system is adopted, which reduces energy consumption by 15%-20% compared with traditional equipment.

At present, this production line is widely used in high and low voltage distribution cabinets, new energy vehicle battery packs, photovoltaic inverters, energy storage equipment and other fields. It provides efficient and stable PVC insulation coating processing for connector busbars, aluminum busbars and copper busbars, and is the core equipment for large-scale production of electrical conductor bars.