Copper Alloy Fixed Contact for HV DC Relays
Precision manufacturing of copper alloy fixed contacts for high voltage DC relays used in new energy vehicles and power systems
Project Overview
Client Requirements
- High electrical conductivity for optimal performance
- Exceptional mechanical strength and durability
- Strict dimensional tolerances for precise fit
- Corrosion resistance for long-term reliability
- High volume production capacity (10,000 units)
Our Solution
- Precision CNC machining with advanced tooling
- Use of high-quality Copper Alloy C17200 for optimal performance
- Stringent quality control and inspection processes
- Surface finishing to enhance conductivity and corrosion resistance
- Efficient production planning to meet 6-week timeline
Project Success Metrics
Technical Specifications
Material Specifications
| Property | Value |
|---|---|
| Material | Copper Alloy C17200 |
| Electrical Conductivity | 98% IACS minimum |
| Hardness | Rockwell B 90-110 |
| Tensile Strength | 480-580 MPa |
| Yield Strength | 380-480 MPa |
| Elongation | 8-15% |
Dimensional Tolerances
| Dimension | Tolerance |
|---|---|
| Contact Surface Flatness | ±0.005 mm |
| Contact Thickness | ±0.01 mm |
| Contact Diameter | ±0.015 mm |
| Mounting Hole Position | ±0.02 mm |
| Overall Length | ±0.03 mm |
| Surface Roughness (Ra) | 0.4 μm maximum |
Manufacturing Process
Material Preparation
High-quality Copper Alloy C17200 is carefully selected and prepared for machining. Material is inspected for chemical composition and physical properties to ensure it meets specifications.
CNC Machining
Precision CNC turning and milling operations are performed to create the complex geometry of the fixed contacts. Advanced tooling and tight process control ensure dimensional accuracy and surface finish.
Surface Finishing
Contacts undergo surface finishing processes to enhance electrical conductivity and corrosion resistance. This includes cleaning, polishing, and optional plating depending on customer requirements.
Quality Inspection
Each contact is thoroughly inspected using advanced measuring equipment, including CMMs and optical comparators, to ensure all dimensional and functional requirements are met. 100% inspection ensures zero defects.
Packaging & Shipping
Finished contacts are carefully packaged to prevent damage during transportation. Parts are labeled with traceability information and shipped according to customer delivery schedules.
Customer Support
Our team provides ongoing technical support and quality assurance throughout the project lifecycle. We work closely with customers to address any questions or concerns and ensure complete satisfaction.
Results & Benefits
Performance Improvements
-
Enhanced Electrical Conductivity
Copper Alloy C17200 provides excellent electrical conductivity, reducing power loss and improving relay performance.
-
Improved Durability
High mechanical strength and corrosion resistance ensure long service life in demanding automotive environments.
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Enhanced Reliability
Precise dimensional control ensures consistent contact pressure and reliable electrical connection.
Business Benefits
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Cost Savings
Efficient manufacturing processes and high yield rates resulted in significant cost savings for EcoPower Systems.
-
Faster Time-to-Market
Meeting the 6-week production timeline enabled EcoPower Systems to accelerate product development and launch.
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Improved Quality
Zero defects and 100% inspection pass rate resulted in improved overall product quality for EcoPower Systems.
Ready to Start Your Project?
Contact us today to discuss your precision manufacturing requirements and how we can help you achieve your goals.
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