CN104662738B - 机械和电接合电导体的方法 - Google Patents

机械和电接合电导体的方法 Download PDF

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CN104662738B
CN104662738B CN201280075080.6A CN201280075080A CN104662738B CN 104662738 B CN104662738 B CN 104662738B CN 201280075080 A CN201280075080 A CN 201280075080A CN 104662738 B CN104662738 B CN 104662738B
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CN104662738A (zh
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D·伊苏斯·弗
E·吉克斯·迪亚兹
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
    • H01R43/0235—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections for applying solder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K1/00—Soldering, e.g. brazing, or unsoldering
    • B23K1/0008—Soldering, e.g. brazing, or unsoldering specially adapted for particular articles or work
    • B23K1/0016—Brazing of electronic components
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
    • B23K31/02—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to soldering or welding
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/02—Soldered or welded connections
    • H01R4/023—Soldered or welded connections between cables or wires and terminals
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/187—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping combined with soldering or welding
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/20—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping using a crimping sleeve
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
    • H01R43/048—Crimping apparatus or processes
    • H01R43/0482—Crimping apparatus or processes combined with contact member manufacturing mechanism
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/46—Bases; Cases
    • H01R13/52—Dustproof, splashproof, drip-proof, waterproof, or flameproof cases
    • H01R13/523—Dustproof, splashproof, drip-proof, waterproof, or flameproof cases for use under water
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
    • H02G1/00—Methods or apparatus specially adapted for installing, maintaining, repairing or dismantling electric cables or lines
    • H02G1/14—Methods or apparatus specially adapted for installing, maintaining, repairing or dismantling electric cables or lines for joining or terminating cables

Abstract

非常长的电导体的接合应该比由简易衬套提供的接合更加牢固，当所述导体将以非常不规则的方式被设置在海底时，所述衬套接合所述导体，并且在衬套或升高的接合装置上具有应力，除了前面提及的不规则，结果是导体非常重。因此，作为本发明的目的的方法包含：焊接导体；贯穿增强衬套；将所述增强衬套放置在导体的焊接区域中且焊接所述衬套；以及随后使衬套变形直至所述衬套的直径等于导体的直径。

Description

机械和电接合电导体的方法
技术领域
本发明更具体地涉及一种用于通过焊接以及随后在放置接合接头的情况下对接头和导体进行处理而接合两个电导体的方法，使得一旦将所述接合接头放置在接合区域中，则接头的直径不超过导体的直径，从而确保纯机械和电结合。
背景技术
接合两个电导体的目的在于获得适合需求的导体长度，在一些实例中在技术上通过使用具有压力螺钉的连接器完成，以使得待接合的导体的端部经过连接器的端部进入到连接器中，由这些螺钉将它们固定在内部。
接合电导体的另一方式是通过将导体的端部焊接在一起，这导致不期望地增加了导体的直径，这对于接下来的包覆是个问题，并且如果该导体需要滑动穿过保护罩或保护管则会增加困难。
另外的接合方式是利用接头或连接器，所述接头或连接器由通过压床的动作而折叠成的表面形成，在这种情况下除了导体的接合区域的直径变化的前述问题，出现的问题在于接合区域的导电性不良且缺乏平整度，因为它包含了用机械压床施加的单次冲击来成形增强衬套。
发明内容
本发明的目的在于在两个导体之间形成接头，具有与原电缆相同的强度，且不改变所述导体的机械或电性能。
我们希望保留的机械性能涉及如下的要求：导体接合点应具有与没有接头的导体相同的强度的要求，且电性能涉及：接合点不应该对整个导体长度上的导电性产生负面影响，这可能会发热。
当导体主要在海底运行时，用于传输电能的导体的安装需要较长的导体，这些导体正常情况下不可能是单根导体，因此不得不将不同部分通过各种已知的方法接合起来。然而，传统的接合是不可能的，这是因为这些导体具有较大的直径，它们必须承受纵向力和扭转的力，因为这些导体被铺设在不规则的表面，也要承受其自身的重量，所以由于导体所处位置以及接近它们的困难和高昂的费用，受损也是个大问题，撇开受损的可能性不说。
在这些导体被放置在软管中成为所谓的脐带电缆之后进行铺设，软管中还存在或不存在其他导体以及管道，以致于在深水下任何受损的修补都需要专门的资源且难于准确定位受损点。
本发明涉及的方法始于预成形平面片材的表面以在机械工具，诸如虎头钳或压床的相互面对的半圆形模具之间的折叠的帮助下通过变形获得增强衬套，逐渐减小所述模具之间的距离以使得由最初板状的平面结构进行变形，直至所述平面结构成为圆柱状，但是并没有闭合该增强衬套的边缘，而是在边缘之间留出一定的α角度，以容许焊接的导体后面经由那些边缘所界定的空间插入到所述衬套内部。预成形所述板的表面的步骤可利用具有冷却回路的夹具完成，该冷却回路在沿纵向焊接所述预成形的衬套的边缘时起作用。
增强衬套的材料可以是导电金属材料的平面片材，导电金属材料包括含铁的、不含铁的及其合金，该导电金属材料在导电性以及机械强度方面具有与导体相同的性能。
然后，一旦导体在它们的一个端部上被焊接，接合区域被提前变形而成的增强衬套、第二组夹具或一系列夹具包裹，将导体和接头和/或连接器插入增强衬套中，每对夹具的直径都比前一个的夹具直径小，通过添加焊料到所述衬套直至增强衬套的自由边缘准备焊接。后一个夹具被设计为具有与前一个夹具相同的直径，但是后面的夹具为增强衬套的表面提供带沟槽的加工面，如上面所述，这些夹具具有冷却回路，所述冷却回路在衬套的边缘被焊接时起作用。
在增强衬套的表面上，有一系列便于后续覆盖接合区域的沟槽。在所有情况下，这里描述的方法取得了导体接合区域的直径与导体被焊接前的导体的直径相同，导体接合区域的直径包括所述增强衬套的壁的厚度。
其他细节和特征将在参照附图的下述整个说明中被示出，所述细节和特征在本发明的附图中仅用于示例性而非限制目的被示出。
附图说明
以下是本发明中不同部件的列表，所述部件在以下附图中用其各自的标记来标识：10增强衬套；11加热成形工作台；12腿部；13平台；14夹具；15杆；16a，16b待连接的导体；17腔室；18边缘；19a，19b导体的端部；20工作台；21夹具；22焊接线。
图1是增强衬套10在形状被改变之前的前视图，该增强衬套从平坦表面改变成如图2所示的开口圆柱表面。
图2是图1中增强衬套10被弯曲且边缘以角度α敞开的前视图。
图3是用于接合导体16的加热成形工作台11的侧视图。
图4a是前视图，且图4b是导体16位于夹具14之间时加热成形工作台11的俯视图。
图5a是由于夹具14、21的动作而使导体上的增强衬套10进行逐步成形操作前加热成形工作台“A”区域的俯视图，焊点19a、19b位于焊接区域内部。
图5b是与图5a相同的俯视图，只是增强衬套10已经获得与焊接的导体16a、16b的直径或横截面大体相同的直径或横截面，即逐步成形操作已经结束且df(最后直径)＝dc(导体直径)。
具体实施方式
在本发明的一个优选实施方式中，这里描述的方法开始于增强衬套10的预成形——如图1中可见，该增强衬套可以是如下材料的平面片材10：铜、铝、钢或其他类似的具有良好导电性的金属，或者是含铁或不含铁材料及其合金——直至它获得图2中所示的开口圆柱状结构，该结构是通过未在附图中示出的机械虎头钳或压床或其他类似系统中的半圆形印模的动作而得到，以使得在预成形之后，在该结构的边缘18之间存在一个角度α，以便接下来可以将预先焊接的导体16通过导体16的焊接区域插入到所述增强衬套10内。
在将片材10预成形成衬套的同时，在导体16的端部19之一上对导体16进行焊接之外还有一个操作，将导体的端部19放置在加热成形工作台11上，加热成形工作台11具有彼此相对的夹具14，这两个夹具的前面具有用于放置导体16的圆形开口腔室17，参见图2，以使得当所述导体16被夹持在夹具14之间时，通过热喷枪等以及焊料将端部19进行焊接，然后环绕焊接区域安装增强衬套10，并开始如图5a和5b中所见的增强衬套10的圆形成形阶段。
如图5a和5b所示，利用第二工作台20对增强衬套10进行最后的成形，该第二工作台具有成对的相对夹具21，所述夹具具有自己的冷却回路，每个在每对夹具之间具有较小距离，以使得增强衬套10是沿纵向逐步变形的，且在“A”区域中的具有导体16的增强衬套10的最后直径与导体的原始直径相同，最后增强衬套10被焊接。
如图5a和5b中可见，两个导体16的接合区域的最后直径“df”等于导体的直径“dc”，如图5a和5b所示，尽管增强衬套10自身具有厚度。只有当直径df＝dc，环绕且保护导体16以及放置有增强衬套10的接合区域的护套才能适配。
前述的方法可以普遍地适用于铜和/或铝线芯、铜铝和钢接头和/或连接器、以及含铁和不含铁材料及它们的合金、具有单根或多根电线的导体、LV，MV，HV，EHV电缆。
结合所附的附图已经充分描述了本发明之后，易于理解的是据此可以进行任何适应性的改变，只要这些变化没有改变下面权利要求所概括的本发明的本质。

Claims (8)

1.一种机械和电接合电导体的方法，所述导体由铜、铝、钢或任何其他导电材料制成，其特征在于，该方法包括以下步骤：
－焊接待接合的导体的端部；
－预成形增强衬套，直至所述增强衬套变成在该增强衬套的边缘之间留出一角度的圆柱状；
－将所述增强衬套放置在之前焊接的所述导体的焊接区域中；
－焊接所述增强衬套的自由的所述边缘，从而将所述导体焊接在内部；
－在所述导体被焊接在内部的情况下逐步成形在所述导体的焊接区域上的所述增强衬套，直至获得df＝dc，其中，df表示所述增强衬套的最后直径，dc表示所述导体的原始直径。
2.根据权利要求1所述的机械和电接合电导体的方法，其特征在于，从平面片材预成形所述增强衬套的步骤是通过虎头钳或压床中的半圆形模具完成的。
3.根据权利要求1所述的机械和电接合电导体的方法，其特征在于，焊接待接合的所述导体的端部的步骤是在内侧面具有圆形凹槽的夹具的帮助下、通过加热所述导体的端部并且通过将焊料以及热喷枪添加到所述端部来焊接所述端部而完成的。
4.根据权利要求1所述的机械和电接合电导体的方法，其特征在于，焊接所述增强衬套的所述边缘的步骤是在整个“A”区域中沿纵向方向进行的，其中，所述“A”区域表示所述增强衬套的逐步成形区域。
5.根据权利要求1所述的机械和电接合电导体的方法，其特征在于，在安装焊接的所述导体之前逐步成形所述增强衬套的步骤中，在机械虎头钳或压床中使用半圆形模具。
6.根据权利要求1所述的机械和电接合电导体的方法，其特征在于，为了在所述导体的其中一个端部上焊接所述导体，使用了加热成形工作台，该加热成形工作台具有彼此相对的夹具，两个夹具的前面具有用于放置所述导体的圆形开口腔室，以便于在所述导体被夹持在所述夹具之间时，使用热喷枪以及使用焊料焊接所述端部，然后环绕所述焊接区域安装所述增强衬套。
7.根据权利要求1所述的机械和电接合电导体的方法，其特征在于，一旦焊接的所述导体被放置在所述增强衬套中，第二工作台用于所述增强衬套的最终折叠，从而所述边缘尽可能地折叠，该第二工作台具有成对的相对夹具，每对夹具之间具有更小的距离，以使得所述增强衬套沿纵向逐步变形，且在“A”区域中具有所述导体的所述增强衬套的最后直径等于所述导体的原始直径，最后焊接所述增强衬套，其中，所述“A”区域表示所述增强衬套的逐步成形区域。
8.根据权利要求7所述的机械和电接合电导体的方法，其特征在于，所述夹具具有冷却回路，该冷却回路在焊接所述增强衬套的所述边缘的时候起作用。
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