CN109326931B

CN109326931B - Distributed miniature distributor, wire system and method of manufacture

Info

Publication number: CN109326931B
Application number: CN201811305300.5A
Authority: CN
Inventors: 米夏埃尔·沃尔特贝格; 马丁·比伯格; 根特·雅各布; 克劳斯·维克赛德; 马丁·塞登施万特; 丹尼尔·泽曼
Original assignee: Lisa Draexlmaier GmbH
Current assignee: Lisa Draexlmaier GmbH
Priority date: 2017-11-03
Filing date: 2018-11-05
Publication date: 2020-07-31
Anticipated expiration: 2038-11-05
Also published as: CN109326931A; DE102017125687B3

Abstract

The invention discloses a distributed miniature power distributor (100, 200, 300, 900) for branching off electric power for several consumers (151) from a round conductor (150, 250, 350, 450, 550, 650) conducting voltage. The distributed small-scale power distributor (100, 200, 300, 900) has: a first contact element (101, 201, 301) and a number of second contact elements (102, 202, 302). The first contact element (101, 201, 301) is coupled on the input side to the round conductor (150, 250, 350, 450, 550, 650) and on the output side to the input side of the second contact element (102, 202, 302), wherein the second contact element (102, 202, 302) can be coupled on the output side to at least one consumer (151). The invention further discloses a corresponding conductor system (940) and a corresponding production method.

Description

Distributed miniature distributor, wire system and method of manufacture

Technical Field

The invention relates to a distributed small-sized power distributor. Furthermore, the invention relates to a conductor system and a manufacturing method.

Background

The invention is mainly described below in connection with an on-board electrical system of a vehicle. Of course, the invention is not limited to use in vehicles and the invention may be used in any electrical network.

The physical on-board electrical system of the vehicle has the task of supplying the control device and the electrical load with electrical energy and providing a data connection. In particular, on-board energy systems for supplying control devices and electrical loads with electrical energy are constantly increasing in size and weight due to the increasing number of electrical consumers in the on-board electrical system. Usually, the electrical leads are responsible only for energy transport. The energy distribution can only take place at the end of the line, for example by means of a current distributor.

In modern vehicles, not only the functional range of the electrical consumers is increased, but also, for example, a further voltage situation of 48V occurs in addition to the existing 12V voltage situation. Furthermore, separate structural spaces for the power supply of 12V, 48V and FUSI-HAF (functionally reliable highly autonomous driving) are required.

Disclosure of Invention

The technical problem to be solved by the invention is therefore to keep the dimensions and weight of the onboard electrical system low by using means that are constructively as simple as possible.

Advantageous developments of the invention are given in the dependent claims, the description and the drawings. In particular, independent claims of one claim category are also extended similarly to dependent claims of another claim category.

The distributed miniature power distributor according to the invention is used for branching off electrical leads from a round conductor conducting voltage for several, i.e. one or more, electrical consumers. The distributed miniature power distributor according to the invention has a first contact element and several, i.e. one or more, second contact elements, wherein the first contact element is coupled on the input side to the round conductor and on the output side directly or indirectly to the input side of the second contact elements, wherein the second contact elements are coupled on the output side to at least one load.

The line system according to the invention is used for supplying electrical consumers in a vehicle. The inventive conductor system has a main conductor coupled to an energy source and at least one distributed branch coupled to the main conductor and to at least one consumer.

The production method according to the invention is used to produce a distributed miniature power distributor according to the invention for tapping electrical power from voltage-conducting conductor bundles for electrical consumers. This manufacturing method according to the present invention has: the method comprises the steps of providing a first contact element and several, i.e. one or more, second contact elements, coupling the first contact element on the input side to a conductor bundle and on the output side to the input side of the second contact elements, and coupling the second contact elements on the output side to at least one consumer.

The invention is based on the recognition that conventional vehicle electrical system topologies for vehicles have disadvantages with regard to installation space and weight. Conventional vehicle electrical system topologies have several levels:

1. generator-battery connection level with a main battery distributor (HSV)

2. Main distribution level from main distributor of battery to fuse and relay box (SV)

3. Distribution layer from SV to lower level of electrical equipment

Conventional on-board power supply system topologies have a central distributor node. This distributor node is at the same time an interface between the levels and is provided onto the wire ends. Since the distribution must be carried out on all sides of the vehicle in all three levels, in the conventional 12V onboard power supply system there are a large number of supply lines which run in parallel and conduct the same supply potential.

The invention avoids parallel paths for the power supply of the individual levels and ensures the shortest possible connection of each load.

To this end, the invention proposes a conductor system. The wiring system has at least one wiring harness. The wire harness further has at least one round conductor. The wire harness may extend across the vehicle, for example, from the battery. As an alternative to the central current distributor, the wire system has at least one round conductor, over the length of which distributed branches, i.e. for example distributed mini-distributors, are arranged close to the load location. The distributed small-scale power distributor directly contacts the round conductor and makes it possible to branch off the round conductor from the line without having to lay the individual layers in parallel in the vehicle. This round conductor, which may branch directly from the wire to the consumer, may also be referred to as a Multi-Drop distributor. By only partially removing the insulation of the round conductor at the corresponding location, the round conductor can be contacted at each location and a center tap can be realized.

To realize this branch, for example, a distributed small distributor is provided. But direct contact of round conductors is also possible. The distributed small power distributor may directly contact the round conductor at any position and thus realize branches emanating from the round conductor at any position of the round conductor.

To this end, the distributed miniature distributor provides a first contact element electrically coupled to the circular conductor. Furthermore, the distributed miniature power distributor provides a second contact element coupled directly or indirectly to the first contact element and further coupled to the conductor or the electrical consumer. It is to be understood that further elements may be arranged between the first contact element and the second contact element, as further described below.

The first contact element is thus used to contact the round conductor. The first contact element therefore couples out electrical power from the round conductor and can thus distribute the electrical power to the corresponding consumer. The second contact element is used for transmitting the electrical power to the respective consumer. In the sense of the present patent application, an electrical consumer is understood to be an electrical power consumer. The consumer can thus be, for example, a control device, an actuator, etc. However, the load can also be, for example, another round conductor, for example, a secondary conductor.

The invention thus makes it possible to arrange branches for supplying electrical loads at any desired point on the circular conductor. The ground feedback can be realized here by a conductive vehicle body of the vehicle. Alternatively, a second round conductor with a corresponding distributed mini-distributor may be provided, which serves as ground feedback to the energy source, i.e. for example to the vehicle battery.

Since the distributed small power distributor can be manufactured with very small dimensions, it can be integrated, for example, into a wire harness.

Further embodiments and improvements result from the dependent claims and from the description with reference to the drawings.

In one embodiment, the first contact element can have a plug contact or a screw or a bore for a screw connection on the output side, the second contact element can have a second plug contact or a corresponding screw or bore on the input side, respectively.

The first contact element and the second contact element may, for example, be directly coupled to each other. For this purpose, the first plug contact and the second plug contact can be designed, for example, as a male end part and a female end part of a plug connection.

If the first contact element and the second contact element are directly connected to one another, the respective load can be coupled to the round conductor very simply. For this purpose, the consumer merely has to be coupled to the second contact element, for example by means of a line, and the second contact element serves as a supply plug for the consumer.

Alternatively, the first contact element and the second contact element may also be indirectly coupled to one another. Indirect coupling is understood to mean that at least one further element is arranged between the first contact element and the second contact element. This enables different functions, such as insurance and diagnostic elements, to be integrated into the distributed mini-distributor. Alternatively or additionally, the at least one securing element can also be integrated into the contact element. This securing element can be designed, for example, as a melt-securing element as a material constriction of the corresponding contact element. This fuse may also be referred to as a stamped grid fuse.

In one embodiment, the first contact element can have a contact plate designed to be flat for coupling with the round conductor, which contact plate can be arranged between the round conductor and the first plug contact.

For weight reasons, aluminum is often used in modern vehicles as the material of the wire harness. However, the plug contact should be made of copper for mechanical stability and electrical conductivity. If the transition between aluminum and copper is wetted, damage to the connection can occur due to galvanic corrosion. A seal against the ingress of moisture is required at the transition between aluminum and copper. The sealing of the generally circular round conductor can be performed at the connection location with the first contact element. To insulate or protect the connection against corrosion, the connection can be cast, potted, foamed or painted, for example. Furthermore, adhesives with butyl groups, for example, are possible. In addition, a separate single line seal may also be used. Instead of a conventional single-wire seal being pushed onto the end of the wire, in the case of a split single-wire seal, two halves of the single-wire seal are placed around the wire.

In particular, if the material of the round conductor and the material of the first plug contact section differ, the contact plate can thus be used, for example, as a distance element which is formed from the material of the round conductor and which separates the first plug contact section from the round conductor in such a way that a sealing of the connection is only required between the contact plate and the first plug contact section. However, this connection can be geometrically optimized for sealing because of the distance from the round conductor or be provided with corrosion protection. The contact plate serves in this case, for example, as a contact or soldering lug for soldering to a round conductor, for example, by means of ultrasound. It should be understood that any other type of electrical contact is also possible. For example, a shrink connection may be used for contacting the round conductor with the first contact element. The shrinkage can be used in particular when the round conductors and the contact elements are made of copper.

In one embodiment, the contact plate can be shaped such that it serves as a boundary of the welding space during welding, which is usually realized by means of a side slide. Thus, a more compact contact area can be achieved by placing the contact element directly against the welded joint. The housing size of the small power distributor can thus be further reduced.

In one embodiment, the contact plate can be formed from aluminum, and the first plug contact can have a clamping contact formed from copper and/or a contact comb formed from copper.

As discussed above, the detachable clamping connection is formed of copper due to mechanical stability and high electrical conductivity. If a separate clamping contact is provided as the first plug contact, this clamping contact can be coupled, for example, directly to the plug fuse (or plug fuses). The contact combs can then be coupled, for example, to a plurality of corresponding contact springs of the carrier circuit board, standard plug-in fuses, etc.

The aluminum contact plate can be connected to the copper contact comb, for example by means of a rolled cladding, i.e. a bimetallic plate. The contact combs can be stamped from a copper plate, for example. The connection locations can then be plated with nickel and zinc or silver, for example, or coated with the corresponding alloys. In this way, effective corrosion protection can be ensured.

By providing a material transition between aluminum and copper away from the round conductor, the distributed mini-distributor can be prefabricated without having to subject the entire round conductor to an electroplating process.

It is understood that sealing or at least covering of the welding location between the round conductor and the contact plate may also be performed.

In one embodiment, the distributed power miniaturisation distributor can have an electrical component, in particular an insurance and/or diagnostic device, which can be arranged between the first contact element and the second contact element.

The electrical component may be, for example, a fuse or the like, and is coupled with the output of the first contact element and the input of the second contact element. It is understood that the electrical component for each second contact element has a respective electrical element, i.e. for example a respective fuse.

The diagnostic device may for example be a device which monitors the voltage level on the branch or branches from the round conductor provided by the small electrical distributor and outputs a corresponding diagnostic signal which may for example be evaluated by the central control unit. For example, a P-type MOSFET may be used, the gate of which is coupled to the voltage path to be monitored. The MOSFET may for example be arranged between a signal conductor conducting a voltage and ground. If there is a short-circuit connection on the voltage path to be monitored, the MOSFET is controlled to conduct and the voltage of the signal conductor is conducted to ground. The signal on the signal conductor transitions from high to low. It is to be understood that a plurality of voltage paths to be monitored can be connected in parallel to the gate of the MOSFET, separated from one another by diodes.

In one embodiment, the first plug contact and the second plug contact can each have a clamping contact for receiving a flat contact strip. As an alternative to, for example, securing the connection to the contact element via the plug contact or the clamping contact of the plug contact, a contact by means of a screw can also be made. The fuse can furthermore be crimped, for example, directly to the copper plate Toxen (double bend crimping).

The first plug contact can have, for example, one clamping contact for each second plug contact. The clamping contact can be used, for example, to receive the usual plug-in fuse in a vehicle, for example a fuse according to ISO8820-3, and to mechanically and electrically contact said fuse.

In one embodiment, the distributed small power distributor can have at least one electrical connection element which can be coupled on the input side to a first plug contact and on the output side to a second plug contact, wherein the at least one connection element can have a receptacle for at least one component.

The connecting element can have, for example, a carrier or a carrier circuit board. Additional components can be arranged on the carrier circuit board with great flexibility. For example, fuse fuses, diagnostic circuits, etc. can be arranged on this connection element. However, additional active components, such as controllers, voltage converters, etc., may also or alternatively be arranged on this printed circuit board. For example, the voltage converter may be arranged directly on the connection element and provide a voltage of 5V or 3.3V for powering the microelectronic element, for example from a 12V wire harness.

IN combination with the controller, the switching CAN be realized, for example, by control commands transmitted via L IN or CAN buses.

The receiving portion for the at least one component can be designed, for example, as a solder joint or a solder pad or as a hole in the circuit board. In addition or alternatively, the connecting element can have a plug contact or a clamping receptacle for further components.

In one embodiment, the distributed power miniaturisation distributor may have a housing which may enclose the first contact element and the second contact element with round conductors. The housing can also have a receptacle for a plug-in fuse or a circuit board and for fixing the wire harness distributor to the vehicle body and thus taking on the function of a holder for the round conductor. For this purpose, the housing can have, for example, holes or latching pins or the like.

The housing may have a plurality of housing elements. For example, the housing may receive a first contact element and a second contact element with round conductors. The housing cover may enclose the housing shell. It should be understood that a corresponding seal can be arranged between the housing shell and the housing cover or between the housing shell and the round conductor or the contact element.

The housing can furthermore serve as a tension release and protect the second contact element against being accidentally pulled out of the first contact element, for example when the first and second contact elements are coupled to one another.

Furthermore, the housing can hold the first contact element and the second contact element in place, if the first contact element and the second contact element have, for example, clamping contacts for receiving a connecting element or a fuse.

In one embodiment, at least one branch can have a distributed small power distributor according to the invention. At least one distributed mini-distributor may be indirectly coupled with at least one customer, and a secondary conductor is disposed between the corresponding distributed mini-distributor and the at least one customer.

A secondary conductor is understood to be a conductor that conducts less electrical power than a primary conductor, i.e. a conductor that conducts less current at the same voltage. The secondary conductor can, for example, also be a round conductor and thus be constructed smaller than the primary conductor. Corresponding small distribution distributors can of course also be provided on the branches from the secondary conductors to the respective consumers.

It should be understood that in principle the secondary conductors may be arbitrarily cascaded. Smaller secondary conductors can thus be branched off from the secondary conductor. Here, it should only be noted that the current carrying capacity of the upper conductor should not exceed the sum of the currents in the lower conductors. The coupling of the secondary conductors to the respective primary conductors can be distributed here by direct connections, for example soldered connections, shrink connections, distributed miniature power distributors according to the invention, etc.

Drawings

Advantageous embodiments of the invention are explained below by referring to the drawings. The figures are as follows:

figure 1 shows a block diagram of an embodiment of a distributed small power distributor according to the present invention;

figure 2 shows a block diagram of a further embodiment of a distributed small power distributor according to the present invention;

figure 3 shows a further block diagram of an embodiment of the distributed small scale power distributor of figure 2 according to the present invention;

figure 4 shows a block diagram of a further embodiment of a distributed small power distributor according to the present invention;

figure 5 shows a further block diagram of the embodiment of the distributed small scale power distributor of figure 4 according to the present invention;

FIG. 6 shows a block diagram of an embodiment of a primary conductor of a conductor system according to the invention;

FIG. 7 shows a flow chart of an embodiment of a manufacturing method according to the invention;

FIG. 8 shows a block diagram of an embodiment of an apparatus for performing at least one step of a manufacturing method according to the invention;

FIG. 9 shows a block diagram of a further embodiment of an apparatus for performing at least one step of a manufacturing method according to the invention;

FIG. 10 shows a block diagram of a further embodiment of an apparatus for performing at least one step of a manufacturing method according to the invention;

fig. 11 shows a schematic representation of a possible embodiment of the first contact element; and

fig. 12 shows a schematic representation of an embodiment of the line system according to the invention.

The drawings are only schematic representations and are intended to be only illustrative of the present invention. Identical or functionally identical elements are provided with the same reference numerals throughout.

Detailed Description

Fig. 1 shows a block diagram of a distributed small power distributor 100. The distributed miniature power distributor 100 is used to branch off the electrical power for several electrical consumers 151 from a circular conductor 150 conducting voltage, said electrical consumers 151 being coupled to the distributed miniature power distributor 100, for example, by means of wires 130. The distributed miniature power distributor 100 has a first contact element 101 coupled with a round conductor 150. Furthermore, the distributed small scale power distributor 100 has a second contact element 102. The second contact element 102 is detachably coupled to the first contact element 101 and thus connects the consumer 151 to the round conductor 150 via the line 103.

By way of example only, the first contact element 101 and the second contact element 102 are illustrated as a plug-and-socket pair. It should be understood that additional implementations are also possible. In particular, further elements may be arranged between the first contact element 101 and the second contact element 102, as explained for example in fig. 2 to 5.

The first contact element 101 is coupled tangentially to the round conductor 151 along the longitudinal axis of the round conductor 151 in a cross section through the round conductor 151, i.e. extends laterally away from the round conductor 151. On the end of the first contact element 101, the first contact element 101 has a socket-like recess into which the second contact element 102 can engage. The notch turns 90 deg. It should be understood that the indentations can also be arranged linearly on the first contact element 101.

With the distributed miniature power distributor 100, branching can be done at any position of the round conductor 150, through which the electrical consumers 151 can be supplied with electrical energy.

Fig. 2 shows a block diagram of a distributed small power distributor 200. The distributed small scale power distributor 200 is based on the distributed small scale power distributor 100 and also has a first contact element 201 coupled with a round conductor 250. Furthermore, a second contact element 202 is provided, which second contact element 202 is provided with a line 203 on the output side in order to contact one or more consumers (not shown).

The distributed small power distributor 200 furthermore has a housing with a first housing shell 205 or yoke and a second housing shell 206. Furthermore, a connecting element 207 is provided, which connecting element 207 is arranged between the first contact element 201 and the second contact element 202. The round conductor 250 is between the first housing shell 205 and the second housing shell 206. If the first housing shell 205 and the second housing shell 206 are split, they thus enclose the round conductor 250 together with the first contact element 201. The second contact element 202 can be introduced into the hollow space of the second housing shell 206, for example, and latched there, for example. It should be understood that additional sealing measures may be implemented, which are not explicitly illustrated here.

In the case of the distributed small scale power distributor 200, the first contact element 201 and the second contact element 202 are introduced into the second housing shell 206 from the same direction. The connecting element 207 is then introduced into the second housing shell 206 from the opposite side. The first contact element 201 and the second contact element 202 may thus for example form a second contact portion of a receiving portion into which the connecting element 207 is inserted.

The connecting element 207 may, for example, have its own housing or be designed as an open element. For example, the connection element 207 may be a carrier circuit board from which contact strips extend in the direction of the first and

second contact elements

201, 202. Further electrical components can be arranged on one or both sides of the carrier circuit board. For example, safety and diagnostic or monitoring devices and/or switching elements can be arranged on the carrier circuit board.

Figure 3 shows an additional block diagram of the distributed small power distributor 200 in an assembled state. In fig. 3 it can be seen how the round conductor 250 with the first contact element 201 is enclosed and held by the first housing shell 205 and the second housing shell 206. It can further be seen that the contact pieces of the connection element 207 engage into the first contact element 201 and the second contact element 202.

Fig. 4 shows a block diagram of a further distributed small power distributor 300. The distributed small power distributor 300 also has a first housing shell 305, said first housing shell 305 receiving a first contact element 301 and a second contact element 302.

The first contact element 301 is coupled, for example welded, to the round conductor 350 and has an angle of 90 °, a portion of the first contact element 301 thus extending parallel to the longitudinal axis of the round conductor 350. The first housing shell 305 encloses the first contact element 301 and the second contact element 302 such that the ends of the first contact element 301 and the second contact element 302 are opposite. The distance between the first contact element 301 and the second contact element 302 is determined by the first housing shell 305 and can be set, for example, such that it is equal to the distance of a typical solder lug of a motor vehicle plug fuse.

The first contact element 301 has a clamping contact 310 and the second contact element 302 has a corresponding clamping contact 311. The clamping

contacts

310, 311 can, for example, receive contact lugs of a motor vehicle plug-in fuse.

It should be understood that a geometry with a plurality of clamping contacts 310 is also selectable at least for the first contact element 301, so that a plurality of second contact elements 302 can be coupled to the first contact element 301, for example, by means of a plug fuse.

Fig. 5 shows an additional block diagram of a distributed mini-distributor 300 with a closed housing. Thus, the second case housing 306 is placed on the first case housing 305. The second housing shell 306 is designed such that it has a receiving opening for the plug-in fuse 307 directly above the clamping contact 310 and the clamping contact 311. When the plug-in fuse 307 is inserted, the second housing shell 306 therefore guides the plug-in fuse 307, so that the contact tabs of the plug-in fuse 307 are inserted directly into the clamping contact 310 and the clamping contact 311.

The second housing shell 306 furthermore has latching

noses

312, 313, which, when the plug-in fuse 307 is inserted, hold the plug-in fuse 307 in place by the latching

noses

312, 313. It will be appreciated that alternative fixings, for example using slides or rods, are also possible. It should further be appreciated that securement may also be provided for the connecting element 207 within the distributed small power distributor 200.

Fig. 6 shows a block diagram of a primary conductor 450 for a distributed small power distributor. The main conductor 450 includes an aluminum core 453 with an outer jacket or insulation 452. The main conductor 450 is partially de-insulated in two locations. At these locations, the primary conductors are contacted by

contact plates

417, 418, respectively. The

contact plates

417, 418 may be welded to the aluminum core 453, for example. Each of the

contact plates

417, 418 is furthermore coupled with a

contact comb

419, 420. The contact combs 419, 420 are made at least for the most part of copper. The unit formed by the

contact plate

417 or 418 and the

contact comb

419 or 420 respectively forms a first contact element.

This design of the first contact element enables a pre-manufacture of the contact element. Thus, the

aluminum contact plates

417, 418 can be connected to the corresponding contact combs 419, 420, for example, by rolling the cladding. Then, corrosion protection, for example made of nickel and zinc or silver or an alloy, can be applied thereon, for example by electroplating. The connection between the contact elements and the main conductor 450 can then be made, for example, by soldering. Since this connection is an aluminum-to-aluminum connection, no high requirements are placed on the protection against corrosion.

For ease of understanding, reference numerals referring to fig. 1 to 6 are maintained in the following description.

Fig. 7 shows a flow chart of a manufacturing method for manufacturing a distributed

small power distributor

100, 200, 300 for branching off electric power for a consumer 151 from a

round conductor

150, 250, 350, 450, 550, 650 conducting voltage.

In a first step "providing" S1, a

first contact element

101, 201, 301 and a number of

second contact elements

102, 202, 302 are provided. In a second step "coupling" S2, the

first contact element

101, 201, 301 is coupled on the input side with the

round conductor

150, 250, 350, 450, 550, 650 and on the output side with the input side of the

second contact element

102, 202, 302. Finally, in a third step "coupling" S3, the

second contact element

102, 202, 302 is coupled on the output side to at least one consumer 151.

The

first contact element

102, 202, 302 can furthermore be provided with a first plug contact on the output side, and the

second contact element

102, 202, 302 can be provided with a second plug contact on the input side. When the

first contact element

102, 202, 302 and one or more

second contact elements

102, 202, 302 are mated, the first plug contact and the second plug contact can be directly engaged inside and outside one another.

In the

first contact element

102, 202, 302, a

contact plate

417, 418, 517, 617, which is designed to be flat, in particular made of aluminum, can be arranged between the

round conductor

150, 250, 350, 450, 550, 650 and the first plug contact. Furthermore, clamping contacts made of copper and/or contact combs 419, 420 made of copper can be arranged on the first plug contact, which are coupled to the

contact plates

417, 418, 517, 617.

Furthermore, electrical components, such as for example safety and/or diagnostic devices, can be arranged between the

first contact element

101, 201, 301 and the

second contact element

102, 202, 302. For this purpose, clamping

contacts

310, 311 for receiving flat contact strips can be arranged on the first plug contact and on the second plug contact, respectively.

The

electrical connection elements

207, 307 can be coupled on the input side with a first plug contact and on the output side with a second plug contact. The

electrical connection element

207, 307 is thus located between the first plug contact and the second plug contact. The connecting

element

207, 307 can furthermore have a receptacle for at least one component.

Finally, a housing may be placed around the

first contact element

101, 201, 301 and the

second contact element

102, 202, 302 with the

round conductors

150, 250, 350, 450, 550, 650. The housing thus encloses the

first contact element

101, 201, 301 and the

second contact element

102, 202, 302 with the

round conductors

150, 250, 350, 450, 550, 650. The housing can at the same time serve as a holder for the connecting element between the

first contact element

101, 201, 301 and the

second contact element

102, 202, 302. This connecting element can be, for example, a fuse (see fig. 5), a circuit board or a conductive bridge.

Fig. 8 shows a block diagram of a welding device 530 for performing at least one step of the manufacturing method according to the invention, showing three different states before, during and after welding.

The left diagram shows the welding equipment before welding. The soldering apparatus 530 has an anvil 534, and the circular conductor 550 rests on the anvil 534. Contact plate 517 is between anvil 534 and round conductor 550. Side sliders 531, 532 are disposed on right and left sides of the anvil 534, respectively. Above the round conductor 550 is arranged an ultrasonic head 533. Since the contact plate 517 protrudes laterally on the left side beyond the anvil 534, the left sliders 531, 532 are correspondingly formed long, so that the left sliders 531, 532 protrude beyond the contact plate 517 up to the circular conductor 550. In addition, the contact comb may be used as a side slider (see fig. 10). Thus, the side slide can be eliminated. This results in greater freedom in the machine installation and also in smaller restrictions in the comb design.

During soldering (middle illustration), the side sliders 531, 532 are guided onto the round conductor 550 and the sonotrode 533 is lowered onto the round conductor 550. The ultrasonic waves emitted by the ultrasonic head 533 weld the contact plate 517 to the round conductor 550. Then, the side sliders 531, 532 return and the welding process ends (right side illustration).

Fig. 9 shows a block diagram of another welding apparatus 630. The welding device 630 is similar to the welding device 530, but the two side slides 631, 632 are identical, i.e. short with respect to the side slide 531. The contact plate 617 in the welding device 630 is bent at the edge of the anvil 534 and therefore requires less space. This enables the use of

short side sliders

631, 632. This

side slide

631, 632 may, for example, already be present in the welding device, which

side slide

631, 632 is already present for contacting the round conductor 650.

It will be appreciated that the contact plates 517, 617 illustrated in fig. 5 and 6 may be contact plates that have been provided with contact combs or additional contact portions.

Fig. 10 shows a block diagram of a further welding device 730. The welding apparatus 730 is similar to the welding apparatus 630, but the welding apparatus 730 has only one side slide 731. The contact 717 is bent upwards by 90 ° on the side opposite the side slide 731 in the welding device 730. The anvil portion 734 has a bulge or seat for the contact portion 717. When the welding device 730 is arranged, only one side slide 731 is present, which significantly simplifies the structure of the welding device 730.

Fig. 11 shows a possible embodiment of a first contact element 817, which can be inserted into the welding device 730. Accordingly, the contact element 817 has a stepped shape which can rest on the anvil portion 734 of the welding device 730.

The contact element 817 furthermore has an opening or hole 835. The holes 835 are used to couple the contact elements 817, for example, with fuses. For this purpose, bolts may be used, for example.

Fig. 12 shows a lead system 940. The wire system 940 has a round conductor 950. The round conductor 950 is coupled with a battery 941. Furthermore, a branch in the form of distributed miniature power distributor 900 is provided on round conductor 950, through which electrical consumers 942 are supplied.

Since the apparatus and method described in detail in the foregoing are examples, the apparatus and method can be modified in a general manner by the person skilled in the art without departing from the scope of the invention. In particular, the mechanical arrangement and dimensional relationship of the various elements to each other is merely exemplary.

List of reference numerals

100. 200, 300, 900 distributed small-sized distributor

101. 201, 301 first contact element

102. 202, 302 second contact element

103. 203, 303 conducting wire

205. 206, 305, 306 shell

207. 307 connecting element

310. 311 clamping contact part

312. 313 latch nose

417. 418, 517, 617, 717, 817 contact plate

419. 420 contact comb

530. 630, 730 welding equipment

531. 532, 631, 632, 731 side slide block

533. 633, 733 ultrasonic head

534. 634, 734 anvil

835 holes

940 conductor system

941 cell

Electrical consumer 942

150. 250, 350, 450, 550, 650, 950 round conductor

151 electrical load

452 aluminium core

453 insulating part

Method steps S1, S2, S3

Claims

1. A distributed miniature power distributor (100, 200, 300, 900) for branching off electric power for a number of electrical consumers (151) from a round conductor (150, 250, 350, 450, 550, 650) conducting voltage, with:

a first contact element (101, 201, 301) and at least one second contact element (102, 202, 302),

wherein the first contact element (101, 201, 301) can be coupled on the input side to the round conductor (150, 250, 350, 450, 550, 650) and on the output side to the input side of the at least one second contact element (102, 202, 302), wherein the at least one second contact element (102, 202, 302) can be coupled on the output side to at least one consumer (151),

wherein the first contact element (101, 201, 301) has a first plug contact or a screw or a bore on the output side and the at least one second contact element (102, 202, 302) has a second plug contact or a corresponding bore or a corresponding screw on the input side,

wherein the first contact element (101, 201, 301) has a contact plate (417, 418, 517, 617, 717, 817) which is designed to be flat for coupling with the round conductor (150, 250, 350, 450, 550, 650), the contact plate (417, 418, 517, 617, 717, 817) being arranged between the round conductor (150, 250, 350, 450, 550, 650) and the first plug contact,

wherein the first contact element (101, 201, 301) is tangentially coupled to the round conductor (150, 250, 350, 450, 550, 650) along a longitudinal axis of the round conductor (150, 250, 350, 450, 550, 650) in a cross section through the round conductor (150, 250, 350, 450, 550, 650).

2. The distributed small power distributor (100, 200, 300, 900) of claim 1, wherein the contact plate (417, 418, 517, 617, 717, 817) is formed of aluminum and the first plug contact portion has a clamping contact portion made of copper.

3. The distributed small power distributor (100, 200, 300, 900) according to claim 1, wherein the contact plate (417, 418, 517, 617, 717, 817) is formed of aluminum and the first plug contact has a contact comb (419, 420) made of copper.

4. The distributed small power distributor (100, 200, 300, 900) according to any of claims 1 to 3, with an electrical connection element arranged between the first contact element (101, 201, 301) and the at least one second contact element (102, 202, 302).

5. The distributed small power distributor (100, 200, 300, 900) according to claim 4, the electrical connection element being an insurance and/or diagnostic device.

6. The distributed small power distributor (100, 200, 300, 900) according to claim 1 or 2, wherein the first plug contact and the second plug contact each have a clamping contact (310, 311) for receiving a flat contact strip.

7. A distributed small power distributor (100, 200, 300, 900) according to any of claims 1 to 3 with at least one electrical connection element (207, 307) coupled with the first plug contact on the input side and with the second plug contact on the output side, wherein at least one electrical connection element (207, 307) has a receptacle for at least one component.

8. A distributed small power distributor (100, 200, 300, 900) according to any of claims 1 to 3 with a housing enclosing the first contact element (101, 201, 301) with the round conductor (150, 250, 350, 450, 550, 650) and the at least one second contact element (102, 202, 302).

9. A line system (940) for supplying electrical loads (151) in a vehicle is provided with

A primary conductor (150, 250, 350, 450, 550, 650), the primary conductor (150, 250, 350, 450, 550, 650) being coupled to an energy source, and

at least one distributed small power distributor (100, 200, 300, 900), the distributed small power distributor (100, 200, 300, 900) being coupled with the main conductor (150, 250, 350, 450, 550, 650) and with at least one electrical consumer (151),

wherein at least one distributed small scale power distributor (100, 200, 300, 900) has a distributed small scale power distributor according to any of claims 1 to 8.

10. The wire system (940) of claim 9, wherein at least one of the distributed small scale power distributors (100, 200, 300, 900) is indirectly coupled with the at least one of the electrical consumers (151) and a secondary conductor is arranged between the corresponding distributed small scale power distributor (100, 200, 300, 900) and the at least one of the electrical consumers (151).

11. A manufacturing method for manufacturing a distributed miniature power distributor (100, 200, 300, 900) for branching off electric power for an electrical consumer (151) from a round conductor (150, 250, 350, 450, 550, 650) conducting voltage, with the following steps:

providing (S1) a first contact element (101, 201, 301) and at least one second contact element (102, 202, 302),

coupling (S2) the first contact element (101, 201, 301) on the input side to the round conductor (150, 250, 350, 450, 550, 650) and on the output side to the input side of the at least one second contact element (102, 202, 302), and

coupling (S3) the at least one second contact element (102, 202, 302) on the output side to the at least one consumer (151),

wherein the first contact element (101, 201, 301) is provided with a first plug contact or a bolt or a hole on the output side and wherein the at least one second contact element (102, 202, 302) is provided with a second plug contact or a corresponding hole or a corresponding bolt, respectively, on the input side,

wherein the first contact element (101, 201, 301) has a contact plate (417, 418, 517, 617, 717, 817) which is designed to be flat for coupling with the round conductor (150, 250, 350, 450, 550, 650), the contact plate (417, 418, 517, 617, 717, 817) being arranged between the round conductor (150, 250, 350, 450, 550, 650) and the first plug contact, and wherein the first contact element (101, 201, 301) is coupled tangentially to the round conductor (150, 250, 350, 450, 550, 650), i.e. extends laterally away from the round conductor, along a longitudinal axis of the round conductor (150, 250, 350, 450, 550, 650) in a cross section through the round conductor (150, 250, 350, 450, 550, 650).

12. Method of manufacturing according to claim 11, wherein a flat contact plate (417, 418, 517, 617, 717, 817) designed for coupling with the round conductor (150, 250, 350, 450, 550, 650) is arranged in the first contact element (101, 201, 301) between the round conductor (150, 250, 350, 450, 550, 650) and the first plug contact, and a clamping contact made of copper is arranged on the first plug contact, wherein an electrical connection element is arranged between the first contact element (101, 201, 301) and the at least one second contact element (102, 202, 302), wherein clamping contacts (310, 311) for receiving flat contact pieces are arranged on the first plug contact and the second plug contact, respectively,

alternatively, a contact comb (419, 420) made of copper is arranged on the first plug contact, wherein an electrical connection element is arranged between the first contact element (101, 201, 301) and the at least one second contact element (102, 202, 302).

13. The manufacturing method according to claim 12, wherein the contact plate (417, 418, 517, 617, 717, 817) is made of aluminum.

14. A method of manufacture as claimed in claim 12, wherein the electrical connection element is an insurance and/or diagnostic device.

15. Manufacturing method according to claim 11 or 12, wherein at least one electrical connection element (207, 307) is coupled with the first plug contact on the input side and with the second plug contact on the output side, wherein the at least one electrical connection element (207, 307) has a receptacle for the at least one component.

16. Manufacturing method according to claim 11 or 12, wherein a housing is placed around the first contact element (101, 201, 301) with the round conductor (150, 250, 350, 450, 550, 650) and the at least one second contact element (102, 202, 302).