DE102005062714B4 - Cable with two conductor systems for power applications - Google Patents

Abstract

Cables (100a to 100e, 100g) for power applications with at least a first and a second conductor system (110, 120), the first conductor system (110) and the second conductor system (120) each having a plurality of isolated individual conductors (110_1, 110_2, 110_3 , 110_4; 120_1, 120_2, 120_3, 120_4), with all individual conductors (110_1, 110_2, 110_3, 110_4) of the first conductor system (110) and all individual conductors (120_1, 120_2, 120_3, 120_4) of the second conductor system (120) in an initial area and in an end area of the cable (100a to 100e, 100g) are each electrically conductively connected to one another, at least one individual conductor (110_1, 110_2, 110_3, 110_4) of the first conductor system (110) at least in sections directly next to and essentially parallel to at least one single conductor (120_1, 120_2, 120_3, 120_4) of the second conductor system (120) is arranged and forms a single conductor group (110_1, 120_1) with this, the cable (100a to 100e, 100g) at least d three individual conductors (120_1, 120_2, 120_3, 120_4) and at least three individual conductor groups (110_1, 120_1; 110_2, 120_2; 110_3, 120_3; 110_4, 120_4), and where sections of the individual conductors (120_1, 120_2, 120_3, 120_4) or individual conductor groups (110_1, 120_1; 110_2, 120_2; 110_3, 120_3; 110_4, 120_4) are intertwined.

Description

The present invention relates to a cable for power applications.

DE 594 855 C apparently a ribbon cable for telecommunication purposes. DE 198 40 757 A1 discloses a connection line for active loudspeaker systems. DE 44 12 749 A1 discloses an apparatus for transmitting signals from an amplifier to a loudspeaker. DE 43 36 230 C1 discloses a low distortion transmitting AC power cable. DE 43 34 961 A1 discloses a cable for signal transmission from an amplifier to a loudspeaker. DE 42 92 010 T1 discloses a connection cable for the transmission of low frequency signals.

DE 20 51 620 B2 discloses a power supply line. EP 0 649 268 A1 discloses an apparatus for signal transmission from an amplifier to a loudspeaker. WO 01/22 435 A1 discloses an intertwined, counter-rotating cable with multiple helices. U.S. 5,122,924 A discloses an electronic component having a plurality of pairs of current carrying paths. U.S. 3,815,054 A discloses a balanced, high frequency, low impedance transmission line. U.S. 1,625,125 A discloses an electrical conductor. US 6 506 971 B1 discloses a small external magnetic field electric cable and a method of manufacturing such a cable. DE 558 622 A discloses a method of making wire groups for telecommunications cables. GB 1 174 944 A discloses an electrical cable for use in telecommunications systems. GB 1 490 532 A discloses an apparatus for making a telecommunications cable. GB 2 326 519 A discloses an electrical cable having conductive and non-conductive braided strands. US 2005/0 045 367 A1 discloses an unshielded twisted pair cable (UTP) with a non-conductive core.

From the US 6,215,062 B1 a cable is known. The cable described there is intended for the transmission of audio signals and has two conductors which are each formed from two individual cables. The individual cables of one conductor are twisted in such a way that openings are created between the intersecting areas of the individual cables through which the individual cables of the other conductor are fed. Overall, the known cable has an orthogonal braided pattern. In this way and due to the symmetrical structure, a conductor connected to the ground potential or its individual cable acts as a ground plane for the individual cables of the other conductor, which means that the cable is less sensitive to common-mode interference and audio signals transmitted via the cable are accordingly less exposed to external interference.

Although the cable according to the US 6,215,062 B1 offers improved protection against interference radiation in the cable or, in the case of an implementation of two different audio channels through the described "ground plane", also improved signal separation of the two audio signals carried by the cable, the configuration described there does not solve the problem of the cable To reduce outgoing electrical and especially magnetic fields that are radiated into the vicinity of the cable and can affect other devices or other components or people in the vicinity.

In addition, it shows US 6,215,062 B1 Due to the orthogonal braiding pattern, cables have such a low copper fill factor that it is unsuitable for power applications.

Accordingly, it is the object of the present invention to develop a cable for power applications in such a way that electromagnetic fields emanating from the cable are reduced and yet there is great flexibility and thus easy laying.

According to the invention, this object is achieved in a cable for power applications in that the cable has at least a first and a second conductor system, the first conductor system and the second conductor system each having a plurality of isolated individual conductors, all individual conductors of the first conductor system and all individual conductors of the second conductor system in a starting area and in an end area of the cable are each electrically conductively connected to one another, with at least one individual conductor of the first conductor system being arranged at least in sections directly next to and essentially parallel to at least one individual conductor of the second conductor system and forming a group of individual conductors with it the cable has at least three individual conductors and at least three groups of individual conductors, and with sections of the individual conductors or groups of individual conductors being interwoven.

The inventive arrangement of the individual conductors of different conductor systems directly next to one another and essentially parallel to one another enables, when the cable is operated in which the first conductor system is used, for example, as an outgoing conductor and the second conductor system, for example, as a return conductor, that in particular the magnetic fields in the individual conductors of the respective Single conductor group of flowing, anti-parallel currents at least partially compensate each other.

In this way, the load of an environment of the cable according to the invention with a the magnetic field emanating from the cable is significantly reduced. A maximum compensation effect can be achieved if all individual conductors of the cable according to the invention are combined with a corresponding individual conductor of another conductor system carrying an anti-parallel current. In this case, the compensation effect occurs for all individual conductor groups.

A particular advantage of the cable according to the invention is that, due to its reduced magnetic field compared to conventional cables, it can be laid closer to other cables or other metallic assemblies. In this way, especially in vehicles or other environments with little available space, an efficient transport of electrical power to a consumer is possible without increased eddy currents or other magnetic influences occurring.

In a typical configuration, the cable according to the invention has two conductor systems, one of which is designed as a forward conductor and one as a return conductor. The currents in the forward conductor and the return conductor, which are divided between them according to the respective number of individual conductors, are antiparallel to one another and their magnetic fields therefore at least partially compensate one another. It is obvious that the described compensation effect occurs when the cable is operated with direct current, just as when the cable is operated with alternating current of, for example, 50 Hz.

Even with currents with higher frequencies up to the three-digit kilohertz range, the configuration of the cable according to the invention results in a lower magnetic field in the vicinity of the cable. Therefore, the cable according to the invention is also particularly suitable for energy transmission within clocked, i.e. e.g. by means of pulse width modulation or the like, operated loads, for supplying asynchronous machines, permanently excited synchronous machines and other electrical loads.

Compared to conventional cables, the cable according to the invention is generally particularly suitable for use in applications that require high currents or current densities in the cable and high frequencies and at the same time place particularly high demands on electromagnetic radiation emanating from the cable or its reduction.

The compensation effect according to the invention is not achieved solely in that a single conductor of the first conductor system is routed together with a single conductor of the second conductor system over the entire cable length. Rather, it is also possible that these two individual conductors together form the magnetic field-compensating group of individual conductors, for example over a first section of the cable. In a further section of the cable, a comparable group of individual conductors can be formed by the same individual conductor of the first conductor system and another individual conductor of the second conductor system, etc.

In addition, e.g. two or more individual conductors of the first conductor system and a single cable of the second conductor system can be combined to form a single conductor group, etc.

One criterion for achieving an optimal compensation effect is, for example, to combine such individual conductors in a single conductor group in which, as expected, comparable current intensities result when the cable is in operation. For complex geometries of the individual conductors, optimization can be supported, for example, by means of a simulation of the resulting magnetic field of a group of individual conductors.

In the same way, using the principle according to the invention, cables comprising three or four conductor systems can also be provided, for example for the implementation of three-phase cables. In this case, too, the individual conductors of different conductor systems are combined into individual conductor groups in which the magnetic fields of the currents flowing through them essentially compensate each other.

Another advantage of the inventive division of the conductor systems into insulated individual conductors is that there is a sufficient conductor cross-section in the cable that can carry the currents, even with high-frequency currents, despite the reduced penetration depth or conductive layer thickness due to the skin effect.

Furthermore, the implementation of the entire conductor cross-section of a conductor system in the form of several individual conductors results in greater mechanical flexibility of the entire cable, so that it can be bent and laid more easily compared to conventional cables with a comparable current carrying capacity. Because of this, the cable according to the invention is also particularly suitable for power transmission in vehicles and machines which have relatively narrow cable ducts, bushings and the like.

Interweaving groups of individual conductors is always possible without impairing the inventive compensation effect of the respective group of individual conductors. The cable according to the invention thus comprises a multiplicity of individual conductor groups with a plurality of individual conductors, and the individual conductor groups or individual conductors are interwoven in sections, as is known, for example, from conventional cables in which, for example, two or more individual wires are interwoven. In addition to the compensation effect according to the invention, such an arrangement has increased mechanical stability due to the interlacing.

A combination of the above-mentioned measures is particularly advantageous in such a way that the individual conductors are routed in parallel next to one another over a relatively large proportion of the cable length in order to reduce the magnetic field emanating from the cable. At the same time, for example, various individual conductors or groups of individual conductors can be interlaced periodically at predefinable intervals in order to increase the mechanical stability of the cable. In this case, there is no interlacing over the entire length of the cable, but rather the cable is only interlaced in sections, and the essential length portion has individual conductors that are parallel to one another and run next to one another.

As a support, it can be provided that the respective individual conductors are arranged directly next to one another and parallel to one another over a total length of at least 20 percent, preferably at least 40 percent, of the entire length of the cable. Such a length portion is preferably obtained through a periodic alternation of cable areas with parallel routing of the individual conductors and cable areas with interlacing.

In addition, it is possible to continuously interweave various individual conductors or groups of individual conductors with one another over the entire length of the cable, preferably only part of the individual conductors or groups of individual conductors of the cable being included in the braiding pattern. In this way, for example, a first number of individual conductors, which are interwoven within the section, and a second number of the remaining individual conductors, which are arranged parallel to one another, are located in a cable section under consideration. In a next cable section, the relationships can be inverse, or part of the first number of individual conductors is intertwined with some of the individual conductors that have not been included in the braided pattern since then, while the other part of the first number of individual conductors is now routed in parallel.

One or more preferably non-metallic guides can also be integrated into the braid as a support. In addition, it is possible to provide a braid surrounding the cable, which further increases the mechanical stability of the cable. Such a braid can preferably contain non-conductive materials such as PVC or other plastics or metallic components and a combination thereof. In this case it is also conceivable not to strand or braid the individual conductors of the cable, but rather to arrange them parallel and next to one another over the entire length of the cable. Partial interweaving of the individual conductors or guides that fix the individual conductors with the braid surrounding the cable is also expedient.

Although the use of a periodic braid pattern is preferred for realizing the cable according to the invention, it is also possible to use a random braid pattern. In order to achieve the desired compensation effect here too, care must be taken to ensure that at least some of the individual conductors are routed parallel to one another over a minimum, predeterminable length of the cable. As already described, this predeterminable length section can also be composed of several individual sections of a corresponding configuration.

In support, it can be provided that individual conductors and / or individual conductor groups are twisted and / or stranded with one another and / or with one another. Stranding of the individual conductors and / or entire groups of individual conductors is also possible. In a particularly advantageous manner, stranding results in a further reduction in the magnetic field emanating from the cable during its operation due to the periodically changing arrangement of the stranded components over the length of the cable.

In a stranding of a single conductor group, which is implemented, for example, by winding the individual conductors involved onto a, for example, centrally arranged winding body, the inventive parallel juxtaposition of the individual conductors and thus the magnetic field compensation are retained, so that even a purely stranded cable, ie a cable without Interweaving of the individual conductors, which has the advantages mentioned.

According to a further very advantageous embodiment of the invention, several individual conductors of a conductor system are arranged rotationally symmetrically around a longitudinal axis of the cable.

In a further very advantageous embodiment of the present invention it is provided that several individual conductors of a conductor system are arranged rotationally symmetrically about a longitudinal axis of an individual conductor of another conductor system. This arrangement is very useful in particular when the individual conductors of the two conductor systems have different cross-sectional areas.

In another very advantageous embodiment of the present invention it is provided that three individual conductors each Conductor system are arranged around the longitudinal axis of the cable that the centers of their cross-sectional areas lie approximately on the corners of an imaginary equilateral triangle. This arrangement of the individual conductors is particularly useful in three-phase cables comprising three or four conductor systems.

In a further particularly advantageous embodiment of the present invention, it is provided that the conductor systems or the individual conductors of one or more conductor systems are arranged such that the cable has an essentially triangular, square or hexagonal cross section. In principle, other cross-sectional shapes, such as circular, ellipse and the like, are also possible with the cable according to the invention, but the design of the cable with a triangular, square or hexagonal cross-section enables the cable to be laid and stacked particularly well. In particular, several cables according to the invention can thus be arranged in a particularly space-saving manner, e.g. in a cable duct or the like.

Overall, the majority of the individual conductors, which together form a conductor system of the cable according to the invention, already provide a very simple scalability of the entire cable. In order to provide a second cable based on a first cable according to the invention, for example, which is designed for a nominal current twice as high as the first cable, only the number of individual conductors of the respective conductor systems of the cable has to be increased so that overall the desired conductor cross-section is obtained.

Another advantage with regard to the scalability of the cable according to the invention arises when the cable is designed in such a way that it has, for example, a triangular or square cross-section. In this case, an existing cable can be scaled with a suitable braiding or twisting pattern by adding a cable of the same type to the existing cable. The two cables are preferably arranged next to one another in such a way that individual conductors of different conductor systems of the adjacent cables complement each other in implementing the principle according to the invention and in turn form individual conductor groups.

Another very advantageous embodiment of the present invention provides that the conductor systems or the individual conductors of one or more conductor systems are arranged and / or twisted and / or braided in a transition area in such a way that the cable has a different cross-sectional shape before the transition area than after the transition area. In other words, a special arrangement of the individual conductors in the transition area enables the cross-sectional shape of the cable to be changed and thus a particularly individual adaptation of the cable to special installation situations.

In the case of cables with a rectangular cross section, the configuration described above can be used, for example, to change the flexibility of the cable with respect to an axis that is orthogonal to the longitudinal axis of the cable.

Another possibility, which is advantageous in this embodiment of the invention, is that the cable can be converted from, for example, a round or polygonal cross-section into an essentially flat cable with a few layers or even only one layer of individual conductors, for example around adapt the outer shape of the cable to a specially shaped connection area such as a contact block or a plug or the like.

In a further, very particularly advantageous embodiment of the present invention, it is provided that at least one individual conductor has a stranded wire consisting of a plurality of individual wires, in particular a copper stranded wire.

In another embodiment of the invention, it is also conceivable that the individual wires of the braid are insulated.

In general, all metals suitable as current conductors for power applications, in particular copper and / or aluminum, come into consideration as the material for forming the stranded wire or conductor systems of the individual conductors not designed as a stranded wire.

According to a further variant of the invention, the cable particularly advantageously has insulation that encases several or all of the individual conductors. In addition to the electrical function, the insulation can also contribute to the mechanical stabilization of the cable.

In addition, it can be provided that the insulation of a single conductor and / or the cable has a dielectric strength of at least 42 volts, preferably at least 60 volts, or of at least 700 volts, in particular of at least 1000 volts.

While when the cable according to the invention is used in the automotive sector with conventional on-board voltages of 12 volts, 24 volts or 42 volts, a dielectric strength of at least 42 volts, preferably at least 60 volts, is sufficient, when used in other energy systems it may be necessary that the Cable or its insulation (s) have a dielectric strength of up to 1000 volts.

The use of the cable according to the invention in modern hybrid vehicles which, in addition to an internal combustion engine, also has an electric motor as a drive, or in vehicles driven purely by an electric motor, is also very advantageous.

For special applications, it is also conceivable to use insulation that has a nominal voltage higher than 1000 volts.

Another advantageous embodiment of the invention proposes that the insulation of an individual conductor has a layer of lacquer and / or a plastic sheath.

In another embodiment it is provided that the individual conductors of all conductor systems have essentially the same cross section. A particularly simple production of the cable according to the invention results when all the individual conductors have the same cross-sectional shape and the same size.

However, it is also conceivable to configure the cable according to the invention in such a way that different individual conductors each have different and / or different sized cross-sections, which results in degrees of freedom in the arrangement of the individual conductors and with regard to possible braiding patterns or stranding patterns.

Power applications for conducting currents> = 1 ampere are particularly useful because the magnetic field compensation according to the invention is particularly useful for larger currents. In particular, the cable according to the invention is therefore advantageously used in power applications from active powers of 100 watts.

A conductor system of the cable according to the invention very advantageously has a conductor cross-section totaling at least ten square millimeters, i.e. taking into account all the individual conductors belonging to this conductor system. Conductor cross-sections of up to 120 square millimeters and more are also conceivable, especially for applications in the automotive sector with relatively low voltages. Due to the almost arbitrary scalability of the cable according to the invention already described, an adaptation of the cable to other nominal currents or other required line cross-sections is easily possible at any time.

In a further very advantageous embodiment of the present invention, at least one individual conductor has a rectangular cross section. Such a design of the individual conductors is particularly interesting for those high-voltage applications that do not require stranding or interlacing of the individual conductors.

Further advantages, features and details emerge from the following description, in which various exemplary embodiments of the invention are shown with reference to the drawing. The features mentioned in the claims and in the description can each be essential to the invention individually or in any combination.

• 1a einen Querschnitt einer ersten Ausführungsform des erfindungsgemäßen Kabels,
• 1b einen Querschnitt des in 1a abgebildeten Kabels an einer anderen Stelle des Kabels,
• 1c eine Detailansicht des Querschnitts aus 1b,
• 1d eine Seitenansicht einer Variante des in den 1a und 1b abgebildeten Kabels,
• 1e eine Seitenansicht einer Variante des in den 1a und 1b abgebildeten Kabels,
• 2a einen Querschnitt einer zweiten Ausführungsform des erfindungsgemäßen Kabels,
• 2b einen Querschnitt einer dritten Ausführungsform des erfindungsgemäßen Kabels,
• 2c einen Querschnitt einer vierten Ausführungsform des erfindungsgemäßen Kabels,
• 2d, 2e jeweils einen möglichen Querschnitt des in 2a abgebildeten Kabels,
• 3a einen Querschnitt einer weiteren Ausführungsform des erfindungsgemäßen Kabels, die zur Realisierung eines Dreiphasensystems geeignet ist,
• 3b einen Querschnitt der ein erstes Leitersystem des in 3a gezeigten Kabels bildenden Einzelleiter,
• 3c einen Querschnitt der ein zweites Leitersystem des in 3a gezeigten Kabels bildenden Einzelleiter,
• 4 einen Querschnitt einer anderen Ausführungsform des erfindungsgemäßen Kabels, die zur Realisierung eines Dreiphasensystems geeignet ist,
• 5a- 5c jeweils einen Querschnitt eines nicht vom Schutzumfang des Patents umfassten Kabels,
• 6a einen Querschnitt einer weiteren Ausführungsform des erfindungsgemäßen Kabels,
• 6b einen weiteren Querschnitt des in 6a gezeigten Kabels, und
• 6c schematisch eine Seitenansicht des in den 6a, 6b abgebildeten Kabels einschließlich eines Übergangsbereichs.

In the drawing shows:

• 1a a cross section of a first embodiment of the cable according to the invention,
• 1b a cross section of the in 1a shown cable at a different point on the cable,
• 1c a detailed view of the cross section 1b ,
• 1d a side view of a variant of the in the 1a and 1b shown cable,
• 1e a side view of a variant of the in the 1a and 1b shown cable,
• 2a a cross section of a second embodiment of the cable according to the invention,
• 2 B a cross section of a third embodiment of the cable according to the invention,
• 2c a cross section of a fourth embodiment of the cable according to the invention,
• 2d , 2e each possible cross-section of the in 2a shown cable,
• 3a a cross section of a further embodiment of the cable according to the invention, which is suitable for realizing a three-phase system,
• 3b a cross section of a first conductor system of the in 3a shown cable forming single conductor,
• 3c a cross section of a second conductor system of the in 3a shown cable forming single conductor,
• 4th a cross section of another embodiment of the cable according to the invention, which is suitable for realizing a three-phase system,
• 5a - 5c each a cross section of a cable not covered by the scope of protection of the patent,
• 6a a cross section of a further embodiment of the cable according to the invention,
• 6b another cross-section of the in 6a shown cable, and
• 6c schematically a side view of the in the 6a , 6b shown cable including a transition area.

1a shows a cross section of a first embodiment of the cable according to the invention 100a . The cable 100a has a first ladder system that consists of the four individual ladders 110_1 , 110_2 , 110_3 , 110_4 is formed. Furthermore, the cable 100a a second ladder system consisting of the four individual ladders 120_1 , 120_2 , 120_3 , 120_4 is formed.

The single ladder 110_1 , 110_2 , 110_3 , 110_4 , 120_1 , 120_2 , 120_3 , 120_4 each have their own, not in 1a the isolation shown, ie they are electrically isolated from one another.

One the single ladder 110_1 , 120_1 detailed view is in 1c specified. The isolation is from this detailed view 110_1a of the single conductor 110_1 and analogous to this the isolation 120_1a of the single conductor 120_1 evident. The other individual conductors 110_2 , 110_3 , 110_4 , 120_2 , 120_3 , 120_4 of the cable have a comparable insulation, which is, for example, one or more layers of lacquer, a plastic sheath made of PVC or other suitable materials.

The single ladder 110_1 , 110_2 , 110_3 , 110_4 , 120_1 , 120_2 , 120_3 , 120_4 of the respective conductor system are at a beginning and preferably also at one end of the cable 100a connected to each other and thus represent the corresponding connection of the relevant conductor system.

According to the invention, there is at least one single conductor 110_1 of the first conductor system at least in sections directly next to and essentially parallel to at least one individual conductor 120_1 of the second conductor system and forms with this a single conductor group 110_1 , 120_1 .

Further individual leader groups are - as from 1a visible - in each case from the other individual ladders 110_2 , 110_3 , 110_4 , 120_2 , 120_3 , 120_4 educated.

The cable according to the invention 100a is preferably used as a forward and return conductor, for example to supply an electrical machine, the first conductor system, for example, assuming the function of the forward conductor, and the second conductor system, for example, assuming the function of the return conductor.

Regardless of whether the forward or return conductor is supplied with direct current or alternating current, this configuration results in anti-parallel currents in the individual conductors of the conductor systems of the cable 100a . Due to the inventive division of the conductor systems into the individual conductors described and their arrangement in pairs, the magnetic fields of the individual conductors caused by the antiparallel currents compensate at least partially, so that one of the cable 100a overall generated magnetic field is less strong and less extensive than with conventional cables without the inventive arrangement of the individual conductors.

For example, the magnetic fields of the individual conductors compensate each other 110_1 and 120_1 flowing, anti-parallel currents at least partially. The same effect is achieved with the other individual conductor groups such as, for example 110_2 , 120_2 ; 110_3 , 120_3 ; 110_4 , 120_4 also achieved.

Due to the configuration of the individual conductors according to the invention, the cable 100a be laid closer to other cables (not shown) without disturbing these or signals transmitted to them by the magnetic field it creates. Furthermore, the division of the two conductor systems into the present total of eight individual conductors enables the cable to be laid better 100a because the individual conductors are mechanically far more flexible than a single, solid conductor system with a cross-sectional area that corresponds to the sum of the cross-sectional areas of the individual conductors.

The individual conductors in turn preferably each have a stranded wire, for example a copper strand, which further increases the flexibility of the individual conductors.

Yet another advantage of the cable according to the invention 100a consists in an improved conductivity in the case of high-frequency currents, in which the penetration depth or the equivalent conductive layer thickness is reduced due to the skin effect and accordingly the entire available cross-sectional area of a conductor system is no longer used.

The cable according to the invention 100a as in 1a indicated by the hexagon shown with a dashed line has a substantially hexagonal cross-sectional area and is accordingly easy to stack or to be lined up with other cables of the same type or to be laid next to them.

To protect or mechanically stabilize the cable 100a can in the area of the in 1a The hexagon indicated by dashed lines also covers the entire cable 100a comprehensive isolation can be provided.

The insulation of the cable 100a or a single conductor 110_1 , 110_2 ( 1c ) can have a dielectric strength of at least 42 volts, preferably at least 60 volts, or at least 700 volts, in particular at least 1000 volts, depending on the area of application.

To achieve the described magnetic field compensation over the largest possible length of the cable 100a can achieve the entire cable 100a the in 1a have shown cross-section. Ie, the single ladder 110_1 , 110_2 , .. are arranged relative to each other as shown, which effectively reduces the cable 100a radiated magnetic field over its entire length results. In this case the already mentioned cable is used advantageously 100a enveloping insulation of the stabilization of the cable 100a . This insulation does not have to cover the entire length of the cable 100a be provided, but can for example be periodically distributed over the length of the cable.

In a further very particularly advantageous embodiment of the cable according to the invention, the individual conductors are 110_1 , 110_2 , 110_3 , 110_4 ; 120_1 , 120_2 , 120_3 , 120_4 and / or stranded the individual conductor groups. Since the juxtaposition and parallelism of various individual conductors of a single conductor group is retained during stranding, a cable with stranded components also has the advantage of the reduced magnetic field according to the invention. The stranding can be carried out in a similar way to conventional cables by winding the relevant components onto a central winding body (not shown) and, in addition to increased mechanical stability due to the changing arrangement of the stranded components of the cable, also results in a further reduction in the magnetic field emanating from the cable.

1d shows a variant of the cable 100a in a side view showing the periodic between a beginning 101 and an end 102 of the cable 100a arranged isolation 103 is recognizable.

In addition or as an alternative, a guide (not shown) preferably made of electrically non-conductive material can be used to hold the individual conductors of the cable 100a in your in 1a to fix the position shown. Such a guide can in turn have, for example, several ropes which are interwoven with one another and around individual or several individual conductors.

The combination of such a guide with a cable 100a enveloping braided shield, as is known from coaxial cables, is also conceivable.

Another aspect of the present invention provides that several individual conductors of the cable 100a are twisted together. For example, the individual conductors 110_2 and 120_2 are twisted with one another without losing their arrangement according to the invention directly next to one another and parallel to one another; ie even with such a twisting, the compensation effect according to the invention remains with regard to that of the cable 100a obtained magnetic field. The other individual conductors are also advantageous 110_1 , 120_1 ; 110_3 , 120_3 ; 110_4 , 120_4 twisted together in the same way, so that the cross-section of the entire cable 100a in the 1b the configuration shown. The full magnetic field compensation according to the invention is also given in this configuration. In addition, the above-described twisting increases the stability of the cable 100a increased.

The twisting can be carried out continuously, for example, preferably over the entire length of the cable. As an alternative to this, it is also possible to twist the individual conductors in sections in the manner described.

A corresponding configuration is exemplified in the 1e shown, which is a side view of another variant of the cable 100a out 1a reproduces.

Over a first length section 104 of the cable 100a all single conductors run out as in the cross-section 1a indicated, and over a subsequent length section 105 of the cable 100a the individual conductors are twisted as described, e.g. in pairs, until the cross-sectional configuration, for example, is correct 1b results. This is followed by the cable 100a a third section of length 106 over which the cable 100a the cross-section according to 1b maintains, etc.

To increase the stability brought about by the twisting, in successive sections 105 different individual conductors each have to be twisted together.

As an alternative or in addition, groups of individual conductors can also be twisted with one another or with individual conductors.

In addition, it is also possible for individual conductors and / or individual conductor groups to be interwoven with one another and / or with one another, as a result of which there is a further increase in the stability of the cable according to the invention 100a results.

The braid pattern can be periodic or random. However, in order to ensure the magnetic field compensation according to the invention, this is Braided pattern or the resulting arrangement of individual conductors or groups of individual conductors are preferably arranged in such a way that the respective individual conductors of the cable 100a in total over a length of at least 20 percent, preferably at least 40 percent, of the entire length of the cable 100a run right next to each other and parallel to each other.

For example, a braided pattern can be used in which the individual conductors of a single conductor group per braiding period are only arranged over as short a section as possible, not parallel and directly next to one another.

The combination of braided individual conductors with a twist or the integration of one or more guides or insulation is also particularly advantageous.

A particularly stable arrangement of a guide or shield on or around the cable 100a results from interweaving the elements of the guide or shielding with the interwoven individual conductors of the cable 100a .

Another advantageous embodiment of the invention is shown in FIG 2a pictured showing the cross section of a cable 100b shows, which has a rectangular cross-sectional shape and can thus be arranged or combined particularly well with other similar cables and generally a large conductor cross-section based on the entire cross-sectional area of the cable 100b offers.

Also in the embodiment according to 2a points the cable 100b in pairs to form single conductor groups 110_1 , 120_1 ; 110_2 , 120_2 combined individual conductors arranged according to the invention 110_1 , 110_2 , 120_1 , 120_2 , .. on.

A further increase in the resulting conductor cross-section while maintaining the same cross-sectional shape of the cable 100b can be implemented using individual conductors, which in turn have an essentially rectangular cross-section.

In the 2 B shown variant of the cable 100b additionally has guides arranged in spaces between the individual conductors 140 on, which are preferably made of non-conductive material and can be included in a stabilizing braid (not shown).

To get information about those in the cable 100b Ruling electromagnetic fields can be used instead of a guide 140 or in addition to this, one or more largely shielded measuring lines, in particular designed as coaxial cables 140a be provided whose shielding is removed over a length range of interest and thus the coupling of electromagnetic waves into the measuring line 140a permitted. That when operating the cable 100b into the measuring line 140a The coupled-in signal can be processed by appropriate evaluation electronics, for example in the area of the beginning of the cable 101 or cable end 102 ( 1d ) to the test lead 140a connected, can be evaluated. The test lead 140a can also be in a different area than the end areas 101 , 102 from the cable 100b be led out.

With this variant of the invention there is advantageously the possibility of measuring a current flowing in the cable using the magnetic field it causes, thus avoiding complex and expensive shunts, as are used in conventional cables for power applications for current measurement. With this type of current measurement, the omission of the shunt also results in a more compact configuration, which is very advantageous.

The integration of further cables into the cable according to the invention is also conceivable. For example, one or more plastic optical waveguides can also be particularly advantageous 140b together with the individual conductors or individual conductor groups of the cable according to the invention are combined to form a cable. This combination enables, for example, a transmission of control signals that are necessary for the operation of a system which uses the electrical conductor systems of the cable according to the invention for energy transmission. In addition to the reduced laying effort for such a combined cable, mechanical support or protection of the optical waveguide cable is also very advantageous 140b through the electrical conductor systems of the cable according to the invention.

2c gives the cross section of another variant of the cable according to the invention 100c again, which also has a substantially rectangular cross-section.

In addition to hexagonal and square cross-sectional shapes, in particular circular or elliptical cross-sectional shapes or other cross-sectional shapes such as 8-shaped or L- or T-shaped or other cross-sections can be realized by the cable according to the invention, so that in addition to the reduced magnetic field radiation according to the invention, maximum flexibility and universal Usability is given.

As with an in 1a The cables shown can also be used in the case of a cable having a rectangular cross section 100b some or all of the individual conductors and / or individual conductor groups can be twisted and / or interwoven with one another and / or with one another, extending over the length of the cable 100b for example those in the 2d and 2e shown cross-sections.

The cable 100b is also particularly well scalable by means of a periodic continuation of its in 2d shown cross-section. Around the cross-sectional area of the cable 100b to double, it is sufficient to use a cable of the same type, e.g. in 2d to the right of the cable 100b to arrange and the corresponding individual conductors of the two conductor systems at the beginning of the cable or at the end of the cable 100b to connect with each other. As a result, each of the two conductor systems of the cable 100b now double the number of individual conductors and thus effectively double the cross-sectional area.

3a shows a cross section of another cable 100d , which is particularly suitable for the implementation of a three-phase system, as it is used in three-phase systems.

The cable 100d has a centrally located guide 140 on, among other things, to stabilize the individual conductors arranged around them of the total of three conductor systems of the cable 100d is provided.

The first conductor system of the cable 100d is in 3a indicated by oblique hatching, and a first single conductor is an example 110_1 of the first ladder system.

The second ladder system 120 of the cable 100d is in 3b specified in more detail and has a total of six unspecified individual conductors, which are rotationally symmetrical about a longitudinal axis of the cable 100d are arranged. The central leadership 140 ( 3a) of the cable 100d is in 3b indicated by the dashed circle.

The third ladder system 130 of the cable 100d is in 3c shown in more detail and has a total of six individual conductors, not shown, which are also rotationally symmetrical about a longitudinal axis of the cable 100d are arranged. The central leadership 140 ( 3a) of the cable 100d is in 3c indicated by the dashed circle.

4th shows a cross section of another cable 100e , which is also particularly suitable for the implementation of a three-phase system, as is used in three-phase systems.

In contrast to the one with reference to the 3a until 3c described cable 100d assign the single ladder 110_1 , 120_1 , 130_1 , .. of the cable 100e different cross-sectional areas.

With both cables 100d , 100e the compensation according to the invention results advantageously from the cable 100d , 100e emitted magnetic field due to the parallel and side by side arranged individual conductors of the different conductor systems 110 , 120 , 130 .

Even with the cables 100d , 100e twisting and / or interweaving of individual or several individual conductors, groups of individual conductors with one another or with one another or, in general, stranding is possible. The referring to the 1 , 2 The principles explained to ensure the beneficial compensation effects apply accordingly.

With reference to FIG 5a until 5c a cable 100f indicated, which is not within the scope of the patent and is for explanatory purposes only.

The cable 100f has a total of six individual conductors 110_1 , 110_2 , 110_3 , .. on which together the first of two conductor systems of the cable 100f form. Likewise, the cable 100f a total of six individual conductors 120_1 , 120_2 , 120_3 , .. on which in turn together the second of the two conductor systems of the cable 100f form.

All individual conductors of the cable 100f As already described, have their own insulation, which, for example, can have one or more layers of lacquer and / or a plastic cover. For the sake of clarity, there is only the isolation 110_1a , 120_1a the single conductor 110_1 , 120_1 in the 5a until 5c pictured.

Such as from 5a can be seen, point the individual conductors 110_1 , 120_1 compared to the other individual conductors 110_2 , 110_3 , 120_2 , 120_3 , .. a relatively large cross-section. For improved compensation for a current flow through the individual conductors 110_1 , 120_1 The resulting magnetic fields are the other individual conductors 110_2 , 110_3 , 120_2 , 120_3 , .. each rotationally symmetrical about a longitudinal axis of the corresponding individual conductor 110_1 , 120_1 arranged.

The cable can be particularly advantageous 100f by twisting or braiding individual or multiple individual conductors 110_2 , 120_2 be stabilized with a smaller cross-section.

For example, this becomes a single conductor 110_2 of the first conductor system of the cable 100f with the single conductor 120_2 of the second conductor system of the cable 100f twisted. This results in different places on the cable 110f each in the 5a until 5c shown cross-section.

In addition, one cannot be in the 5a until 5c shown routing of the cable 100f also be intertwined.

In a further particularly advantageous variant of the invention, it is provided that the conductor systems or the individual conductors of one or more conductor systems are in a transition area 150 ( 6c ) of the cable 100 g so arranged and / or twisted and / or braided that the cable 100 g before the transition area 150 has a different cross-sectional shape than after the transition area 150 .

6a accordingly shows the cross section of the in 6c cable shown in a side view 100f with respect to the line aa looking in the direction of the arrow. This cross section is essentially square and has an alternating arrangement of individual conductors next to one another 110_1 , 120_1 , .. of the two conductor systems of the cable 100f on.

Within the transition area 150 ( 6c ) this cross-section is created by suitable interlacing or twisting of the individual conductors or another suitable arrangement of the individual conductors in the in 6b The cross-section shown is transformed by the cable 100f for example along the line bb ( 6c ) having.

The dashed circles in 6b indicate the location of the individual ladders in front of the transition area 150 , i.e. in 6c to the left of the transition area 150 , at that in a behind the transition area 150 , i.e. in 6c to the right of the transition area 150 lying area form the laterally outer individual conductors, cf. 6b .

The transition area according to the invention 150 allows the cross-sectional shape of the cable to be changed 100 g with simultaneous stabilization due to the twisting or interlacing of individual conductors.

In preferred variants of the cable according to the invention, the insulation 110_1a , 120_1a of a single conductor and / or the cable itself has a dielectric strength of at least 42 volts, preferably at least 60 volts, or of at least 700 volts, in particular of at least 1000 volts. These voltage values result from the main areas of application of the cable according to the invention in the motor vehicle sector, for example for the transmission of energy between a power source and an electric motor of a motor vehicle equipped with a hybrid drive or a purely electric vehicle, and generally in power electronics.

In preferred variants of the cable according to the invention, at least one conductor system of the cable has a conductor cross-section totaling at least ten square millimeters. That is, the sum of the cross-sectional areas of all individual conductors is preferably at least ten square millimeters. However, the cross-sectional area of a conductor system can also be up to 120 square millimeters or more.

By way of example, cables according to the invention configured in this way are suitable for the transmission of electrical powers of up to 5 kW or more. Due to the magnetic field compensation, the cable according to the invention is particularly well suited for transporting energy by means of switched currents, such as those used in controls based on pulse width modulation.

An effective reduction in the magnetic field radiated by the cable according to the invention is to be expected up to frequencies of the currents conducted via the cable of up to 100 kHz and more.

Claims (21)

Cables (100a to 100e, 100g) for power applications with at least a first and a second conductor system (110, 120), the first conductor system (110) and the second conductor system (120) each having a plurality of isolated individual conductors (110_1, 110_2, 110_3 , 110_4; 120_1, 120_2, 120_3, 120_4), with all individual conductors (110_1, 110_2, 110_3, 110_4) of the first conductor system (110) and all individual conductors (120_1, 120_2, 120_3, 120_4) of the second conductor system (120) in an initial area and in an end area of the cable (100a to 100e, 100g) are each electrically conductively connected to one another, at least one individual conductor (110_1, 110_2, 110_3, 110_4) of the first conductor system (110) at least in sections directly next to and essentially parallel to at least one single conductor (120_1, 120_2, 120_3, 120_4) of the second conductor system (120) is arranged and forms a single conductor group (110_1, 120_1) with this, the cable (100a to 100e, 100g) at least d three individual conductors (120_1, 120_2, 120_3, 120_4) and at least three individual conductor groups (110_1, 120_1; 110_2, 120_2; 110_3, 120_3; 110_4, 120_4), and where sections of the individual conductors (120_1, 120_2, 120_3, 120_4) or individual conductor groups (110_1, 120_1; 110_2, 120_2; 110_3, 120_3; 110_4, 120_4) are intertwined. Cable (100a to 100e, 100g) according to Claim 1 , characterized in that there is a periodic braid pattern. Cable (100d) according to one of the preceding claims, characterized in that several individual conductors (110_1, 110_2, 110_3, 110_4) of a conductor system (110, 120, 130) are arranged rotationally symmetrically around a longitudinal axis of the cable (100d). Cable (100a to 100c, 100e, 100g) according to one of the preceding claims, characterized in that several individual conductors (110_1, 110_2, 110_3, 110_4) of a conductor system (110) are rotationally symmetrical about a longitudinal axis of an individual conductor of another conductor system (120, 130) are arranged. Cable (100a to 100e, 100g) according to one of the preceding claims, characterized in that three individual conductors (110_1, 110_2, 110_3) of a conductor system (110, 120, 130) so around the longitudinal axis of the cable (100d to 100e, 100g) are arranged so that the centers of their cross-sectional areas lie approximately on the corners of an imaginary equilateral triangle. Cable (100a to 100c, 100g) according to one of the preceding claims, characterized in that the conductor systems (110, 120, 130) or the individual conductors (110_1, 110_2, 110_3, 110_4; 120_1, 120_2, 120_3, 120_4) one or a plurality of conductor systems (110, 120, 130) are arranged in such a way that the cable (100a to 100c, 100g) has a substantially triangular, square or hexagonal cross section. Cable (100a to 100e, 100g) according to one of the preceding claims, characterized in that the conductor systems (110, 120, 130) or the individual conductors (110_1, 110_2, 110_3, 110_4; 120_1, 120_2, 120_3, 120_4) one or several conductor systems (110, 120, 130) are arranged and / or twisted and / or braided in a transition area (150) in such a way that the cable (100a to 100e, 100g) has a different cross-sectional shape before the transition area (150) than after Transition area (150). Cable (100a to 100e, 100g) according to one of the preceding claims, characterized in that at least one individual conductor (110_1, 110_2, 110_3, 110_4; 120_1, 120_2, 120_3, 120_4) has a strand consisting of a plurality of individual wires. Cable (100a to 100e, 100g) according to Claim 8 , characterized in that the braid is a copper braid. Cable (100a to 100e, 100g) according to one of the Claims 8 or 9 , characterized in that the individual wires of the strand are insulated. Cable (100a to 100e, 100g) according to one of the preceding claims, characterized in that at least one guide (140) is present. Cable (100a to 100e, 100g) according to Claim 11 , characterized in that the guide (140) is not electrically conductive. Cable (100a to 100e, 100g) according to one of the preceding claims, characterized by an insulation (103), which several or all individual conductors (110_1, 110_2, 110_3, 110_4; 120_1, 120-2, 120-3, 120-4) enveloped. Cable (100a to 100e, 100g) according to one of the preceding claims, characterized in that the insulation (110_1a, 120_1a) of a single conductor (110_1, 110_2, 110_3, 110_4; 120_1, 120_2, 120_3, 120_4) has a lacquer layer and / or a Has plastic shell. Cable (100a to 100c, 100g) according to one of the preceding claims, characterized in that the individual conductors (110_1, 110_2, 110_3, 110_4; 120-1, 120-2, 120-3, 120-4) of all conductor systems (110, 120, 130) have essentially the same cross section. Cable (100e) to one of the Claims 1 until 14th , characterized in that different individual conductors (110_1, 110_2, 110_3, 110_4; 120_1, 120_2, 120_3, 120_4) each have different and / or different sized cross-sections. Cable (100a to 100e, 100g) according to one of the preceding claims, characterized in that at least one conductor system (110, 120, 130) has a conductor cross-section totaling at least ten square millimeters. Cable (100b) according to one of the preceding claims, characterized in that at least one individual conductor (110_1, 110_2, 110_3, 110_4; 120_1, 120_2, 120_3, 120_4) has a rectangular cross-section. Cable (100a) according to one of the preceding claims, characterized by at least one braided shield made of electrically conductive material. Cable (100a) Claim 19 , characterized in that the braided shield covers an entire cross section of the cable (100a). Cable (100b) according to one of the preceding claims, characterized by at least one integrated measuring line (140a) and / or at least one integrated optical waveguide (140b).

Images