DE102012203571C5 - A method for plastically forming a plurality of electrically conductive layers of a flat conductor to a multi-dimensional contour and devices for this method - Google Patents

A method for plastically forming a plurality of electrically conductive layers of a flat conductor to a multi-dimensional contour and devices for this method

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Publication number
DE102012203571C5
DE102012203571C5 DE102012203571.0A DE102012203571A DE102012203571C5 DE 102012203571 C5 DE102012203571 C5 DE 102012203571C5 DE 102012203571 A DE102012203571 A DE 102012203571A DE 102012203571 C5 DE102012203571 C5 DE 102012203571C5
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starting
forming
electrically conductive
free
molding tool
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DE102012203571B3 (en
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Klaus Specht
Christian Heigl
Michael Wortberg
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Lisa Draexlmaier GmbH
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Lisa Draexlmaier GmbH
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    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/012Apparatus or processes specially adapted for manufacturing conductors or cables for manufacturing wire harnesses
    • H01B13/01254Flat-harness manufacturing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60RVEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R16/00Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for
    • B60R16/02Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for electric constitutive elements
    • B60R16/0207Wire harnesses
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60RVEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R16/00Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for
    • B60R16/02Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for electric constitutive elements
    • B60R16/0207Wire harnesses
    • B60R16/0215Protecting, fastening and routing means therefor
    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00Insulated conductors or cables characterised by their form
    • H01B7/08Flat or ribbon cables
    • H01B7/0823Parallel wires, incorporated in a flat insulating profile

Abstract

A method of plastically forming a plurality of electrically conductive layers of a flat conductor into a multi-dimensional contour, comprising the steps of: providing a source material (30) comprising the plurality of electrically conductive layers (36) each separated by an electrical insulation (37) and stacked into a package are, wherein the electrically conductive layers (36) are displaceable relative to each other, fixing the starting material (30) in a portion (31), sequentially forming the starting material (30), wherein the forming of the fixed portion (31) emanating from and continued the fixed portion (31) to a free end (33) of the starting material, wherein the electrically conductive layers can move relative to each other during forming, tracking the starting material (30) from the free end (33) ago during the sequential forming.

Description

  • The present invention relates to flat conductors, in particular of aluminum, which are used in wiring harnesses of motor vehicles and can be used in addition to the energy and / or signal supply for mass recirculation in the motor vehicle. In particular, the present invention relates to a method for plastically forming a plurality of electrically conductive layers of such a flat conductor to a multi-dimensional contour, which is adapted for example a motor vehicle floor group contour in order to lay the flat conductor along this. Moreover, the present invention also relates to devices for carrying out such a method.
  • By using flat conductors, in particular made of aluminum, the installation space and the conductor weight can be greatly reduced in comparison to previously used round conductors. Furthermore, the geometric shape of the flat conductor also has electrical advantages over round conductors.
  • In addition, due to the use of different combinations of materials in the motor vehicle floor pan with partly non-electrically conductive materials grounding returns are necessary. The flat conductors are therefore usually multilayer flat conductors with supply and mass function in different layers. These flat conductors, whose electrically conductive layer is plastic, that is not elastic and which are optionally multi-layered with a plurality of electrically conductive layers and insulation layers must be converted to an analogous contour in order to be able to lay them along the vehicle floor group contour, as is known for example from US Pat DE 10 2006 049 604 A or the WO 2004/051675 A is known. Due to the length of the flat conductor of up to 4 m, a thickness of about 7 mm and the use of as pure as possible aluminum many forming techniques and forming processes can not be used without problems.
  • For example, compression molding (complete forming) causes the aluminum to flow, which may result in a change or damage to the texture and cross-sectional area. In addition, a very complex system technology is required for the corresponding dimensions of the flat conductor.
  • In known CNC forming processes or Rollenumformungen occurs high leverage in the forming and deformation by the weight and the plasticity of the material.
  • As a further prior art is the US 3,415,096 A to name a method for plastically forming at least one electrically conductive layer of a flat conductor to a multi-dimensional contour. In this case, a starting material comprising the electrically conductive layer is provided, which is passed between two toothed rollers, which cause the three-dimensional deformation. In this case, the starting material is tracked from the free end during the forming. Further, the DE 10 2008 003 332 A1 a harness for engine compartment wiring of a motor vehicle from a flat cable, which is preformed by means of bending devices. The US 3,836,415 A describes a method and an apparatus for the plastic forming of round conductors into a multi-dimensional contour. Finally, the reveals DE 10 2008 061 671 A1 a motor vehicle power cable in the form of a ribbon cable having at least two conductors arranged one above the other with insulating elements surrounding the conductors, wherein a lubricant is introduced between the insulation elements.
  • Against this background, the object of the present invention is to provide a method for plastic deformation of at least one electrically conductive layer of a flat conductor to a multi-dimensional contour and a corresponding apparatus for performing this method, with which changes or damage to the structure and / or the cross-sectional area the electrically conductive layer and high leverage during forming or deformation can be avoided.
  • This object is achieved by a method having the features of claim 1 and devices having the features of claim 18, 19 or 20. Advantageous developments of the present invention can be found in the subclaims and the following description and the figures.
  • The present invention is based on the idea of sequentially transforming a starting material having a plurality of electrically conductive layers, for example continuously or in sections from a fixed region, and to feed starting material away from an end facing away from the fixation. As a result, deformation with low shear and without flow of the electrically conductive material, in particular in the case of aluminum, can be realized, as a result of which constant conductor cross-sectional areas can be realized and material damage can be avoided or reduced. The leverage can be significantly reduced by the tracking.
  • Accordingly, the present invention proposes a method of plastic forming several electrically conductive layers of a flat conductor to a multi-dimensional contour.
  • In this case, in the devices according to the invention, but not the method according to the invention in a simplest form, a starting material consisting only of the electrically conductive layer, for example an aluminum conductor with a rectangular cross-section is provided. The starting material is preferably in one-dimensional form, but may also be preformed. In its simplest form, the starting material is comparable to a flat rod or a flat band of electrically conductive material, in particular aluminum.
  • In addition, the electrically conductive layer of the provided starting material may be provided at least in regions and at least on one side with an electrical insulation. However, the insulation can also be provided on two sides, three sides or completely enveloping (four sides).
  • According to the invention, in particular when using the flat conductor for signal, energy and mass recirculation in a motor vehicle main, already provided a starting material having a plurality of electrically conductive layers, which are each stacked separately by an electrical insulation to form a package, wherein the electrically conductive layers are relatively displaceable during forming. The latter is necessary so that compression or thinning of the electrically conductive layers can be prevented or reduced. For this purpose, the electrically conductive layer is designed to be displaceable relative to the insulation of another electrically conductive layer in the inventive method.
  • In order to connect the layers of the package during or after the forming, preferably permanently, a preferably activatable adhesive layer is preferably provided between the insulation and the adjacent electrically conductive layer. Before activating the adhesive this has in the inventive method sliding properties to allow the mentioned relative displacement of the electrically conductive layers to each other during forming and thus to achieve the desired effect. For the permanent connection of the layers of the package, it may be advantageous to fix the layers before and / or during the permanent bonding at least partially to each other, which can be realized by inserting the already formed package in a backdrop, by attaching jaws and / or mounting pins can. The adhesive layer may be activated before, during or after thermoforming, for example by means of tool heating and / or induction.
  • According to another embodiment, it is also conceivable with the device according to the invention, but not with the method according to the invention, to separately reform several starting materials, each consisting of only the electrically conductive layer, according to the method according to the invention and only subsequently with the interposition of insulation and optionally adhesive layers to stack to a package. This stacked packet could then also be permanently connected as described above.
  • In order to transform the starting material according to the method according to the invention, the starting material, irrespective of how many layers it has, is fixed in a partial region. In this case, the portion may be located at one end of the starting material or in an area between the ends. After fixing takes place a sequential (continuous or sectional) reshaping of the starting material, starting from the fixed portion to a free end of the starting material out. In other words, the deformation is first started in the vicinity of the fixed partial region and the transformation continues from there and away from the fixed partial region toward the free end. During this forming, the starting material is tracked from the free end. This can be realized in the simplest embodiment, characterized in that the free end is loose, that is, at least in the longitudinal direction is freely displaceable. For example, it may be slidable longitudinally and transversely. It is also conceivable to provide the starting material in roll form and to fix the free end of the roll. The roller preferably remains freely rotatable, so that by rotating the roller, the starting material can be automatically tracked. Alternatively, it is also conceivable to control the tracking, that is targeted and tailored to the process material tracking, depending on the stage in which the transformation is.
  • If the mentioned portion is located between the ends, it is further conceivable to carry out the sequential forming from the fixed portion in two opposite directions, whereby the cycle time of the method can be reduced by the simultaneous deformation in opposite directions.
  • Furthermore, it can be advantageous to track the fixation in the partial area during the sequential forming (the fixation follows the deformation) or to provide one or more fixations in other areas that have already been formed. This can be done continuously during the forming or when interrupting the forming, the additional or tracking fixation, preferably takes place in the areas in where a relatively large springback of the starting material is expected during forming.
  • The sequential forming can be accomplished most easily by providing the stock between opposing rolls of a roll former and contouring the roll former. In this case, the roll converter with the at least two rollers for producing a two-dimensional contour in two dimensions (comprising the longitudinal direction of the starting material) and for producing a three-dimensional contour in three dimensions (comprising the longitudinal direction of the starting material) can be moved.
  • According to an alternative embodiment, it is also conceivable to introduce the starting material into a molding tool with a contour-imparting surface and to fix it in the said sub-area on the surface of the molding tool. The sequential forming in this case is carried out by sequentially applying the starting material to the surface of the mold, starting from the partial area toward a free end of the starting material. When forming in opposite directions as mentioned above, the sequential application to the surface also occurs in opposite directions from the portion.
  • The sequential application can take place here by means of an impression roller moved from the fixed partial region to the free end of the starting material, in contrast to processes in which the flat conductor or the starting material is completely reshaped in one step or reduces the leverage effect for CNC bending processes can be.
  • Alternatively, it is also conceivable to realize the sequential application by a plurality of sequentially arranged forming punches, which are controlled sequentially from the fixed partial area to the free end of the starting material. The Anformstempel can be realized by pneumatic or hydraulic cylinder with or without controlled joints (multi-axis). It is conceivable to make the forming dies heated in order to connect possibly existing multiple layers during intermediate forming by intermediate and activatable adhesive layers (this also applies to the previously mentioned forming rolls or the rolls of the roll converter). Even when using stamping dies, it is possible to reduce the leverage, in contrast to CNC bending.
  • In a further alternative embodiment, it is also conceivable to achieve the sequential application by means of a membrane applied with fluid sequentially to the surface of the molding tool, wherein the sequential molding can take place by controlling the fluid supply or by a forming chain. When using a forming chain, it may also be possible to suspend the free end of the starting material on the forming chain and thereby track, whereby a contact between the contour surface giving the tool and the starting material can be avoided.
  • In a further alternative embodiment, the sequential forming of the starting material may be carried out by a first group having a plurality of sequentially arranged forming dies on one side of the starting material and a second group having a plurality of sequentially arranged forming dies on an opposite side of the starting material, wherein the forming dies of the first and second Supplement group to the multi-dimensional contour and be controlled sequentially from the fixed portion to the free end of the starting material. For this purpose, one or more stamps of one group and associated stamps of the other group can be controlled simultaneously at first. The Anformstempel, as mentioned above, have controlled joints to allow multi-axis and thus three-dimensional deformation. In addition, a local and temporary deformation of the starting material on the final contour in materials with higher elastic fractions is possible by this configuration. Furthermore, start-up and retention can be optimized and the deflection of the remaining region of the starting material can be reduced during forming.
  • In addition to the method according to the invention, the present invention also proposes a device for forming at least one electrically conductive layer of a flat conductor into a multi-dimensional contour, in particular for carrying out the above method. In one embodiment, the device comprises a shaping tool with a contoured surface and a fixing device for fixing a starting material introduced into the molding tool, comprising the electrically conductive layer in a partial area on the surface of the molding tool. Further, a forming device is provided, through which the starting material can be applied sequentially to the surface of the mold starting from the partial area to a free end of the starting material. Furthermore, a tracking device for tracking the starting material when applying to the surface of the mold is provided. The shaping device can, as mentioned above, be formed by an impression roller which can be moved towards the free end of the starting material or can be formed by an integratable to the surface of the molding tool, be formed with fluid acted membrane or an above-mentioned Rollenumformer be with two opposite roles, which is starting from the fixation of the provided starting material to the free end in at least two, preferably three dimensions movable.
  • Other features that can be implemented alone or in combination with one or more of the above features, insofar as the features are not contradictory, can be found in the following description of preferred embodiments. This is done with reference to the accompanying drawings, in which:
  • 1 a device according to a first embodiment of the present invention and for carrying out the method according to the invention schematically;
  • 2 a device according to a second embodiment of the present invention and for carrying out the method according to the invention schematically;
  • 3 a device according to a third embodiment, which is not part of the present invention, but suitable for carrying out the method according to the invention, schematically represents;
  • 4 schematically illustrates an apparatus according to a fourth embodiment of the present invention and for carrying out the method according to the invention;
  • 5 a device according to a fifth embodiment of the present invention and for carrying out the method according to the invention schematically;
  • 6 a device according to a sixth embodiment, which is not part of the present invention, but is suitable for carrying out the method according to the invention, schematically;
  • 7 schematically shows a role converter as part of a device according to the invention according to a seventh embodiment schematically in a) plan view of the rollers of the converter or b) side view of the roller converter schematically represents;
  • 8th a cross-section through a starting material with an electrically conductive layer, a three-sided provided insulation and an adhesive layer is;
  • 9 a package of two structures, as in 8th are shown, shows;
  • 10 schematically illustrates an apparatus according to an eighth embodiment of the present invention and for carrying out the method according to the invention;
  • 11 schematically illustrates an apparatus according to a ninth embodiment of the present invention and for carrying out the method according to the invention;
  • 12a and b show fixing brackets or devices, the z. B. in the device 11 can be used; and
  • 13 Fixing brackets or devices shows the z. B. in the device 11 can be used.
  • It is understood that in the various views and different embodiments, like reference numerals have been used for comparable or similar elements and will not be described again. Rather, the description of the elements in one embodiment also applies to the corresponding elements of the other embodiment.
  • In the 1 The device shown has a mold half 10 on, the surface giving a contour 11 includes. The contour giving surface 11 specifies the two- or three-dimensional shape into which the starting material 30 from which the flat conductor is formed, to be reshaped.
  • Furthermore, a fixing device 12 provided to the starting material 30 in a subarea 31 to fix. The subarea 31 is in the embodiment in 1 at one end 32 from opposite ends 32 and 33 of the starting material 30 arranged. In addition, the device comprises a forming device 13 in the form of a translationally movable carriage 14 as indicated by the arrows A in 1 is shown. On the sledge 14 is a movable robot arm 15 mounted, at the end of a forming or Anformrolle 16 located with the surface 34 of the starting material 30 , which are the contour-giving surface 11 of the mold 10 is facing away, is brought into contact with the starting material 30 to the shaping contour 11 of the mold 10 to apply. Finally, a tracking device 18 provided with the starting material 30 , as in 1 through the arrow 17 shown, can be tracked during forming. The tracking device 18 can in the simplest way by an edge of the mold 10 be formed on the bottom 35 of the starting material 30 free rests. Optionally, a lateral guide may be provided, so that the starting material 30 only in the direction of the arrow 17 is trackable, but kept in a direction perpendicular to it.
  • For the starting material 30 For example, it may be a flat rod, for example of rectangular cross-section, of electrically conductive material, for example aluminum or an aluminum alloy. In addition, the starting material 30 or the electrically conductive layer to be isolated on one side, two sides, three sides or completely enveloping, wherein the electrically conductive layer together with the insulation, the starting material 30 forms.
  • It is also conceivable that an adhesive layer is provided on the insulation layer on one side in order to later connect a plurality of such structures into a package. In the method according to the invention several layers are already layered into a package and this package as a starting material 30 formed in one of the devices described.
  • For example, the starting material 30 , as in 8th represented, be configured. This comprises an electrically conductive layer 36 with rectangular cross section, which may be made of aluminum or an aluminum alloy, for example. Three sides of the rectangular cross section are complete with an insulation 37 Mistake. Further, an adhesive layer 38 on the insulation in the area of the top of the composite of electrically conductive layer 36 and isolation 37 on the isolation 37 intended. This structure can be used, for example, as a starting material 30 in one of the devices according to the invention with the inventive method as starting material 30 be transformed. Subsequently, the thus formed composite can be permanently connected to other formed composite structures in the same or similar configuration to form a flat conductor.
  • Alternatively, it is also conceivable several structures, as in 8th are presented, to package a package and this package as a source material 30 in one of the devices of the present invention and in accordance with the method of the present invention. Such a package is in 9 shown in cross-section and is purely exemplary of two structures, as in 8th are shown together. The two structures are loosely on top of each other and the top of the adhesive layer 38 that is between the electrically conductive layer 36 the one structure and the isolation 37 the other structure is arranged, preferably, the electrically conductive layer 36 facing, sliding properties, so that the two structures during forming relative to each other, in particular in the longitudinal direction of the starting material 30 (perpendicular to the leaf level in 9 ) can move. As a result, compression or thinning of the layer structure can be reliably avoided.
  • The following is the operation of the device 1 and thus also explains the method according to a first embodiment of the present invention.
  • First, a starting material 30 , for example, like in 9 shown in the mold half 10 provided and in the area 31 at its end 32 through the fixators 12 fixed, for example, pinched. Following is the role 16 the forming device 13 immediately after the fixing device 12 and as by the arrow 19 indicated under pressure in contact with the top 34 of the starting material 30 brought. The role forms 16 the starting material or puts this to the contour giving surface 11 of the mold 10 at. Starting from the area 19 becomes the forming device 13 with the role 16 in contact with the surface 34 of the starting material 30 along the contour giving surface 11 moves as indicated by the arrows 20 and 21 in 1 is indicated, the starting material 30 starting from the subarea 31 successively reshaped or given to the contour surface 11 of the mold 10 is created. During this forming, the free end 33 as by the arrow 17 in 1 indicated, slipping and thus continuously updated. As a result, a deformation with low shear and thus a flow of the electrically conductive material, in particular of the aluminum can be avoided. Therefore, conductor cross-sectional areas can be kept constant and avoid material damage during forming as far as possible. Also, the leverage is on the starting material 30 during forming, in contrast to the example of a CNC bending process, significantly reduced. In the method according to the invention, a packaged starting material is used, it being noted that the individual structures, each comprising an electrically conductive material, must be able to slide away from one another during forming in order to avoid upsetting or thinning of the layer structure.
  • For connecting the individual structures of the package, it is conceivable during the forming process, the adhesive layer by induction or heating of the tool, for example the Anformrolle 16 or the mold 10 To activate, after cooling, to achieve a permanent connection between the individual structures of the package. Alternatively, it is also conceivable first to reshape at least partially and to fix the formed starting material in regions. This can be done by clamping jaws, fixing pins, inserting in a backdrop or multiple fixing devices 12 (see also 12 and 13 ) be realized. The heating can then also after the forming in turn by heating the mold of the mold half 10 or be realized by induction and subsequent cooling.
  • Finally, it is conceivable to foam or encapsulate the package in order to realize a complete electrical insulation.
  • Furthermore, it is conceivable that the fixing device 12 in the course of the forming process, that is the movement of the forming device 13 in 1 from left to right, track, so that the fixation 12 the forming device 13 when reshaping follows (see also 10 and 11 ). In this case, the fixation should be carried out in areas where it is to be reckoned with a high springback of the starting material during forming. Instead of tracking the fixing 12 It is also conceivable to provide additional fixing devices which are successively actuated during the successive reshaping in order to successively realize an additional fixation in areas of expected high springbacks.
  • A second embodiment is in 2 played. This differs from the design of the device in 1 in that the fixing device 12 in a middle area between the opposite ends 32 and 33 of the starting material 30 is provided, that is, the subarea 31 lies between the ends 32 and 33 ,
  • Furthermore, two forming devices 13 provided, each starting from the subarea 31 in opposite directions, a successive transformation starting from the subregion 31 take place.
  • Also by this embodiment, the same advantages as above can be realized. Otherwise, this embodiment does not differ from the embodiment in FIG 1 ,
  • In the third embodiment in FIG 3 becomes the forming device 13 through a variety of stamps 40 educated. These may be pneumatic or hydraulic punches, which successively starting from the by the fixing device 12 fixed portion 31 the starting material to be driven and thus a successive transformation of the starting material 30 starting from the subarea 31 takes place. In this case, nine such Anformstempel are shown. For complete reshaping, however, further stamping dies configured in a similar manner are necessary. In addition, the first Anformstempel the fixing device 12 In other words, the fixing device 12 in this embodiment, as in other embodiments also take over a forming function. Again, the Anformstempel can be heated to activate when forming a package an activatable adhesive layer and permanently connect the package during forming. In addition, it is conceivable to provide the stamping dies with controlled joints so that multi-axis printing is possible and the stamping dies can optionally be pressed against the starting material in several directions, as indicated by the arrows 20 . 21 in 3 is indicated schematically.
  • Of course, it is also in this embodiment of the forming device 13 possible, the fixing device 12 in the middle or in an area between the ends 32 . 33 and to drive the Anformstempel starting from this central portion successively in opposite directions, as with reference to 2 has been explained above.
  • The device of the fourth embodiment in 4 differs again by the type of forming device 13 , This is in this embodiment by a membrane 41 educated. This is an upper tool 44 provided that together with the mold 10 and its shaping surface 11 forming a chamber, wherein the membrane 41 to form a dense cavity 45 with the mold half 44 connected is. The cavity 45 is with a fluid, in particular an incompressible fluid through a fluid inlet 43 fillable. To the starting material 30 successively starting from the subarea 31 passing through a fixator 12 is fixed, to the contour giving surface 11 of the mold 10 The fluid is introduced through the fluid inlet 43 in the cavity 45 introduced and the membrane 41 puts itself under pressure, as by the arrows 20 and 21 indicated, surface giving to the contour 11 on or is formed on this, whereby the starting material 30 is transformed. The successive molding of the membrane 41 to the contour giving surface 11 with interposed starting material 30 is thereby by the fluid supply through the inlet 43 controlled.
  • Again, it would be conceivable during forming by heating the fluid or introducing an already hot fluid to activate any existing adhesive layer to permanently connect a composite of several stacked into a package structures. Otherwise, the same advantageous effects as in the other embodiments are achieved in this embodiment as well.
  • The embodiment in 4 If appropriate, it can be further developed such that, in addition to the membrane 41 a forming chain 42 (Fifth embodiment in 5 ) is provided, at which the starting material 30 with one end 33 is hung, with the tracking along the arrow 17 is realized by the forming chain. Also, the forming chain 42 for controlling the successive application of the membrane 41 to the contour giving surface 11 of the mold 10 be used. Of course, it is also conceivable the forming chain 42 in the embodiment in 4 convict, but at the tracking, as in 4 is shown over the edge 18 hold. On the other hand, hanging up the end offers 33 at the forming chain 42 the advantage of having a contact of the starting material 30 with the edge 18 of the mold 10 avoided and thus damage during tracking can be avoided.
  • A further sixth embodiment is in 6 shown in more detail. This attacks the approach of the third embodiment with respect to the Anformstempel, but waives the mold half 10 with the contour giving surface 11 ,
  • Rather, in the embodiment in 6 several Anformstempel provided, wherein the Anformstempel on one side 34 of the starting material 30 form a first group and the Anformstempel 40 on an opposite side 35 of the starting material 30 form a second group. The Anformstempel the first and second group complement each other to the multi-dimensional contour, which should receive the starting material at the end. In other words, the Anformstempel complement each other 40 or their contour-giving surfaces to the contour-giving surface 11 as they are in terms of the mold 10 was explained. Here are the Anformstempel 40 the first and second groups respectively from the subarea 31 triggered, where appropriate, two Anformstempel a group can be controlled simultaneously, if it allows the shaping accordingly. Thus, also in this embodiment, starting from the subarea 31 a successive transformation of the starting material 30 ,
  • The tracking is controlled in this embodiment, however. This is the starting material 30 by stamp 46 be clamped and released in each case during forming. Also allows the design of the stamp 46 a rotation of the end 33 as indicated by the arrow 47 is indicated, thus the starting material 30 for the forming by the respective Anformstempel 40 optimally positioning the two groups. As a result of this configuration, local as well as temporary overshoots of the starting material to the final contour can be realized in the case of materials having higher elastic proportions. Also, optimized start-up and retention or counter-holding and the reduction of the deflection of the remaining area during the forming are possible. Otherwise, the same advantages as previously explained are achieved as well.
  • Again, it is possible controlled joints in the Anformstempeln 40 be provided to realize a multi-axis and possibly to implement a force application in two directions, as regards 3 was explained.
  • Finally, referring to the 7a and b illustrates a seventh embodiment, which is a development of the embodiments in 1 and 2 in accordance with the embodiment in 6 represents. Here comes a Rollenumformer with two roles 16 used, which are provided at a distance from each other, which allows the starting material 30 between the rollers. The roller converter, which is the forming device 13 is there, as in 7a shown, in the direction A, that is, the longitudinal direction of the starting material 30 movable and for contouring at least in the directions 20 and 22 , Thus, by moving the Rollenumformers 13 in 7 , starting from a fixed partial area 31 (in 7 not shown), similar to in 1 or with two roller converters 13 , as in 2 , along the starting material 30 and under contouring movements towards 20 the transformation takes place. In this case, the two structures in the region of the central adhesive layer 38 slide off each other.
  • Otherwise, this embodiment does not differ from the previously described and additionally described possibilities also arise in this embodiment.
  • In this regard, it is understood that the individual aspects of the different embodiments can also be combined with one another, in particular as regards the fixation by the fixing device 12 with the arrangement at one end or in an area between the ends and for the tracking of the fixing device 12 during reshaping or additional fixing with additional fixation devices 12 during forming as well as for the type of tracking of the starting material 30 along the arrow 17 applies. For example, the device 46 can also be used in the other embodiments. It would also be conceivable to realize the forming in opposite directions by means of different forming devices as described.
  • In the 10 is another device for forming a starting material 30 shown using the example of a flat conductor. The starting material 30 is at one end 32 by means of a fixing device 12 fixed, with a second end 33 is set as free end (similar to for example 2 ). For forming and contouring the starting material 30 is a role converter 13 (similar to the one in 7 ) intended. Along the forming path of the Rollenumformers 13 are several Umformfixierstempel 131 arranged, the two sides of the starting material 30 hold, ie perpendicular to the longitudinal extent of the starting material 30 act, fix it after forming in its shape and a springback of the starting material 30 counteract. The Umformfixierstempel 131 can thereby, as shown, be axially rotatable and arranged in a plurality, wherein the non-deformed region of the starting material 30 free between the Umformfixierstempel 131 extends and this only after the forming of the starting material 30 fix. The fixed part 31 thus extends approximately to the forming roller 13 , In other words, the fixed subrange 31 during the forming of the starting material 30 tracked.
  • There is also a feeder 100 provided to the maneuvering area of the free end 33 limit.
  • To the starting material 30 to transform into a desired shape of the role converter is at least 3-axis movable.
  • In the 11 is another variant of a forming device, similar to the 2 and 10 represented. In this variant is provided, the starting material 30 along a backdrop rail 11 a mold 10 by means of a roller converter 13 (similar to the one in 7 ), wherein the role of converter 13 along the backdrop rail 11 between a fixed end 32 and a free end 33 of the starting material 30 emotional. The fixed end 32 is based on a fixing device 12 fixed in his position. As can be seen from the figure forms the backdrop rail 11 a shaping surface.
  • To a springback of the starting material 30 to counteract after forming, at least in some areas more Fixierklammern 131 used, which is the starting material 30 fix in its position. These fixing clips 131 can, for example, perpendicular to the longitudinal extent of the starting material 30 slidably disposed so as to grip the starting material 30 immediately after forming with the roll converter 13 is possible (see 12a , b). Of course, for example, a plugging the Fixierklammern 131 on a rear wall of the mold 10 conceivable (see 13 ).
  • As already described and illustrated, the roller transducer moves 13 along a backdrop rail 11 , the one or more parts, ie consisting of several parallel rails, may be executed. In particular, in the execution of parallel rails may be the role of converter 13 move between the rails and deliver a force acting on the suspension of the Rollenumformers during the deformation of the starting material on the rails. In addition, a secured course of the role converter 13 possible. Instead of specially trained rails, for example, a groove or shoulder on the rear wall of the mold 10 conceivable.
  • Similar to the embodiment in FIG 10 in this embodiment is a feeder 100 provided, which is also arranged multi-axially displaceable, a Rangierauslenkung of the starting material 30 during forming, while facilitating the guidance of the stock during drawing. In the 11 finds a fixing clip 131 also in the function of a feeder 100 Application.
  • The 12a and 12b represent an embodiment of a fixing device 12 and / or a fixing clip 131 for use in, for example, the 10 or 11 is, for simplicity, only the term Fixierklammer 131 continues to be used. The fixing clip 131 is shaped like a tuning fork and has two fixing legs 121 on that over a suspension 123 connected to each other. The fixing clip 131 extends between two mutually parallel guide rails 11 a mold 10 so that the starting material 30 between the fixing legs 121 is held. It is envisaged that each flat side wall 301 of the starting material 30 a fixation leg 121 is opposite, so that after forming the starting material 30 , In particular bending, a restoring force F can be counteracted. Of course, a Fixierklammer 131 with only one fixing leg 121 be provided.
  • The suspension 123 is connected to a guide (not shown) with which the fixing clip 131 can be arranged immediately after forming an area. Like from the 12a You can see several fixing clips 131 on the formed starting material 30 to be ordered.
  • The 13 shows a further alternative for fixing a deformed starting material 30 , In contrast to the fixing clip 131 from the 12a , b becomes a fixation hat here 131 above the starting material 30 arranged. The fixation hat 131 is substantially omega-shaped and includes two fixing legs 121 over a footbridge 125 are connected. The two fixation legs 121 extend to your end to a support leg 126 , wherein the fixing legs 121 substantially perpendicular to the support legs 126 stand. Between the fixation legs 126 the starting material runs 30 so that it's from the fixation hat 131 gripped and fixed.
  • On the support legs 126 are each bolts 122 in openings 127 on the back wall of a mold 10 intervene and the Fixierhut 131 and thus the starting material 30 fix. Bolts 122 can be tapered for easy insertion into the openings 127 run, with the bolts 122 with barbs, clamps and / or threads (not shown) for attaching the fixation hat 132 can be provided on the rear wall.
  • As can be seen from the figures, the Umformfixierstempel 131 , the fixing bracket 131 and the fixation hat 131 partially after the forming of the starting material 30 be arranged on this, so that the fixed part 31 along the formed starting material 30 extends.
  • The Umformfixierstempel 131 , the fixing bracket 131 and the fixation hat 131 can at the the starting material 30 associated areas with activation elements (not shown) may be provided, for example, an adhesive layer on the starting material 30 to activate and / or cure.

Claims (20)

  1. A method for plastically forming a plurality of electrically conductive layers of a flat conductor into a multi-dimensional contour, comprising the steps of: providing a starting material ( 30 ) comprising the plurality of electrically conductive layers ( 36 ), each by an electrical isolation ( 37 ) and stacked into a package, the electrically conductive layers ( 36 ) are displaceable relative to each other, fixing the starting material ( 30 ) in a subarea ( 31 ), sequential forming of the starting material ( 30 ), wherein the forming of the fixed portion ( 31 ) and from the fixed portion ( 31 ) to a free end ( 33 ) of the starting material is continued, wherein the electrically conductive layers can shift relative to each other during forming, feeding the starting material ( 30 ) from the free end ( 33 ) during sequential forming.
  2. Process according to Claim 1, in which the starting material ( 30 ) is provided as a flat bar or flat band.
  3. Process according to Claim 1 or 2, in which the starting material ( 30 ) two opposite ends ( 32 . 33 ) and the subregion ( 31 ), in which the starting material ( 30 ) is fixed, between the ends ( 32 . 33 ), wherein the sequential forming starting from the fixed portion ( 31 ) in opposite directions in each case starting from the fixed portion ( 31 ) to one of the ends ( 32 . 33 ) of the starting material ( 30 ) takes place.
  4. Method according to one of the preceding claims, in which the electrically conductive layer ( 36 ) of the source material ( 30 ) at least partially at least on one side with an insulation ( 37 ) is provided.
  5. A method according to any preceding claim, wherein the layers of the package are permanently bonded during or after forming.
  6. Method according to claim 5, wherein between isolation ( 37 ) and adjacent electrically conductive layers ( 36 ) of the package an activatable adhesive layer ( 38 ) is arranged for permanently connecting the layers of the package, which has sliding properties prior to activation, in order to prevent the relative displacement of the electrically conductive layers ( 36 ) to allow each other during forming.
  7. Method according to claim 5 or 6, in which the layers of the package are fixed to one another before and / or during the permanent connection at least in regions.
  8. Method according to one of the preceding claims, in which the fixation in the subregion ( 31 ) is tracked during the sequential forming or at least follows a fixation in other areas.
  9. Method according to one of the preceding claims, in which the starting material ( 30 ) by introducing the starting material ( 30 ) in a mold ( 10 ) with contouring surface ( 11 ) and in the said sub-area ( 31 ) on the surface ( 11 ) of the molding tool ( 10 ), wherein the sequential forming by sequential application of the starting material ( 30 ) to the surface ( 11 ) of the molding tool ( 10 ) starting from the subregion ( 31 ) to the free end ( 33 ) of the starting material ( 30 ) takes place.
  10. Method according to one of the preceding claims, in which the starting material ( 30 ) by introducing the starting material ( 30 ) for the electrically conductive layer ( 36 ) between opposing rollers ( 16 ) a role converter ( 13 ) and the sequential forming by contouring moving the rollers ( 16 ) along the starting material ( 30 ) he follows.
  11. Method according to Claim 9, in which the sequential application is effected by means of one of the fixed subareas ( 31 ) to the free end ( 33 ) of the starting material ( 30 ) moving impression roll ( 6 ) he follows.
  12. Method according to Claim 9, in which the sequential application by a plurality of sequentially arranged forming punches ( 40 ) from the fixed portion ( 31 ) to the free end ( 33 ) of the starting material ( 30 ) are sequentially addressed.
  13. A method according to claim 9, wherein the sequential application by a sequentially to the surface ( 11 ) of the molding tool ( 10 ) forming fluid-loaded membrane ( 41 ) he follows.
  14. Process according to claim 13, in which the sequential molding of the membrane ( 41 ) to the surface ( 11 ) of the molding tool ( 10 ) by controlling the fluid supply.
  15. Process according to claim 13, in which the sequential molding of the membrane ( 41 ) to the surface of the mold by a forming chain ( 42 ) he follows.
  16. Method according to claim 15, wherein the free end ( 33 ) of the starting material ( 30 ) on the forming chain ( 42 ) and by the molding of the membrane ( 41 ) with the forming chain ( 42 ) to the surface ( 11 ) of the molding tool ( 10 ) when forming the starting material ( 30 ) is tracked.
  17. Method according to one of claims 1 to 8, wherein the sequential forming of the starting material ( 30 ) by a first group with a plurality of sequentially arranged Umformstempeln ( 40 ) on one side ( 34 ) of the starting material ( 30 ) and a second group with several sequentially arranged Umformstempeln ( 40 ) on an opposite side ( 35 ) of the starting material ( 30 ), whereby the forming dies ( 40 ) of the first and second groups to the multi-dimensional contour and of the fixed portion ( 31 ) to the free end ( 33 ) of the starting material ( 30 ) are sequentially addressed.
  18. Device for forming at least one electrically conductive layer of a flat conductor into a multi-dimensional contour, comprising a molding tool ( 10 ) with contouring surface ( 11 ) and a fixing device ( 12 . 131 ) for fixing a in the mold ( 10 ) introduced starting material ( 30 ) comprising the electrically conductive layer ( 36 ) in a subarea ( 31 ) on the surface ( 11 ) of the molding tool ( 10 ); a forming device ( 13 ), through which the starting material ( 30 ) sequentially to the surface ( 11 ) of the molding tool ( 10 ) starting from the subregion ( 31 ) to a free end of the starting material ( 30 ) can be applied; and a tracking device for tracking the starting material ( 30 ) when applied to the surface ( 11 ) of the molding tool ( 10 ), wherein the forming device ( 13 ) one of the fixed portion to the free end of the starting material ( 30 ) movable impression roll ( 16 ).
  19. Device for forming at least one electrically conductive layer of a flat conductor into a multi-dimensional contour, comprising a molding tool ( 10 ) with contouring surface ( 11 ) and a fixing device ( 12 . 131 ) for fixing a in the mold ( 10 ) introduced starting material ( 30 ) comprising the electrically conductive layer ( 36 ) in a subarea ( 31 ) on the surface ( 11 ) of the molding tool ( 10 ); a forming device ( 13 ), through which the starting material ( 30 ) sequentially to the surface ( 11 ) of the molding tool ( 10 ) starting from the subregion ( 31 ) to a free end of the starting material ( 30 ) can be applied; and a tracking device for tracking the starting material ( 30 ) when applied to the surface ( 11 ) of the molding tool ( 10 ), wherein the forming device ( 13 ) one sequentially to the surface ( 11 ) of the molding tool ( 10 ) conformable, fluidizable membrane ( 41 ).
  20. Device for forming at least one electrically conductive layer of a flat conductor into a multi-dimensional contour, comprising a fixing device ( 12 . 131 ) for fixing a provided starting material ( 30 ) comprising the electrically conductive layer ( 36 ) in a subarea ( 31 ); a forming device ( 13 ), through which the starting material ( 30 ) starting from the subregion ( 31 ) to a free end ( 33 ) of the starting material ( 30 ) is sequentially formed, wherein the shaping device ( 13 ) opposite rollers ( 16 ) has between the provided starting material ( 30 ) is insertable and the sequential forming contour giving along the starting material ( 30 ) are movable; and a tracking device for tracking the starting material ( 30 ) during forming.
DE102012203571.0A 2012-03-07 2012-03-07 A method for plastically forming a plurality of electrically conductive layers of a flat conductor to a multi-dimensional contour and devices for this method Active DE102012203571C5 (en)

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DE102015201465A1 (en) 2015-01-28 2016-07-28 Hochschule Karlsruhe Method and device for producing a cable harness
DE202015103854U1 (en) 2015-07-22 2015-08-10 Bayerische Motoren Werke Aktiengesellschaft Track for use in the electrical system or as a battery line of vehicles
DE102018115557B3 (en) 2018-06-28 2019-07-04 Kromberg & Schubert Gmbh & Co. Kg Automated cable laying for cable harnesses of electrical systems using two force-controlled robots

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