DE102015219701A1 - Method for producing an electrical connection between two electrically conductive components and a crimping device - Google Patents

Abstract

The invention relates to a method for establishing an electrical connection between a first electrically conductive component and a second electrically conductive component by means of a crimping process, comprising the following steps: presetting an energy that is to be converted for the crimping process for establishing the electrical connection; Inserting the components (1.1, 2) between two crimping tools (3, 4), crimping the components (1.1, 2) between the crimping tools (3, 4), the crimping tools (3, 4) being moved relative to each other for this purpose, and the given energy is converted during this movement. The invention also encompasses a crimping device designed to carry out the method.

Description

TABLE OF THE INVENTION

Method for producing an electrical connection between two electrically conductive components and a crimping device

FIELD OF TECHNOLOGY

The invention relates to a method for producing an electrical connection between two electrically conductive components by a crimping process according to claim 1. Furthermore, the invention comprises a crimping device according to claim 6

Often, such electrical connections are used in cables such as in motor vehicles or aircraft and usually needed in large quantities. For the cost-effective provision of appropriate cables, a simple and high-quality assembly is of great importance.

STATE OF THE ART

From the EP 1 143 578 A1 For example, a contact processing station is known in which a spring-loaded pressing jaw is used in order to be able to press cables independently of fluctuations in the wire thicknesses.

SUMMARY OF THE INVENTION

The invention has for its object to provide a method of electrical connection between two electrically conductive components, which allows electrical connections with relatively low production costs to produce high quality. In addition, the invention also includes a novel crimping apparatus for producing such high quality electrical connections.

This object is achieved by the features of claim 1 and claim 6.

• – Vorgabe einer Energie, die für den Crimpprozess zur Herstellung der elektrischen Verbindung umgewandelt werden soll,
• – Einlegen der Komponenten zwischen zwei Crimpwerkzeuge,
• – Crimpen beziehungsweise Verpressen der Komponenten zwischen den Crimpwerkzeugen, wobei die Crimpwerkzeuge zu diesem Zweck während des eigentlichen Crimpens beziehungsweise Verpressens relativ zueinander bewegt werden und die vorgegebene Energie während dieser Bewegung umgewandelt wird.

According to the invention, the method for producing an electrical connection between a first electrically conductive component and a second electrically conductive component by means of a crimping process comprises the following steps:

• Specification of energy to be converted for the crimping process to make the electrical connection,
• Inserting the components between two crimping tools,
• Crimping or pressing of the components between the crimping tools, wherein the crimping tools are moved relative to each other for this purpose during the actual crimping or pressing and the predetermined energy is converted during this movement.

The predetermined potential energy is thus converted into deformation energy, in particular during the deformation of the two components. In this case, preferably the potential energy is first converted into kinetic energy and the kinetic energy subsequently in deformation energy. Insofar as losses, in particular frictional losses, occur in this conversion of potential energy into kinetic energy, the energy available for deformation may be somewhat smaller than the predetermined potential energy. These losses can be taken into account, for example, in a calibration process of the crimping device, so that the predetermined potential energy is increased by the losses to be expected. Accordingly, in the case of lossy observation, the predetermined potential energy during this movement is not completely converted (into deformation energy) during the actual crimping or pressing.

Advantageously, the specification of the energy by positioning a drop weight in a predetermined height, so that in this embodiment, a certain gravitational energy is given. In a further embodiment of the invention, the specification of the energy also takes place by a determination or change in the mass of the case weight.

Alternatively, the specification of the energy can be made by the selection and dimensioning of a propellant or a gas generator, so that, for example, as a potential energy, a certain chemical energy is given.

According to a development of the invention, the relative speed of the crimping tools moving relative to one another is measured before crimping. In this way it can be checked whether the given energy has been converted to an expected level in kinetic energy, which is converted during the movement of the crimping tools in the actual crimping process into deformation energy.

Advantageously, the first conductive component is configured as a conductor comprising a plurality of individual wires.

In a further embodiment of the invention, the second conductive component is a plug contact, as used for example in electrical couplings.

The invention also relates to a crimping device for producing an electrical connection between a first electrically conductive component and a second electrically conductive component. The crimping apparatus comprises a first crimping tool and a second crimping tool, wherein the crimping tools are arranged to be movable relative to each other so that the components between the crimping tools are crimpable or compressible. The crimping device has a device for specifying a particular potential energy, wherein this energy or amount of energy for carrying out the crimping process for the production of the electrical connection can be converted in particular into deformation energy.

Advantageously, the means for prescribing an energy comprises an arrangement for positioning a drop weight at a predetermined height. The arrangement for positioning advantageously comprises a component for holding and releasing or releasing the drop weight.

The crimping apparatus may have a measuring device for measuring the relative speed of the crimping tools moving relative to each other. Advantageously, the measuring device is designed and arranged such that the speed can be measured at a location immediately before a deformation of one of the components occurs, ie before the region where the actual crimping or pressing takes place.

The new method and the corresponding crimping device make it possible to produce high-quality electrical connections even if one or both components are supplied in fluctuating quality. For example, the first component may be configured as a conductor having a plurality of individual wires. It may happen that at least in the end region of the conductor, which is intended to be subjected to the crimping process, missing one or more individual wires. In conventional methods, for example, when a crimp force monitoring is performed, missing individual wires can not be reliably detected. However, missing individual wires have a negative effect on the service life, the (mechanical) load capacity and the transmission capability of electric current or electrical signals in the field due to an insufficient electrical connection, ie insufficient compression or crimping.

Despite the quality fluctuations or defects of the two components, the present invention makes it possible to produce high-quality electrical connections by the energy approach described here. As a result, the invention thus inherently ensures, as it were, a consistent quality of the electrical connections.

Advantageous embodiments of the invention will remove the dependent claims.

Further details and advantages of the cable according to the invention will become apparent from the following description of embodiments with reference to the accompanying figures.

BRIEF DESCRIPTION OF THE DRAWINGS

It show the

1 a side view of a cable, comprising the first components configured as a conductor, prior to the preparation of the electrical connection,

2a a side view of a second electrically conductive component,

2 B a front view of the second electrically conductive component,

3 a crimping device in a first operating position,

4 the crimping device in a second operating position.

DESCRIPTION OF THE EMBODIMENTS

In the 1 is a side view of one end of a cable 1 shown, which should be edited or assembled. The cable 1 includes an outer jacket 1.3 , where the coat 1.3 is made of electrically insulating material. The cable 1 In the illustrated embodiment, further comprises four twisted wires. The wires each comprise an internal conductor, hereinafter referred to as the first electrically conductive component 1.1 referred to as. Each of the conductors or each of the first components 1.1 consists of a variety of stranded strands and is each of an insulation 1.2 surround. Radially outward with respect to the insulations 1.2 is the coat 1.3 ,

As part of the assembly, the ends of the wires are stripped over a length x away, so that the conductors are exposed there. The first components 1.1 in the form of these conductors comprise, as mentioned above, twisted individual wires, wherein in the figures for clarity, the explicit representation of the individual wires was omitted.

As the second electrically conductive component 2 used in the illustrated embodiment, a crimp or plug contact according to the 2a . 2 B , The second electrically conductive component 2 or the plug contact here comprises an open crimp claw 2.1 as well as a coupling end 2.2 that for the preparation of a plug connection with another coupling part in the intended use of the cable 1 suitable is. The second electrically conductive components 2 are for better processability on a carrier strip 7 a bandware arranged ( 3 ).

In the 3 a crimping device is shown. This includes a first crimping tool 3 , for example a crimping die, and a second crimping tool 4 , such as an anvil or a second crimping punch. The first crimping tool 3 is with a pole 5.3 connected. At this pole 5.3 is a case weight 5.1 attached. The drop weight 5.1 together with the pole 5.3 is within a fixed guide element 9 , which may be configured for example as a linear guide with rolling elements, arranged movable in the direction z. At the top of the pole 5.3 is in the presented embodiment, a ferromagnetic element 5.31 attached with a high permeability μr.

In the 3 the crimping device is shown in a position which is an insertion of the components 1.1 . 2 between the two crimping tools 3 . 4 allowed. By a holding element 5.2 , z. B. in the form of an electromagnet, the case weight 5.1 be held in a height .DELTA.h relative to an end position. To apply the force required for this purpose, the electromagnet is connected via a cable 5.21 energized with the consequence that an attraction between the ferromagnetic element 5.31 , and the holding element 5.2 is produced.

The holding element 5.2 can be used to adjust the height .DELTA.h in the direction z in different positions. In the illustrated embodiment is therefore on the holding element 5.2 an external thread provided in an internal thread of a stationary component 8th engages the crimping device. By rotation of the retaining element 5.2 Thus, a stepless adjustment of the height .DELTA.h can be made.

In addition, the crimping device has a measuring device 6 which is used to determine the speed of the first crimping tool 3 suitable is. Here can be a measuring device 6 be used, for example, based on an optical or inductive principle.

In the packaging phase according to the 3 becomes the first component 1.1 So the conductor, the crimping device fed so that this first component 1.1 in the second component 2 , especially in the crimp claw 2.1 to come to rest. The two electrically conductive components 1.1 . 2 are then located between the first crimping tool 3 and the second crimping tool 4 and are positioned for crimping or crimping.

Next, the actual crimping process becomes the first crimping tool 3 along a z-direction relative to the second crimping tool 4 emotional. For this purpose, the current for actuating the holding element 5.2 interrupted, so the case weight 5.1 with the rod 5.3 including ferromagnetic element 5.31 and the first crimping tool 3 falls down. Just before the first crimping tool 3 the second electrically conductive component 2 or the open crimp claw 2.1 the speed v of the first crimping tool is touched 3 measured and stored.

m

= bewegte Masse,

g

= Erdbeschleunigung,

Δh

= Höhe,

v

= gemessene Geschwindigkeit,

Fm

= mittlere Kraft während der Verformung,

Δz

= Strecke, über welche die Verformung erfolgt.

Then, according to the 4 by the kinetic energy of the moving components, the crimping or deformation of the components 1.1 . 2 between the crimping tools 3 . 4 performed. The first crimping tool 3 lays down while it's the two components 1.1 . 2 deforms the distance Δz back. Thus, in the first approximation, the following relationship applies: m · g · Δh = ½ · m · v ² = Fm · Δz, With:

m

= moving mass,

G

= Gravitational acceleration,

.delta.h

= Height,

v

= measured speed,

fm

= average force during deformation,

Az

= Distance over which the deformation takes place.

In the presented method, it does not depend on the knowledge of the force curve during crimping. Rather, the new method and corresponding crimping device is based on the idea that a given predetermined energy for deformation ensures the quality of the crimped connection, even if the components to be crimped 1.1 . 2 Are subject to quality fluctuations.

After deforming the two components 1.1 . 2 becomes the case weight 5.1 with the associated components again raised by the amount .DELTA.h. For this purpose, a motorized lifting device is provided, which is not explicitly shown in the figures. At the same time can be determined by checking the measured speed v, if the crimping device has worked properly. So For example, it can be determined whether frictional effects in the guidance of the rod reduce the given amount of energy.

The drop weight 5.1 , the retaining element 5.2 and the pole 5.3 with the ferromagnetic element 5.31 form a facility 5 to specify a (potential) energy, here a gravitational energy. The energy to be converted for the crimping process to make the electrical connection can be obtained by varying the height Δh and / or changing the mass of the drop weight 5.1 (For example, by adding or removing a partial weight) varied or specified.

In the method, therefore, first by adjusting the height .DELTA.h and / or changing the mass of the drop weight 5.1 made a default for the energy that is to be converted for the crimping process to make the electrical connection. This requirement is based on the results of preliminary tests. After the corresponding energy specification has been set, the components to be connected become 1.1 . 2 between the crimping tools 3 . 4 inserted. Then the components 1.1 . 2 between the crimping tools 3 . 4 compressed or crimped. This will be the crimping tools 3 . 4 moved relative to each other, wherein the predetermined energy is converted during this movement, in particular in deformation and heat energy.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• EP 1143578 A1 [0004]

Claims (8)

Method for establishing an electrical connection between a first electrically conductive component ( 1.1 ) and a second electrically conductive component ( 2 ) by a crimping process, comprising the following steps - presetting an energy which is to be converted for the crimping process to establish the electrical connection, - inserting the components ( 1.1 . 2 ) between two crimping tools ( 3 . 4 ), - crimping the components ( 1.1 . 2 ) between the crimping tools ( 3 . 4 ), wherein the crimping tools ( 3 . 4 ) are moved relative to each other for this purpose and the predetermined energy is converted during this movement. Method according to claim 1, wherein the specification of the energy by positioning a falling weight ( 5.1 ) takes place at a predetermined height (Δh). Method according to one of the preceding claims, wherein the relative speed (v) of the mutually moving crimping tools is measured before crimping. Method according to one of the preceding claims, wherein the first conductive component ( 1.1 ) is configured as a conductor comprising a plurality of individual wires. Method according to one of the preceding claims, wherein the second conductive component ( 2 ) is a plug contact. Crimping device for establishing an electrical connection between a first electrically conductive component ( 1.1 ) and a second electrically conductive component ( 2 ), comprising a first crimping tool ( 3 ) and a second crimping tool ( 4 ), wherein the crimping tools ( 3 . 4 ) are arranged movable relative to each other, so that the components ( 1.1 . 2 ) between the crimping tools ( 3 . 4 ) are crimpable, characterized in that the crimping device is a device ( 5 ) for preselecting energy convertible to the crimping process for making the electrical connection. A crimping apparatus according to claim 6, wherein said means for presetting energy comprises an assembly ( 5.2 ) for positioning a falling weight ( 5.1 ) at a predetermined height (Δh). Crimping device according to claim 7, wherein the crimping device comprises a measuring device ( 6 ) for measuring the relative velocity (v) of the crimping tools ( 3 . 4 ) having.

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