DE102016105227B4 - Connection device, connection method, contact element and connector housing - Google Patents

Abstract

Connecting device (1) for connecting one end (3, 41) of a line (2, 40) to a contact element (5, 45, 49, 53) which has a coupling section (6, 47, 51, 55, 58, 64) : with a contact receptacle (9), which is designed to receive the contact element (5, 45, 49, 53); with a heat source (15), which is designed, the end (3, 41) of the line (2, 40) to melt before insertion into the contact element (5, 45, 49, 53), and with a line feed (12) which is formed, the melted end (3, 41) of the line (2, 40) into the contact element (5, 45) , 49, 53); the heat source (15) being designed to connect the fused end (3, 41) of the line (2, 40) to the coupling section (6, 47, 51, 55, 58, 64) of the contact element ( 5, 45, 49, 53) to be welded.

Description

Technical area

The present invention relates to a connecting device for connecting one end of a line to a contact element. The present invention also relates to a connection method, a contact element and a connector housing.

Technical background

The present invention is described below mainly in connection with cable harnesses, in particular for applications in the vehicle sector. It goes without saying, however, that the present invention can be used in all applications in which cables have to be contacted. For example, the present invention can also be used for contacting network lines or in switch cabinet construction or the like. Use in connection with fiber optic cables is also possible.

A large number of electrical and electronic devices are used in modern motor vehicles. In particular, vehicle control units are networked with one another via digital bus systems. The ever advancing digitization and networking consequently leads to increasingly complex cable harnesses in vehicles.

In the production of such cable harnesses, which can comprise hundreds of meters of individual cables, braids are usually used, which are cut to the appropriate length and provided with appropriate electrical contacts.

the DE 103 52 482 A1 Figure 11 shows an apparatus in which the steps of compaction, end connector welding, terminal welding and crimping can be performed in a single apparatus.

However, contacting by means of crimp connections is complex, particularly with very thin strands.

the DE 10 2010 027 033 A1 shows a conductor with a contact part which is connected to the conductor via a connection part with a crimp connection and a welded connection.

Description of the invention

The object of the present invention is to enable simple contacting of electrical lines.

The object is achieved by the subjects of the independent claims.

Accordingly, there is provided: A connecting device for connecting one end of an electrical line, e.g. a stranded conductor, a stranded wire or stranded wire, in particular a signal line, to a contact element, e.g. a sheet metal contact for fitting in a plug housing, which has a coupling section. The connecting device has a contact receptacle which is designed to receive and fix the contact element. Furthermore, a preferably controllable heat source is provided which is designed to melt the end of the line before it is introduced into the contact element. A line feed is also provided which is designed to introduce the melted end of the line into the contact element, in particular in an automated manner. Furthermore, the heat source is designed to weld the fused end of the line to the coupling section of the contact element, preferably at the end face.

Furthermore, the following is provided: a connection method for connecting an end of a line to a contact element, which has a coupling section, comprising the steps of receiving and fixing the contact element, melting the end of the line, inserting, in particular automated, the melted end of the line into the contact element, and preferably the end face welding of the melted end of the line to the coupling section of the contact element, for example with a heat source such as a laser.

Furthermore, a contact element for use with a connecting device according to the invention and / or a method according to the invention is provided. The contact element has a coupling section which has a support for one end of a line. Furthermore, the contact element has a positioning section which is arranged in an axial extension of the coupling section and forms a guide into the coupling section for the line. The line or its end is thus inserted into the positioning section, which can be designed, for example, like a channel or a tube. The line or its end is guided through the positioning section to the coupling section until the end of the line rests against the support. The end of the line can then be welded to the support.

Finally, the following is provided: a connector housing for use with a connecting device according to the invention and / or a method according to the invention. The connector housing has a number, ie one or more, of Contact chambers, which are designed to each receive a contact element, and a welding opening on each of the contact chambers.

In order to reduce the weight of cable harnesses in vehicles, for example, electrical signal lines with a cross-section of less than or equal to 0.35mm ^{2 are installed} in large quantities in the vehicle. Their share can be over 75% per cable harness or cable set. Up to now, these have usually been pre-produced on fully automatic machines with the help of crimping technology.

The present invention is based on the knowledge that many variants of signal lines are built into a vehicle cable set (cable cross-section, length, color, different contact parts) and therefore a fully automated production of the cable set is currently difficult due to the many machine configurations with crimping technology required for this is feasible.

The present invention is based on replacing the complex crimping technique with a direct or material connection between the contact element and the end of the line. For this purpose, the end of the line is automatically inserted into the contact element and welded there to the coupling section. In particular, contactless fusion welding technology can be used for this purpose.

The contact element can be punched and bent from sheet metal, for example. The support can be formed from a sheet metal section or sheet metal lugs bent into the coupling section. The contact element can alternatively be formed by an empty crimp contact. The contact lugs of the crimp contact are therefore bent inwards without a line between them. The contact lugs consequently form the coupling section against which the end of the line rests before the welding process.

The present invention replaces the mechanical joining process, e.g. a crimping process. The welding process can take place directly on the construction board, on which e.g. a cable harness for a vehicle is produced. Prefabrication of contacted conductor ends can therefore be dispensed with. A construction board is a device on which e.g. cable harnesses for motor vehicles are usually built by hand or at least partially by hand and has the receptacles for holding parts as well as sections of the cable harness.

By welding the end of the cable, in contrast to the frictional connection during crimping, a material connection is created. Such a connection of the line to the contact element is mechanically much more stable than a crimp connection. If the tensile strength of the welded connection meets the requirements of the respective application, a separate strain relief can be dispensed with, for example. Furthermore, a welded connection is less sensitive to vibrations, corrosion and other environmental influences than a corresponding crimp connection.

Further, particularly advantageous configurations and developments of the invention emerge from the dependent claims and the following description, with the features of various exemplary embodiments being able to be combined to form new exemplary embodiments. In particular, the independent claims of one claim category can also be developed analogously to the dependent claims of another claim category.

In one embodiment, the connecting device can have a stripping device which is designed to strip the end of the line, that is, to free it from the insulation. For example, the connecting device can also have a receptacle for cable reels or spools, on which the individual cable reels are arranged. The stripping device can then unroll the corresponding line in the required length from the cable reel before the welding process and strip the end of the line so that it can be inserted into the contact element through the line feed.

In one embodiment, the heat source can be designed to melt the end of the line on the end face before it is introduced into the contact element. For example, the line feed can position the end of the line accordingly. When melting, the end of the line can be heated with a predetermined amount of heat for a predetermined period of time. In this way, the melting process can be controlled and a defined amount of the line material melted. Due to the surface tension of the melt, an approximately spherical or teardrop-shaped head forms at the end of the line. Of course, a different heat source can be used for melting the end of the line than for the welding process. In particular, if the same heat source is used to melt the end of the line, the end of the line can be rotated during this process so that the melt is not pulled down by gravity and a uniform spherical shape is formed. The line and the heat source can thus remain in the position in which they are required for the subsequent welding process, ie in the horizontal position. The mechanics of the connecting device can thus be kept simple will. Alternatively, the line feed can also position the end of the line vertically under the heat source when it is melted. For this purpose, the mechanics of the line feed can, for example, be designed to be pivotable.

If the end of the line is melted and accordingly forms a spherical head, the handling of e.g. stranded lines is simplified. The individual wires of the strand can then no longer splice outwards, i.e. bend, e.g. when the end is axially inserted into the contact element. Furthermore, such a spherical head can be pushed very easily, e.g. through sealing elements, without damaging them. This is particularly advantageous for connectors, for example, with a sealing mat in front of the receiving chambers for the contact elements or with single-wire seals.

The process of melting can also be used as an alternative to stripping by the stripping device. For this purpose, the amount of heat can be determined in such a way that the insulation burns off or evaporates and the end of the line melts as required. In particular, a predetermined temperature profile can also be generated by the heat source, which e.g. first leads to burning or evaporation of the insulation and then to melting of the end of the line.

In one embodiment, the heat source can be designed as a laser source which emits a laser beam. A laser makes it possible to concentrate heat in a targeted manner in a small space. This means that lines with very small diameters can also be effectively welded. Furthermore, a laser enables a very fast process with high melting rates. A possible laser can, for example, have a power of 100W and emit pulses with 10kW power and a duration of less than 1s, in particular less than 100ms, e.g. 15ms - 25ms. Alternatively, the heat source can comprise, for example, heating wires, gas flames or the like

In one embodiment, the heat source can be power-controlled or -regulated. This makes it possible to adapt the temperature during welding to different materials of the line. Predefined temperature profiles can also be implemented.

In one embodiment, the line feed can be designed to press the end of the line into the contact element with a predetermined force, also known as a pre-force, during welding. In the melting phase of the welding process, the pre-force ensures a supply of material through conductor material, so the line "moves up" steadily, thus preventing constriction and shrinkage at the welding point. The initial force remains until it cools down. After the melt has solidified, the joining process is complete.

Furthermore, the welding process can also be configured in such a way that only an exactly defined part of the spherical end of the line is melted and this part of the ball serves as a material reservoir at the end of the line. Depending on the application, it is then possible to dispense with pushing the line through the pre-force.

In one embodiment, the connecting device can have a dynamometer which is designed to detect the force between the line and the contact element and to check whether predetermined forces are present during the connection of the end of the line to the contact element. Both the introduction of the end into the coupling section and the welding of the end of the line can be controlled by means of a corresponding force-displacement monitoring system. Characteristic features of the course can be monitored. Such characteristic features can be e.g. Reaching the end of the coupling section, e) a constant level of force in the welding and holding phase, and f) the welding path.

Furthermore, after the welded joint has cooled down, the dynamometer can carry out a so-called “pull-out test” to verify the weld. It goes without saying that such an “exit test” is not carried out for every connection. The "exit test" can be carried out, for example, after the connection device has been converted to a specific cable or a specific contact element. Furthermore, during the automated production of a large number of connections between cables and contact elements, an interval can be specified in which “exit tests” are carried out. For example, after every 100 or 150 connections, a corresponding “exit test” can be carried out and documented for quality assurance purposes.

In addition, in one embodiment, an optical monitoring system can be provided which checks the geometry of the weld and outputs an error message if the geometry deviates excessively from a predetermined nominal geometry.

In order to avoid damage to the contact part and, for example, a connector housing, in one embodiment additional purge air can be blown in or the line and / or the contact element can be cooled in some other way.

In one embodiment, the connecting device can have a housing receptacle for receiving a plug housing with a number, that is to say one or more, of contact chambers. The contact chambers are designed to each receive a contact element. Furthermore, the connector housing has a welding opening on each of the contact chambers. The contact can be designed to receive a contact element for each contact chamber, e.g. from a belt or magazine, and to insert a contact element into each of the contact chambers. Furthermore, the line feed can be designed to introduce the end of a line into the coupling sections of each of the contact elements seated in the contact chambers. Finally, the heat source can be designed to weld each of the ends to the corresponding coupling section in the respective contact chamber through the respective welding opening. With the housing receptacle, it is possible to provide not only individual lines with a contact element. Rather, a complete connector or a complete connector housing can be automatically fitted directly on the building board. The welded connection is made in the contact chambers of the respective connector housing. In connector housings, a sealing mat is often arranged in front of the contact chambers or single wire seals are used in the contact chambers. These sealing elements usually consist of rubber or another flexible material. If the contact element is connected to the line before it is in the contact chamber, the usually angular contact element must be pushed through the sealing element. The flexible material of the sealing element can be damaged by the edges of the contact element.

The present invention avoids such damage, since only the end of the line, in particular a spherical, that is to say round, end of the line has to be passed through the respective sealing element. The contact element itself can be inserted into the respective contact chamber before the sealing element is attached.

If the contact element has a fixation for the insulation of the line, i.e. a so-called strain relief, this can be closed before, during or after the welding process, e.g. pressed. This can in particular also take place through the welding opening, which for this purpose can, for example, be designed as a corresponding elongated hole. Such strain reliefs are usually produced using conventional crimping technology. However, they only serve to mechanically fix the insulation of the line and have no electrical function whatsoever.

In one embodiment, the connecting device can have a closure device which is designed to close the welding openings after welding. The welding openings must be closed after the welding process so that the contact elements are shielded from environmental influences such as moisture, dust and the like. Depending on the design of the connector, for example a potting compound can be poured into the welding opening or a locking clip of the connector housing can be closed.

In addition to the coupling section and the positioning section, the contact element can also have a strain relief section and a contact section. The strain relief section can, for example, adjoin the positioning section and, for example, have two wings or tabs that can be folded around the insulation of the cable. The contact section can form the male or female part of an electrical plug connection.

In one embodiment, the connector housing can have a displaceable clamp which releases the welding openings in an open position and which closes the welding openings in a closed position.

In one embodiment, the connector housing can have a first housing half which has contact chambers that are open at the top, the welding openings are thus implicitly formed by the contact chambers that are open at the top. In addition, a second housing half can be provided, which has coupling elements for coupling to the first housing half and which can be placed on the first housing half after connecting the line with corresponding contact elements in the contact chambers.

The connecting device can be used to process any material. For example, a wire or strand made of copper can be welded to a contact element made of copper. It goes without saying that the contact element or the end of the line can also be coated, e.g. tin-plated or silver-plated. With the aid of the connecting device, different materials can also be welded to one another. The connecting device is therefore not restricted to connecting identical materials to one another.

For example, a line made of aluminum can be connected to a contact element made of copper. If the direct welding of two different materials should be problematic, in one embodiment a pin made of the line material can be crimped into the contact element, for example a conventional crimp contact. The pin can of course also be made of any other suitable material, ie of any material which can be welded to the material of the line. The line is consequently not welded directly to the contact element but to the pin. With an appropriate selection of the pin, two identical materials can again be welded to one another or materials can be welded to one another for which the welding can be carried out easily.

In order to support the welding of the pin to the line, the pin can have a correspondingly shaped coupling section at its end pointing towards the line. The coupling section on the pin can have any of the shapes disclosed in this patent application for the coupling section of the contact element. Furthermore, the coupling section of the pin can, for example, have a recess in the form of a hemisphere. The end of the line can be inserted into this to be worn away.

Corresponding contact elements can already be fitted to the connecting device, that is to say fed with the corresponding pin. Alternatively, the connecting device can insert corresponding pins into a contact element if necessary.

Figure list

• 1 eine schematische Darstellung einer Ausführungsform einer erfindungsgemäßen Verbindungsvorrichtung;
• 2 eine weitere schematische Darstellung einer Ausführungsform der erfindungsgemäßen Verbindungsvorrichtung;
• 3 eine weitere schematische Darstellung einer Ausführungsform der erfindungsgemäßen Verbindungsvorrichtung;
• 4 eine schematische Darstellung einer Ausführungsform eines erfindungsgemäßen Kontaktelements;
• 5 eine schematische Darstellung einer weiteren Ausführungsform eines erfindungsgemäßen Kontaktelements;
• 6 eine schematische Darstellung einer weiteren Ausführungsform eines erfindungsgemäßen Kontaktelements;
• 7 eine schematische Darstellung einer weiteren Ausführungsform eines erfindungsgemäßen Kontaktelements;
• 8 eine schematische Darstellung einer weiteren Ausführungsform eines erfindungsgemäßen Kontaktelements;
• 9 eine weitere schematische Darstellung der Ausführungsform des erfindungsgemäßen Kontaktelements der 8; und
• 10 ein Ablaufdiagramm einer Ausführungsform eines erfindungsgemäßen Verfahrens.

The principle of the invention is explained in more detail below by way of example with reference to the accompanying figures. The same components are provided with identical reference numbers in the various figures. Show it:

• 1 a schematic representation of an embodiment of a connecting device according to the invention;
• 2 a further schematic representation of an embodiment of the connecting device according to the invention;
• 3 a further schematic representation of an embodiment of the connecting device according to the invention;
• 4th a schematic representation of an embodiment of a contact element according to the invention;
• 5 a schematic representation of a further embodiment of a contact element according to the invention;
• 6th a schematic representation of a further embodiment of a contact element according to the invention;
• 7th a schematic representation of a further embodiment of a contact element according to the invention;
• 8th a schematic representation of a further embodiment of a contact element according to the invention;
• 9 a further schematic representation of the embodiment of the contact element according to the invention in FIG 8th ; and
• 10 a flow chart of an embodiment of a method according to the invention.

Detailed description

1 shows a schematic representation of a connecting device 1 , the one designed as a stranded wire 2 with a contact element 5 connects. The contact element 5 has a positioning section 7th , a coupling section 6th and a contact portion 8th on.

The administration 2 exhibits insulation 4th on that at their end 3 was removed.

The positioning section 7th serves for the correct positioning and guidance of the end 3 the line 2 until this is correct in the coupling section 6th lies. The contact section 8th represents a male or female plug element which forms the electrical contact of a corresponding plug. Alternatively, the contact portion 8th For example, it can also be a connection lug that is soldered onto a printed circuit board or the like. Such terminal lugs can, for example, be soldered in advance to the printed circuit board, which is then fixed in the connecting device.

The connecting device 1 instructs a contact 9 on which the contact element 5 picks up and fixes. In 1 is the establishment of contact 9 schematic with two clamps 10 and 11 shown that the contact element 5 pinch. It goes without saying that any other type of fixation is possible. For example, this can also be the contact section 8th corresponding female or male counterpart can be inserted into the contact element 5 to hold and fix.

The connecting device 1 also has a line feed 12th on. This leads the line 2 or the end 3 the line 2 in the positioning section 7th one until the end 3 the line 2 in the coupling section 6th lies, or until the end 3 the line 2 on the ends of the tabs 60 , 61 (see also 7th ) rests, i.e. is in contact with them. the Cable feed 12th is also schematic with two clamps 13th , 14th depicted showing the line 2 pinch. Here, too, it goes without saying that any other type of fixation and guidance of the line 2 is possible. For example, the line 2 be guided in a tubular line feed or the like. Furthermore, for example, movable elements, such as driven rollers, can be used to guide the line 2 to transport.

There is the end 3 the line 2 in position, i.e. in the coupling section 6th , heated by a laser 15th with a laser beam 16 the end 3 the line 2 so that this melts and with the ends of the tabs 60 , 61 is welded. Of course, the laser beam can 16 alternatively or additionally also the ends of the tabs 60 , 61 heat until they melt.

After the melt has cooled, that's the end 3 the line 2 with the tabs 60 , 61 of the coupling section 6th welded. So there is a material connection between the line 2 and the coupling element 5 .

2 shows the connecting device 1 , which was supplemented by further elements. So is a stripping device 17th provided, which for example with the help of the blades 18th , 19th the end of the line 2 stripped. Will lead 2 Stripped directly before processing, the individual lines do not have to be pre-processed. This enables automatic direct removal and assembly of the cable 2 eg from a cable reel (not shown separately) directly before processing the cable 2 e.g. on the building board. Will the end 3 the wire designed as a stranded wire 2 The individual wires of the strand are stripped directly before processing 2 not connected to each other. The end 3 can directly in this state in the contact element 5 to be introduced.

Alternatively, as in 2 shown, but the laser can 15th the end 3 the strand 2 Heat so that the individual wires of the braid 2 merge with each other and form a spherical head. A merging of the end 3 connects the individual wires of the strand 2 so that they cannot bend.

The laser 15th can also be used as an alternative to the stripping device 17th be used. The laser can do this 15th the isolation in the end 3 the line 2 eg burn off or evaporate.

In 2 is also a dynamometer 20th shown the one on the line 2 acting force recorded. The dynamometer 20th can lead the entire processing operation 2 monitor.

• - die Kraft beim Einführen des Endes 3 in das Kontaktelement 5;
• - den Kraftaufwand und die Weglänge beim Durchqueren des Kontaktelements 5 bzw. des Positionierabschnitts 7 bis zum Koppelabschnitt 6;
• - den Kraftabfall nach dem Durchqueren des Kontaktelements 5 bzw. des Positionierabschnitts 7;
• - den steilen Kraftanstieg beim Erreichen des Endes des Koppelabschnitts 6;
• - ein konstantes Kraftniveau in der Schweiß- und Haltephase; und
• - den Schweißweg

For example, the dynamometer 20th Monitor characteristic features, such as force-displacement relationships. Characteristic forces or paths can be determined, for example, for:

• - the force when inserting the end 3 in the contact element 5 ;
• - the force required and the length of the path when crossing the contact element 5 or the positioning section 7th to the coupling section 6th ;
• - the drop in force after crossing the contact element 5 or the positioning section 7th ;
• - the steep increase in force when reaching the end of the coupling section 6th ;
• - a constant level of force in the welding and holding phase; and
• - the welding path

The force meter can use the recorded values 20th For example, provide a higher-level controller, which can evaluate the welding process on the basis of these values. Furthermore, the control can document these values for each welded connection and assign them to a data record assigned to the respective line for purposes of quality assurance.

Not shown, but of course also possible, is an optical monitoring of the welded connection, e.g. by an image recognition system with a corresponding image analysis.

3 also shows the connecting device 1 , which around a housing mount 21 was added.

The housing recording 21 takes a connector housing according to its name 22nd on what lines 2 are to be arranged with corresponding contact elements.

The connector housing 22nd has three contact chambers by way of example only 23 , 24 , 25th on, in which (not shown) each a contact element 5 can be introduced. The housing recording 21 replaces contact 9 the 1 and 2 . But it is a variant of the establishment of contact 9 possible which the contact element 5 in the contact chambers 23 , 24 , 25th fixed.

The connector housing 22nd also has on top of each of the contact chambers 23 , 24 , 25th a sweat opening 26th , 27 , 28 through which the laser beam 16 the end 3 the respective line with the corresponding contact element 5 or its coupling section 6th welded.

Is a seal of the connection between the ends 3 and contact element 5 not necessary, the connection process can be ended here. If this connection is to be sealed, however, the closure device can 29 the sweat openings 26th , 27 , 28 close. The locking device 29 is shown here as a potting compound reservoir, which the potting compound through a nozzle 30th into the sweat holes 26th , 27 , 28 can bring in.

Alternatively, for example, the connector housing can consist of two housing halves, the welding process being carried out when the contact elements 5 lie in the lower half of the housing. The connector housing is then closed by placing the second housing half on the first housing half. As a further alternative, a connector housing with a movable locking clip can be provided which, in an open position, encompasses the welding openings 26th , 27 , 28 releases and closes it in a closed position.

It goes without saying that individual elements of the embodiments of the connecting device 1 the 1 , 2 and 3 can be freely combined with each other.

4th shows a schematic representation of a contact element according to the invention 45 with a positioning section 46 , a coupling section 47 and a contact section 48 . One line 40 with an insulation 42 and one stripped end 41 is such in the contact element 45 arranged that the end 41 on the ends of the bent tabs 60 , 61 rests.

The ends of the tabs 60 , 61 are radial, i.e. perpendicular to the longitudinal axis of the line 40 or the contact element 45 closed. In this configuration the ends of the tabs 60 , 61 is only a small part of the end 41 on. However, the melt spreads out when the end is welded together 41 such that the ends of the tabs 60 , 61 completely with the end 41 be welded. Furthermore, these are the ends of the tabs 60 , 61 easy to manufacture.

5 shows a schematic representation of a further contact element according to the invention 49 . In contrast to the contact element of the 4th are the ends of the tabs 60 , 61 in the 5 rounded. Ie the ends of the tabs 60 , 61 are the spherical contour of the end 41 the line 40 customized. The contact surface between the end 41 and the ends of the tabs 60 , 61 is therefore maximized.

6th shows a schematic representation of a further embodiment of a contact element according to the invention 53 .

With the contact element 53 are the ends of the tabs 60 , 61 curved radially outwards. That kind of tabs 60 , 61 is also very easy by bending the tabs accordingly 60 , 61 to manufacture. At the same time, the contact area between the ends increases 41 and the ends of the tabs 60 , 61 Compared to the arrangement of the 4th .

7th shows a contact element 62 in its original form, i.e. after the contact element 62 punched out but before it was bent into shape.

The positioning section 57 and the coupling section 58 are formed in one piece and the edges on which the contact element are marked by dashed lines 62 is bent to bring it into its final shape. The tabs 60 extend axially at the respective outer edge of the contact element 62 from the coupling section 58 in the direction of the contact portion 59 .

The tabs 60 , 61 are in the coupling section 58 folded. In the representation of the 7th So out of the picture plane. After that, the material that makes up the wall of the positioning section 57 and the coupling section 58 forms upwards, i.e. also out of the image plane, are folded.

The tabs 69 , 70 at the entrance of the positioning section 57 can then be bent slightly outwards, around the entry opening of the positioning section 57 to enlarge.

8th shows a schematic representation of a further embodiment of a contact element according to the invention 71 in its original form. The contact element 71 has a positioning section 63 , a coupling section 64 and a contact portion 65 on.

The contact element 71 further comprises one of the positioning portion 63 preceding strain relief section 66 on. The strain relief section 66 is essentially by two radially out of the contact element 71 protruding wings 67 , 68 educated. The wings 67 , 68 can for example be placed vertically upwards, i.e. out of the image plane, before welding with a cable.

After inserting a cable into the contact element 71 , can the wings 67 , 68 be folded over the insulation of the respective line and squeeze it. Alternatively, the wings 67 , 68 can also be folded over a single core seal and fix it. Furthermore, two strain relief sections 66 be arranged one behind the other. One of those strain relief sections 66 can fix the insulation of the respective line. The second of the Strain relief section 66 can fix a single core seal.

9 shows the contact element 71 the 8th in folded condition. You can clearly see how the wings 67 , 68 the space above the contact element 71 enclose and pinch insulation of a line there.

10 Figure 12 shows a flow diagram of the connection method for connecting one end 3 , 41 one line 2 , 40 with a contact element 5 , 45 , 49 , 53 , which has a coupling section 6th , 47 , 51 , 55 , 58 , 64 .

The procedure begins with the recording S1 and fixing the contact element 5 , 45 , 49 , 53 . Then the end will be 3 , 41 the line 2 , 40 in the contact element 5 , 45 , 49 , 53 introduced, S2. In conclusion, the end will 3 , 41 the line 2 , 40 with the coupling section 6th , 47 , 51 , 55 , 58 , 64 of the contact element 5 , 45 , 49 , 53 welded, S3.

To ensure correct welding of the end 3 , 11 with the coupling section 6th , 47 , 51 , 55 , 58 , 64 ensure the end can 3 , 41 the line 2 , 40 during the welding with a predetermined pre-force in the contact element 5 , 45 , 49 , 53 be pressed.

The welding process can also be monitored. For this purpose, the force between the line can be used during the connection 2 , 40 and the contact element 5 , 45 , 49 , 53 are detected and checked whether during the connection of the end 3 , 41 the line 2 , 40 with the contact element 5 , 45 , 49 , 53 given forces exist.

The method can also be supplemented by further steps. For example, the end 3 , 41 the line 2 , 40 must be stripped before welding. The end 3 , 41 the line 2 , 40 can then before insertion into the contact element 5 , 45 , 49 , 53 , in particular on the end face, are welded or melted.

The method according to the invention cannot only be used with individual lines 3 , 41 be performed. Rather, the method can also be done with a connector housing 22nd carried out which several lines 3 , 41 can accommodate.

This variant of the method also provides for receiving and fixing a connector housing 22nd with a number of contact chambers 23 , 24 , 25th before. The contact chambers 23 , 24 , 25th are formed, each with a contact element 5 , 45 , 49 , 53 to record. Furthermore, the connector housing 22nd at each of the contact chambers 23 , 24 , 25th a sweat opening 26th , 27 , 28 on.

When picking up and fixing S1 is then for each contact chamber 23 , 24 , 25th a contact element 5 , 45 , 49 , 53 recorded. One contact element each 5 , 45 , 49 , 53 is then in each of the contact chambers 23 , 24 , 25th introduced. When inserting S2 is in each of the in the contact chambers 23 , 24 , 25th seated contact elements 5 , 45 , 49 , 53 the end 3 , 41 one line 2 , 40 introduced. Finally, when welding S3 each of the ends 3 , 41 with the corresponding coupling section 6th , 47 , 51 , 55 , 58 , 64 in the respective contact chamber 23 , 24 , 25th through the respective welding opening 26th , 27 , 28 welded through. Then the welding openings 26th , 27 , 28 be locked.

Since the devices and methods described in detail above are exemplary embodiments, they can be modified in a wide scope in the usual way by the person skilled in the art without departing from the scope of the invention. In particular, the mechanical arrangements and the proportions of the individual elements to one another are only exemplary.

List of reference symbols

1

Connecting device

2, 40

management

3, 41

end

4, 42

insulation

5, 45, 49, 53, 62, 71

Contact element

6, 47, 51, 55, 58, 64

Coupling section

7, 46, 50, 54, 57, 63

Positioning section

8, 48, 52, 56, 59, 65

Contact section

9

contact

10, 11

Clamp

12th

Cable feed

13, 14

Clamp

15th

laser

16

laser beam

17th

Stripping device

18, 19

Sound

20th

Dynamometer

21

Housing mount

22nd

Connector housing

23, 24, 25

Contact chamber

26, 27, 28

Sweat opening

29

Locking device

30th

jet

60, 61

Tabs

66

Strain relief section

67, 68

wing

69, 70

Tabs

S1, S2, S3

Procedural steps

Claims (15)

Connecting device (1) for connecting one end (3, 41) of a line (2, 40) to a contact element (5, 45, 49, 53) which has a coupling section (6, 47, 51, 55, 58, 64) : with a contact receptacle (9) which is designed to receive the contact element (5, 45, 49, 53); with a heat source (15) which is designed to melt the end (3, 41) of the line (2, 40) before it is inserted into the contact element (5, 45, 49, 53), and with a line feed (12) which is designed to introduce the melted end (3, 41) of the line (2, 40) into the contact element (5, 45, 49, 53); wherein the heat source (15) is formed, the melted end (3, 41) of the line (2, 40) with the coupling section (6, 47, 51, 55, 58, 64) of the contact element (5, 45, 49, 53 ) to be welded. Connection device (1) according to Claim 1 , with a stripping device (17) which is designed to strip the end (3, 41) of the line (2, 40). Connecting device (1) according to one of the preceding claims, wherein the heat source (15) is designed to melt the end (3, 41) of the line (2, 40) at the front before it is inserted into the contact element (5, 45, 49, 53) . Connecting device (1) according to one of the preceding claims, wherein the heat source (15) is designed as a laser source which emits a laser beam (16). Connecting device (1) according to one of the preceding claims, wherein the line feed (12) is designed to push the end (3, 41) of the line (2, 40) into the contact element (5, 45, 49) with a predetermined initial force during welding. 53). Connecting device (1) according to one of the preceding claims, with a dynamometer (20) which is designed to detect the force between the line (2, 40) and the contact element (5, 45, 49, 53) and to check whether predetermined forces are present during the connection of the end (3, 41) of the line (2, 40) to the contact element (5, 45, 49, 53). Connecting device (1) according to one of the preceding claims, with a housing receptacle (21) for receiving a plug housing (22) with a number of contact chambers (23, 24, 25) which are formed, each with a contact element (5, 45, 49, 53), and with a welding opening (26, 27, 28) on each of the contact chambers (23, 24, 25); wherein the contact receptacle (9) is designed to receive a contact element (5, 45, 49, 53) for each contact chamber (23, 24, 25) and in each case a contact element (5, 45, 49, 53) in each of the contact chambers (23 , 24, 25) to be introduced; wherein the line feed (12) is formed into the coupling sections (6, 47, 51, 55, 58, 64) of each of the contact elements (5, 45, 49, 53) seated in the contact chambers (23, 24, 25) the end (3, 41) to introduce a line (2, 40); and wherein the heat source (15) is formed, each of the ends (3, 41) with the corresponding coupling section (6, 47, 51, 55, 58, 64) in the respective contact chamber (23, 24, 25) through the respective welding opening ( 26, 27, 28) to be welded through. Connection device (1) according to Claim 7 , with a closure device (29) which is designed to close the welding openings (26, 27, 28) after welding. Connection method for connecting one end (3, 41) of a line (2, 40) to a contact element (5, 45, 49, 53) which has a coupling section (6, 47, 51, 55, 58, 64), comprising the Steps: Receiving (S1) and fixing the contact element (5, 45, 49, 53); Melting the end (3, 41) of the line (2, 40); Inserting (S2) the melted end (3, 41) of the line (2, 40) into the contact element (5, 45, 49, 53); and Welding (S3) the melted end (3, 41) of the line (2, 40) to the coupling section (6, 47, 51, 55, 58, 64) of the contact element (5, 45, 49, 53). Connection procedure according to Claim 9 , further comprising: stripping the end (3, 41) of the line (2, 40) and / or wherein the melting has an end-face melting. Connection procedure according to one of the previous ones Claims 9 and 10 , wherein the end (3, 41) of the line (2, 40) during the welding with a predetermined preload is pressed into the contact element (5, 45, 49, 53) and / or during which the force between the line (2, 40) and the contact element (5, 45, 49, 53) is detected and it is checked whether predetermined forces are present during the connection of the end (3, 41) of the line (2, 40) to the contact element (5, 45, 49, 53). Connection procedure according to one of the previous ones Claims 9 until 11 , further comprising: receiving and fixing a plug housing (22) with a number of contact chambers (23, 24, 25) which are designed to receive a contact element (5, 45, 49, 53) each, and with a welding opening (26, 27, 28) on each of the contact chambers (23, 24, 25); wherein when receiving and fixing for each contact chamber (23, 24, 25) a contact element (5, 45, 49, 53) is received and in each case a contact element (5, 45, 49, 53) in each of the contact chambers (23, 24, 25) is introduced; the end (3, 41) being inserted into the coupling sections (6, 47, 51, 55, 58, 64) in each of the contact elements (5, 45, 49, 53) seated in the contact chambers (23, 24, 25) a conduit (2, 40) is inserted; whereby when welding each of the ends (3, 41) to the corresponding coupling section (6, 47, 51, 55, 58, 64) in the respective contact chamber (23, 24, 25) through the respective welding opening (26, 27, 28) is welded through; and wherein the welding openings (26, 27, 28) are closed in particular after the welding. Contact element (5, 45, 49, 53) for use with a connecting device (1) according to one of the Claims 1 until 8th and / or a method according to one of the Claims 9 until 12th , with: a coupling section (6, 47, 51, 55, 58, 64) which has a support for one end (3, 41) of a line (2, 40), and a positioning section (7, 46, 50, 54 , 57, 63), which is arranged in the axial extension of the coupling section (6, 47, 51, 55, 58, 64) and a guide for the line (2, 40) in the coupling section (6, 47, 51, 55, 58, 64). Connector housing (22) for use with a connecting device (1) according to one of the Claims 1 until 8th and / or a method according to one of the Claims 9 until 12th , with: a number of contact chambers (23, 24, 25) which are designed to each receive a contact element (5, 45, 49, 53); and with a welding opening (26, 27, 28) on each of the contact chambers (23, 24, 25). Connector housing (22) Claim 14 with a displaceable clamp which in an open position releases the welding openings (26, 27, 28) and which closes the welding openings (26, 27, 28) in a closed position; or with a first housing half, which has contact chambers (23, 24, 25) open at the top, and with a second housing half, which has coupling elements for coupling to the first housing half and which after the connection of line (2, 40) with corresponding contact elements (5, 45, 49, 53) in the contact chambers (23, 24, 25) can be placed on the first housing half.

Images