DE102019210427A1 - Method for producing an electrically conductive connecting element and connecting arrangement with this connecting element - Google Patents

Abstract

The invention relates to a method for producing an electrically conductive connecting element (2) of an electrical connection arrangement (1) by compacting a part of at least one electrical conductor (3), wherein during the compacting or in the course of the process following the compacting, at least one to the side surfaces (4 ) of the connecting element (2) spaced and / or angled and differentiable therefrom contact surface (5) is formed for a respective anti-rotation element (6). The invention also relates to a connection arrangement (1) comprising the connection element (2) produced by the method and an electrically conductive connection partner (12), with an anti-rotation element (6) of the connection arrangement (1) resting on each contact surface (5).

Description

The invention relates to a method for producing an electrically conductive connecting element of an electrical connecting arrangement by compacting a part of at least one electrical conductor.

The invention further relates to a connection arrangement comprising a connection element produced by means of the method and an electrically conductive connection partner.

In order to supply and / or discharge electrical energy from an energy source to an electrical machine, in particular an electrical motor, it is necessary to make contact with the stator of the electrical machine. This is done regularly by screwing in particular flexible power lines, which accordingly extend from the stator, to a power rail. The respective end of the power lines facing the power rail is usually designed with a cable lug.

As part of the screw connection of the cable lug and busbar, in addition to the torque of the actual screw connection, a torque occurs due to so-called underhead friction, which is caused by the screw pretensioning force and the coefficient of friction between the screw head and the contact partner of the screw head, in particular the cable lug.

The torque that occurs due to the under-head friction causes the cable lug to rotate with it and thus there is no defined position of it, and that this can even lead to damage to the connected stator.

For this reason, in particular the cable lug that acts as the support partner of the screw must be fixed during the screwing process and / or the torque resulting from the under-head friction must be supported.

In this context, through the DE 10 2011 108 581 A1 a connection of stator winding lines of an electric motor with supply lines is known, whereby the pivoting movement of the lines provided with cable lugs is to be prevented using a box-shaped anti-rotation part. For this purpose, the anti-rotation part has wall sections that are spaced apart from one another, into the interstices of which the lines are introduced and screwed into terminal plates arranged in the interior of the anti-rotation part. When the lines are twisted, the wall sections act as a lateral stop.

The DE 10 2014 221 578 A1 an arrangement is also described for the torsion-proof fastening of a cable provided with a cable lug in a clamping plate. For this purpose, the clamping plate has a recess into which the cable lug is pushed or inserted, in particular laterally. For this purpose, the cable lug and the recess of the clamping plate have mutually corresponding shapes, with these having contact surface pairings running obliquely with respect to a longitudinal direction of the clamping plate. This results in various developments, partly triangular or also trapezoidal configurations of the recess and cable lug. The fastening of the clamping plate and cable lug in relation to one another takes place here by means of a screw, for which purpose an internal thread is formed in the clamping plate.

Also the DE 10 2015 011 695 A1 a twist-proof connection of a cable lug with a receiving body can be seen, whereby the receiving body itself - and thus the cable lug - can be fastened to a metallic body via a bolt. For this purpose, the receiving body has, on the one hand, a recess for the form-fitting enclosing of the bolt and, on the other hand, a receiving area for the standard cable lug. The receiving area here corresponds to the contour of the cable lug and, thereby recessed, is shaped with a semicircular section and an adjoining, linear section.

However, disadvantageously all these configurations have in common a comparatively complex structure with a plurality of components. These must be assembled precisely with small tolerances to each other, which makes this assembly extremely complicated.

Against this background, the invention is based on the object of implementing the method and the connecting arrangement of the type mentioned at the outset in such a way that assembly is simplified.

This object is achieved with a method according to the features of claim 1. The subclaims relate to particularly expedient developments of the invention.

According to the invention, a method for producing an electrically conductive connecting element - in particular a cable lug - of an electrical connection arrangement by compacting a part of at least one electrical conductor - in particular consisting of strands twisted together - is provided. Here, during the Compacting or in the course of the method following compacting - indirectly or directly - at least one contact surface, which is spaced and / or angled from side surfaces of the connecting element, in particular parallel, and thus differentiable from these, is designed for a respective anti-rotation element. The side surfaces of the connecting element should be the lateral surfaces of the connecting element, which partially encircle and, in contrast to the top and bottom surfaces, do not form a connection with a connection partner of the connection element and / or a fastening means, in particular for fastening the connection element and connection partner. The spacing and / or angling of the contact surface or contact surfaces with respect to these side surfaces of the connecting element can advantageously make it possible to introduce a connection partner of the connecting element, for example a busbar, at an increased distance from the anti-rotation element, preferably two mutually spaced anti-rotation elements, into the connection arrangement . In particular with two anti-rotation elements, the connection partner could be inserted between the anti-rotation elements with a high tolerance and thus in a simple manner, in particular wedging or bumping of the connection partner against the anti-rotation elements and thus simplifying assembly. In this case, the connecting element should essentially have the same width as the connecting partner, accordingly apart from any spaced-apart contact surfaces. This is comparable in the case of contact surfaces angled with respect to the side surface or the side surfaces. Since the contact surface or contact surfaces would regularly have to be parallel to the connection partner so that the anti-rotation elements do not collide with it, it would be necessary for the connection element to be arranged in an angular position opposite the connection partner, which would also allow an increased distance between the connection partner and the anti-rotation elements.

In general, it should also be noted that the part of the electrical conductor which is compacted to form the connection element or the cable lug would be one of the ends or even both ends of the electrical conductor, in particular consisting of strands. Compacting of the electrical conductor is to be understood in particular as the solidification by, for example, sintering or welding of the strands of the electrical conductor under the influence of pressure and, in particular, heat generated by a current flow.

In an extremely advantageous development of the method according to the invention, at least one safety stop projecting beyond a side edge of the connecting element is formed in the connecting element, in particular in at least one edge region of the connecting element. Here, the safety stop or the safety stops should have the contact surfaces for a respective anti-rotation element. The formation of the safety stops offers an effectively simple possibility of allowing the contact surfaces to be spaced apart from the side surfaces of the connecting element. In addition, a connection partner, possibly forming a connection arrangement with the connection element, and the connection element itself would not have to be changed, in particular reduced, in terms of their width and / or thickness, which in terms of the restrictions due to the compacting of the electrical conductor, in particular consisting of strands, and in terms of maximum transferable currents between Connection element and connection partner would only be difficult or impossible to implement.

It is also favorable if, before compacting, an electrical conductor to be compacted transversely to the longitudinal direction of the connecting element to be compacted is arranged at least one second electrical conductor protruding beyond the sides of the electrical conductor, the second electrical conductor being inserted or respectively inserted into the connecting element during compacting Part of the connecting element. In this way, for example, one securing stop or several, preferably two, securing stops can be formed directly on the connecting element, wherein these can in particular have the contact surface or contact surfaces for the anti-rotation element or elements. For this purpose, for example, two second electrical conductors could be arranged transversely to the - first - electrical conductor and then compacting could be carried out.

It is also to be regarded as particularly favorable if the at least one safety stop is introduced into the connecting element - immediately - following compacting by means of stamping and / or cutting. In particular, in the case of an embossing of the safety stop in an edge area or opposite edge areas of the connecting element, the safety stop or the safety stops should be formed from the connecting element in such a way that this or these partly protrude beyond the side edge of the connecting element due to the material displacement during embossing. In principle, any cross-sectional shape of the safety stop is conceivable due to the embossing, but a circular cross-section should preferably be provided. The formation of the safety stop by means of separation can take place in particular if, for example, a second electrical conductor or even several second electrical conductors were arranged transversely to the - first - electrical conductor before compacting and thus a part protruding over the side edges of the electrical conductor or the connecting element is present from which through Separate a safety stop or several, preferably two safety stops can be formed.

In an also profitable embodiment of the invention, a part of a respective securing stop, in particular formed by means of embossing, facing away from the connecting element is cut off, in particular by means of a cutting tool, so that a respective contact surface is created in the respective securing stop. The part of the safety stop can advantageously be separated by means of punching. The creation of the contact surface by separating part of the safety stop offers profitable the possibility of z. B. compared to a direct formation of the contact surface when compacting the electrical conductor to ensure a contact surface with improved surface quality and thus to be able to allow a lower tolerance between the contact surface and the anti-rotation element.

A promising embodiment of the method according to the invention is further characterized in that the conductor is shaped before and / or during the compacting, so that the compacted connecting element has two sections angled to one another. This advantageously makes it possible for the distance or the tolerance between the connection partner and the anti-rotation device to be advantageously increased when a connection arrangement is designed which includes a further connection partner in addition to the connection element, while the contact area between the connection element and connection partner and its width continue to be designed to be consistently high can be. This profitably means that no restrictions would have to be made with regard to the maximum transmittable current strengths.

An embodiment of the invention is also to be regarded as having advantages, in which the second electrical conductor is a stranded conductor, for example a braid, and / or a sheet metal. The use of a second stranded conductor or a sheet metal as a second electrical conductor introduced prior to compacting offers the advantage that the process parameters required for compacting do not have to be adapted, or only have to be adapted to a small extent. In addition, the use of a sheet metal or a stranded conductor made in particular of copper offers the prospect of simple processing of this by means of cutting, in particular punching.

The object is also achieved with a connection arrangement according to the features of patent claim 8. The subclaims relate to particularly expedient developments of the invention.

According to the invention, a connection arrangement is thus also provided which has the connection element produced by means of the method according to the invention - in particular a cable lug - and an electrically conductive connection partner - in particular a busbar. Here, an anti-rotation element of the connecting arrangement rests on each contact surface. Furthermore, it is profitable if the connecting element has two contact surfaces in order to be able to ensure protection against twisting of the connecting element and / or the connecting partner by means of a fastening means both when attaching and when loosening a particularly non-positive connection between the connecting element and the connecting partner. The fastening means can in this case be a screw, whereby this would be passed through respective openings in the connection element and connection partner and engages in a corresponding mating thread.

In a particularly advantageous development of the connection arrangement, a safety stop projecting beyond the respective side edge of the connection element is formed on the two opposite edge regions of the connection element, the safety stops being offset from one another in the longitudinal direction of the connection element. In this case, these should each be oppositely spaced from a pivot point, which is determined in particular by the fastening means, so that securing against rotation is accordingly ensured both when fastening and when loosening the fastening element. The shape of the securing stops offers an effectively simple possibility of allowing the contact surfaces to be spaced apart from the side surfaces of the connecting element, whereby the connecting partner could be inserted between the anti-rotation elements with a high tolerance and thus in a simple manner and in particular wedging or abutting the connecting partner the anti-rotation elements can be avoided profitably. The contact surfaces should be designed parallel to one another.

In this context, an embodiment of the connection arrangement is also beneficial if the anti-rotation elements in or across the longitudinal direction of the The connecting element rest on the contact surfaces. In this case, it would be necessary for the width of the safety stops, which extends in relation to the side edge of the connecting element, to differ, depending on the system. If the anti-rotation elements are to rest on the contact surfaces of the locking stops transversely to the longitudinal direction of the connecting element, the locking stops are only to be designed so wide that there is a small tolerance between the anti-rotation element and the contact surface. In the case of contact in the longitudinal direction of the connecting element, the width of the securing stops would accordingly have to be selected such that they extend at least as far as a respective contact area of contact surface and anti-rotation element.

• 1a bis 1c Weiterbildungen einer Verbindungsanordnung;
• 2a bis 2c die Herstellung einer ersten Weiterbildung des Verbindungselements;
• 3a bis 3c die Herstellung einer ersten Weiterbildung des Verbindungselements in zweiter Darstellung;
• 4a bis 4c die Herstellung einer zweiten Weiterbildung des Verbindungselements;
• 5a bis 5c die Herstellung einer dritten Weiterbildung des Verbindungselements;
• 6a, 6b die Herstellung einer vierten Weiterbildung des Verbindungselements.

The invention allows numerous embodiments. To further clarify its basic principle, several of them are shown in the drawing and are described below. The drawing shows in

• 1a to 1c Developments of a connection arrangement;
• 2a to 2c the production of a first development of the connecting element;
• 3a to 3c the production of a first development of the connecting element in a second illustration;
• 4a to 4c the production of a second development of the connecting element;
• 5a to 5c the production of a third development of the connecting element;
• 6a , 6b the production of a fourth development of the connecting element.

The 1a to 1c are each further developments of a connection arrangement 1 to be taken, these each being the electrically conductive connecting element 2 , designed as a cable lug, as well as the connection partner, which is also electrically conductive 12 exhibit. The connection partner 12 is designed here as a busbar. The connecting element 2 in turn is made by compacting part of the electrical conductor 3 manufactured. To avoid twisting the connecting element 2 towards the connection partner 12 by fastening and / or loosening the fastening means designed as a screw 13th is at the transverse to the longitudinal direction L. opposite side surfaces 4th of the connecting element 2 each one over the respective margin 7th protruding safety stop 8th shaped, with the safety stops 8th each the contact surface 5 exhibit. These contact surfaces 5 are thereby to the side surfaces 4th run at a distance, which leads to the fact that the connection partner 12 a large distance to the anti-rotation elements 6th has to which the connecting element 2 when attaching and / or loosening the fastener 13th over the contact surfaces 5 applies. This can be the case in the 1a Further developments shown are made possible both when attaching and when releasing, since each of the upper and / or the lower area of the safety stops 8th to the anti-rotation elements 6th applies. This is because the in 1a shown anti-rotation elements 6th as well as the safety stops 8th are designed such that the anti-rotation elements 6th transverse to the longitudinal direction L. of the connecting element 2 on the contact surfaces 5 issue. In case of 1 b and 1c this is only when attaching the fastener 13th possible, because in these developments the anti-rotation elements 6th longitudinal L. of the connecting element 2 on the contact surfaces 5 the safety stops 8th issue. In addition, the training shows 1b that just a safety stop 8th with the contact surface 5 and only one anti-rotation element 6th is executed. Furthermore, the safety stops 8th in the in the 1a and embodiments of the connecting arrangement shown in FIG. 1c 1 longitudinal L. of the connecting element 2 to each other and on both sides of the fastening means 13th Defining pivot point arranged offset.

In the 2a to 2c as well as 3a to 3c are sections of the production of the connecting element 2 shown, which, as already described above, is generated in that first a part of the electrical conductor 3 is compacted. Immediately on compacting the electrical conductor 3 following, is in to the transverse to the longitudinal direction L. opposite edge areas of the connecting element 2 , which are also transverse to the longitudinal direction L. opposite margins 7th include, one over each side of the page 7th of the connecting element 2 protruding safety stop 8th formed by means of embossing. This creates the protrusion of the safety stop 8th by displacing material of the connecting element 2 outward. Following the stamping of the safety stops 8th becomes a connecting element 2 remote part of a respective safety stop 8th separated so that in the course of the procedure indirectly following the compacting in the respective safety stop 8th a respective one to the side surfaces 4th objected and thus differentiable contact area 5 is trained. To these contact surfaces 5 lie down, as in 2c shown, the anti-rotation elements for the purpose of anti-rotation 6th at.

Furthermore, the 4a to 4c and 5a to 5c the production of one each Further development of the connecting element 2 can be seen in which prior to compacting the electrical conductor 3 to the connecting element 2 first the transverse to the longitudinal direction L. of the connecting element 2 across the pages 9 of the electrical conductor 3 protruding, second electrical conductor 10 is arranged. The - first - electrical conductor is then compacted 3 and the second electrical conductor 10 to the connecting element 2 like this in the 4b and 5b is shown. By separating part of the connecting element after compacting 2 is in the fastener 2 on which are transverse to the longitudinal direction L. opposite side surfaces 4th each one over the margins 7th of the connecting element 2 protruding safety stop 8th educated. The safety stops 8th are to each other in the longitudinal direction L. executed staggered and, due to the separation, again point to the side surfaces 4th spaced contact surfaces 5 on. The ones in the 4a to 4c and connecting elements shown in FIGS. 5a to 5c 2 differ only in that the second electrical conductor 10 the continuing education of 4a to 4c a sheet and in the training of 5a to 5c is a stranded conductor.

The 6a and 6b is also the production of a further development of the connecting element 2 can be seen in which, on the compacting of the in 2a shown connecting element 2 following, in each case to the transverse to the longitudinal direction L. opposite side surfaces 4th of the connecting element 2 to the side surfaces 4th angled and thus differentiable contact surfaces 5 be formed by separating. In this case, the electrical conductor is shaped before and during compacting 3 so that the compacted fastener 2 even two angled sections 11 having.

List of reference symbols

1

Connection arrangement

2

Connecting element

3

electrical conductor

4th

Side face

5

Contact surface

6th

Anti-rotation element

7th

Margin

8th

Safety stop

9

pages

10

second electrical conductor

11

section

12

Connection partner

13

Fasteners

L.

Longitudinal direction

QUOTES INCLUDED IN THE DESCRIPTION

This list of the documents listed by the applicant was 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.

Patent literature cited

• DE 102011108581 A1 [0007]
• DE 102014221578 A1 [0008]
• DE 102015011695 A1 [0009]

Claims (10)

A method for producing an electrically conductive connection element (2) of an electrical connection arrangement (1) by compacting a part of at least one electrical conductor (3), characterized in that during the compacting or in the course of the process following the compacting, at least one to the side surfaces (4 ) of the connecting element (2) spaced apart and / or angled and differentiable therefrom contact surface (5) is formed for a respective anti-rotation element (6). Procedure according to Claim 1 , characterized in that at least one safety stop (8) protruding beyond a side edge (7) of the connecting element (2) is formed in the connecting element (2). Procedure according to the Claims 1 or 2 , characterized in that before compacting at least one transverse to the longitudinal direction (L) of the electrical conductor (3) to be compacted to the connecting element (2) is a second electrical conductor (10) protruding beyond the sides (9) of the electrical conductor (3) is arranged. Method according to at least one of the preceding claims, characterized in that the at least one safety stop (8) is introduced into the connecting element (2) following the compacting by means of stamping and / or cutting. Method according to at least one of the preceding claims, characterized in that a part of a respective safety stop (8) facing away from the connecting element (2) is separated so that a respective contact surface (5) is created in the respective safety stop (8). Method according to at least one of the preceding claims, characterized in that the electrical conductor (3) is shaped before and / or during compacting, so that the compacted connecting element (2) has two sections (11) angled to one another. Method according to at least one of the preceding claims, characterized in that the second electrical conductor (10) is a stranded conductor and / or a sheet metal. Connection arrangement (1) comprising the connection element (2) produced by means of the method according to at least one of the preceding claims and an electrically conductive connection partner (12), with an anti-rotation element (6) of the connection arrangement (1) resting on each contact surface (5). Connection arrangement (1) according to Claim 8 , characterized in that a safety stop (8) projecting beyond the respective side edge (7) of the connecting element (2) is formed on the two opposite edge areas of the connecting element (2), the safety stops (8) in the longitudinal direction (L) of the connecting element (2) are arranged offset from one another. Connection arrangement (1) according to the Claims 8 or 9 , characterized in that the anti-rotation elements (6) rest on the contact surfaces (5) in or across the longitudinal direction (L) of the connecting element (2).

Images