DE102020207810A1 - Method of manufacturing a resistor assembly and resistor assembly - Google Patents

Abstract

The invention relates to a method for producing a resistor assembly (24) for a battery sensor (10), the resistor assembly (24) having a first connection element (12), in particular for contacting a battery terminal of a vehicle battery, and a second connection element (16), in particular for Contacting a ground line and a resistance element (20), the first connection element (12) and the second connection element (16) each having a first connection surface (32, 34) with a second connection surface (36, 36) provided on the resistance element (20). 38) are electrically connected, with the following steps: Providing the first connection element (12) and / or the second connection element (16) and the resistance element (20), the first connection element (12), the second connection element (16) and / or the resistance element (20) have a coating (40, 42, 44), with at least one first connection surface (32, 34) and / or the coating is removed from a corresponding second connection surface (36, 38), - aligning the first connection element (12) and / or the second connection element (16) and the resistance element (20) so that a first connection surface (32, 34) on a second Connecting surface (36, 38), - connecting the at least one first connecting surface (32, 34) to the adjacent second connecting surface (36, 38) using a welding process. The invention further relates to a resistor assembly (20) produced using such a process and a battery sensor (10) with such a resistor assembly (20).

Description

The invention relates to a method for manufacturing a resistor assembly for a battery sensor and a resistor assembly manufactured using this method, the resistor assembly having a first connection element, a second connection element and a resistance element which electrically connects the first connection element and the second connection element to one another. The invention also relates to a resistor assembly produced using such a method.

Battery sensors are used in vehicles to obtain information about the battery status, for example the battery charge status. The battery parameters to be recorded are, for example, the battery voltage, the battery current and the temperature of the battery, with the battery voltage and the battery current in particular having to be recorded permanently in order to be able to make an exact statement about the state of the battery, for example the state of charge.

The current is detected, for example, by detecting a voltage drop across a measuring resistor arranged in the load current. The electrical resistance of the measuring resistor is known very precisely. Due to the detected voltage drop, the current flowing through the measuring resistor, i.e. the load current, can be determined very precisely using Ohm's law.

Usually, a material is used for the measuring resistor which has a low temperature dependence and a low aging drift of the electrical resistance, for example a copper-nickel-manganese alloy.

The connection elements are made from a material with a high conductivity, for example from copper or a copper alloy. For example, a first connection element has a battery pole terminal and a second connection element has a cable connection for a ground cable. The cable connection for the ground cable can be formed, for example, by a cable lug or by a bolt.

Connection sections for making contact with the connection elements are usually provided on the measuring resistor. To produce the resistor assembly, the connection elements and the resistance element consisting of the connection sections and the measuring resistor are aligned relative to one another, so that a first connection area provided on the connection elements and a second connection area provided on the resistance element, in particular the connection section, can be connected to one another.

In the prior art, the connection elements, in particular the second connection element to which the ground cable is attached, are connected to the connection sections of the measuring resistor by soldering, in particular by resistance brazing. Alternatively, it is known to weld the connection elements and the resistance element, for example using a resistance welding process. The connection sections consist of the same or a similar material as the connection elements, so that welding is simplified.

Reliable contact between the connection elements and the measuring resistor must be ensured during regular vehicle operation. This is necessary to ensure reliable determination of the battery condition. In addition, the connection between the connection element and the measuring resistor must withstand the loads occurring during vehicle operation, for example mechanical loads such as vibrations or shocks or temperature fluctuations. In particular, the second connection element to which the earth cable is attached must be connected to the measuring resistor in a stable manner.

Furthermore, such a resistor assembly should be simple and inexpensive to manufacture.

The object of the invention is to provide a method for producing a resistor assembly for a battery sensor that enables the resistor assembly to be manufactured simply and inexpensively, the resistor assembly having to reliably withstand the loads occurring in the vehicle. The object of the invention is also to provide such a resistor assembly and a battery sensor with such a resistor assembly.

• - Bereitstellen des ersten Anschlusselements und/oder des zweiten Anschlusselement sowie des Widerstandselements, wobei das erste Anschlusselement, das zweite Anschlusselement und/oder das Widerstandselement eine Beschichtung aufweisen, wobei an zumindest einer ersten und/oder einer korrespondierenden zweiten Anschlussfläche die Beschichtung entfernt ist,
• - Ausrichten des ersten Anschlusselements und/oder des zweiten Anschlusselement sowie des Widerstandselements, sodass eine erste Anschlussfläche an einer zweiten Anschlussfläche anliegt,
• - Verbinden der zumindest einen ersten Anschlussfläche mit der anliegenden zweiten Anschlussfläche mit einem Schweißverfahren.

To achieve the object, a method for producing a resistor assembly for a battery sensor is provided, the resistor assembly having a first connection element, in particular for contacting a battery terminal of a vehicle battery, a second connection element, in particular for contacting a ground line, and a resistance element, the The first connection element and the second connection element are each electrically connected to a first connection area with a second connection area provided on the resistance element. The procedure consists of the following steps:

• - Providing the first connection element and / or the second connection element and the resistance element, the first connection element, the second connection element and / or the resistance element having a coating, the coating being removed from at least one first and / or a corresponding second connection surface,
• - Alignment of the first connection element and / or the second connection element and the resistance element so that a first connection surface rests against a second connection surface,
• - Connecting the at least one first connection surface to the adjacent second connection surface with a welding process.

The connection elements and the resistance element usually have a coating in order to increase the resistance to corrosion of the resistance assembly. In a welding process in particular, the material of the coating present in the area of the connection surfaces is also melted and, after subsequent curing, is located in the joint area between the first and second connection surfaces, whereby the stability of the connection and the electrical conductivity can be influenced. In order to avoid this, before the connection process between the connection elements and the resistance element, it is ensured that there is no coating on the connection surfaces, so that the welding areas can be made much more precisely. In this way, on the one hand, the quality of the welding areas and thus the mechanical strength can be improved. Furthermore, it is ensured that the electrical conductivity of the resistor assembly is always constant in the welding area, since there is no contamination from the material of the coating.

The coating on the first and / or the second connection surface and / or on the resistance element is preferably removed before the alignment. This means that the connection elements and the resistance element are first completely coated, which ensures a simple coating process. The coating on the connection surfaces is only removed before the connection elements and the resistance element are aligned. Another advantage of this embodiment of the method is that the connection surfaces can be individually adapted during the joining process. In particular, different alignments can be implemented for the cable outlet, wherein the first connection surfaces on the first or on the second connection element and / or the second connection surface on the resistance element can be selected according to the desired orientation of the first connection element and / or the second connection element and the coating is removed accordingly can.

For example, the coating is removed using an abrasive process, which enables the coating to be removed quickly and reliably.

The coating can be removed, for example, with a laser, with which the coating can be removed particularly quickly and flexibly. In particular, different areas can be removed so that a quick adaptation to different connection surfaces or their alignment can take place.

Alternatively, the coating can also be removed when the coating is applied, or no coating can be applied to the connection surfaces. This can be done, for example, by masking in which the connection surfaces are covered so that no coating is applied to them. In this embodiment, the connection elements and the resistance element are delivered in such a way that they can be aligned and connected to one another without additional processing.

At least one material elevation can be provided on at least one first connection surface and / or a second connection surface, which is melted during the welding process and then solidifies, the coating being removed at least in the area of the material elevation and an area of a connection surface opposite the material elevation. The material elevation thus provides the material for the welding process.

The first connection surfaces and the second connection surfaces are preferably welded using a resistance welding process in which the connection surfaces are heated by pressure and current in such a way that the connection surfaces partially melt and are welded to one another during the subsequent cooling. Due to the material elevations, the connection surfaces are only in contact with one another at certain points in the area of the material elevations, whereby the current and the pressure are concentrated on these areas, resulting in greater heating in these areas and thus a melting of the material in this area. As a result, the welding process can be better regulated and better welding results can be achieved.

With such a method in particular, the coating in the area of the material elevations would result in severe contamination in the welding area. In addition, the coating could change the geometry of the material elevations. In particular, the contact area between the connection areas could be enlarged, as a result of which higher currents would be required to heat the contact areas. Since the method described above means that there is no coating in the area of the connection surfaces, the quality of the welding method, among other things, can be significantly improved, especially with such a welding method.

The welding process is, for example, a resistance welding process, with the coating in particular being removed in a contact area of the welding electrodes. In a resistance welding process, the current is applied to the two components, i.e. to the connection elements and the resistance element, by means of electrodes. By removing the coating in the contact areas, the electrical contact between the electrodes and the components is improved. On the other hand, contamination of the electrodes by the coating in the contact areas is prevented.

The coating is preferably an anti-corrosion coating, in particular a tin coating.

To achieve the object, a resistor assembly for a battery sensor is also provided, the resistor assembly having a first connection element, in particular for contacting a battery terminal of a vehicle battery, a second connection element, in particular for contacting a ground line, and a resistance element, the first connection element and the second connection element is electrically connected by a first connection area to a second connection area provided on the resistance element. The resistor assembly is produced by a method according to one of the preceding claims.

To achieve the object, a battery sensor, in particular for a vehicle, is also provided, with such a resistor assembly and with at least one detection device for detecting battery parameters.

• 1 eine perspektivische Darstellung eines Batteriesensors mit einer erfindungsgemäßen Widerstandsbaugruppe;
• 2 eine schematische Darstellung der Widerstandsbaugruppe des Batteriesensors aus 1 ;
• 3a - 3d Verfahrensschritte zur Herstellung der Widerstandsbaugruppe aus 2;
• 4 eine schematische Darstellung verschiedener Positionen des zweiten Anschlusselements am Widerstandselement; und
• 5a - 5e Ausführungsformen eines Anschlusselements für die Widerstandsbaugruppe aus 2.

Further advantages and features emerge from the following description in conjunction with the accompanying drawings. In these show:

• 1 a perspective view of a battery sensor with a resistor assembly according to the invention;
• 2 a schematic representation of the resistor assembly of the battery sensor 1 ;
• 3a - 3d Process steps for manufacturing the resistor assembly 2 ;
• 4th a schematic representation of different positions of the second connection element on the resistance element; and
• 5a - 5e Embodiments of a connection element for the resistor assembly from 2 .

In 1 is a battery sensor 10 shown with a first connection element 12 that has a battery post clamp 14th having a second connection element 16 that has a cable connector 18th for a ground cable, as well as with a resistance element 20th that is the first connector 12 and the second connection element 16 electrically connects to each other. Furthermore, one is not shown in detail here in a housing 22nd arranged detection device for at least one battery parameter.

For example, the detection device is a voltage detection device for detecting a voltage drop across the resistance element due to a current flowing between the first connection element and the second connection element. From the detected voltage drop and the known electrical resistance of the resistance element 20th can be between the first connection element 12 and the second connection element 16 , so the one about the battery sensor 10 , flowing load current can be determined.

The first connection element 12 , the second connection element 16 and the resistance element 20th together form a resistor assembly 24 which are shown schematically in 2 is shown. On this resistor assembly 24 the detection devices and the housing are mounted during the manufacture of the battery sensor.

As in 2 can be seen, has the resistance element 20th a measuring resistor 26th which consists of a material that has a low dependence of the electrical resistance on the temperature and a low aging drift of the electrical resistance. For example, the measuring resistor 26th made of a copper-nickel-manganese alloy. Furthermore, the resistance element 20th two connection sections 28 , 30th for contacting the first connection element 12 and the second connection element 16 on.

The connection elements 12 , 16 each have a first connection surface 32 , 34 with which the connection elements 12 , 16 one at each of the connection sections 28 , 30th provided second connection surface 36 , 38 with the resistance element 20th are connected. The connection element 12 , 14th as well as the resistance element 20th exhibit a coating 40 , 42 , 44 on, preferably an anti-corrosion coating. For example, the coating is made of tin or a tin alloy

The connection between the connection elements 12 , 16 preferably takes place with a welding process, in particular with a resistance welding process, in which the connection surfaces are heated by current and pressure and thus welded.

The manufacturing process is described below with reference to 3a to 3c described, here only the connection between the second connection element 16 and the resistance element 20th is described. The first connection element 12 is already with the resistance element 20th connected, and this can be done in the same way that is used below for establishing the connection between the second connection element 16 and the resistance element 20th is described.

Alternatively, the first connection element 12 integral with the resistance element 20th be trained.

In a first process step, the connection element 16 as well as the resistance element 20th provided. As in particular in 3a can be seen on the first connection surface 34 several material surveys 46 provided in the direction of the second connection surface 38 protrude. These material elevations consist of the same material as the connection surface 34 .

The material surveys 46 are preferably used in the manufacture of the second connection element 16 manufactured. For example, the material surveys 46 produced by a stamping or pressing process. Alternatively, this can also be done after the connection element has been produced 16 on the connection surfaces 34 be applied.

After the connection elements have been manufactured 14th , 16 as well as the resistance element 20th these become flat, in particular completely, with a coating 40 , 42 , 44 provided, in particular an anti-corrosion coating.

After providing the connection element 16 as well as the resistance element 20th becomes the coating 42 , 44 at the connection surfaces 34 , 38 away ( 3b) . Furthermore, the coating is applied in contact areas 48 , 50 removed, which in the embodiment shown here are provided on surfaces opposite to the connection surfaces.

The coatings 40 , 42 , 44 are removed, for example, with an abrasive process, for example a laser process. The coatings are preferably completely removed 42 , 44 at the connection surfaces 34 , 38 as well as the contact areas 48 , 50 to prevent contamination in the welding area or contamination of the electrodes. Alternatively, the coating 42 , 44 can only be partially removed.

Furthermore, the coatings 40 , 42 , 44 also removed by any other suitable method.

Then the connection element 16 as well as the resistance element 20th aligned in the desired position relative to one another, with the first connection surface 34 of the second connection element 16 with the material surveys 46 at the second connection surface 38 of the resistance element 20th is present ( 3c ).

After aligning the second connection element 16 on the resistance element 20th the first connection surface is welded 34 and the second pad 38 by melting the material elevations 46 as well as the adjacent areas of the connection surfaces 34 , 38 and subsequent curing of the material of the material elevations 46 and the pads 34 , 38 .

The connection elements are preferably 14th , 16 as well as the connection sections 28 , 30th made of the same or a similar material, so that the welding creates a homogeneous structure at the welding areas.

In the present case, the energy is introduced by applying a current between the second connection element 16 and the resistance element 20th about electrodes 52 , 54 that are at the contact areas 48 , 50 be created. Due to the small cross-section of the material elevations 46 compared to the connection element 16 or in comparison to the resistance element 20th the current causes strong local heating of the material elevations 46 and the adjacent areas of the pads 34 , 38 ( 3d ).

As the coatings 42 , 44 have also been removed in the area of the electrodes, there is a reliable current flow between the electrodes and the connection element 16 or the resistance element 20th ensured. In addition, there is no contamination of the electrodes by the coatings 42 , 44 in the area of contact areas 48 , 50 .

As the pads 34 , 38 and the material surveys 46 consist of the same material, is created by the subsequent hardening of the material of the material elevations 46 a form-fitting, in particular one-piece connection between the connection surfaces 34 , 38 , so the second connection element 16 and the resistance element 20th which has a very high strength.

As the coatings 42 , 44 at the connection surfaces 34 , 38 are removed, only the material of the material bumps is removed 46 melted. Thus there are in the welding area between the connection surfaces 34 , 38 no contamination from the coatings 42 , 44 .

The melting of the material bumps 46 and the adjacent areas of the pads 34 , 38 can also be done in other ways through a high energy input in the area of the material elevations 46 take place, for example by an ultrasonic welding process. As the pads 34 , 38 initially only via the material surveys 46 attached to the second pad 38 are in contact with each other, takes place on the material elevations 46 a concentration of the energy flow, which leads to a strong local heating of the material elevations 46 and thus to a melting of the material elevations 46 leads.

Alternatively, any other method can also be used which results in heating and melting of the material elevations 46 leads, for example, a laser welding process.

Instead of removing the coating on the pads 32 , 34 , 46 , 38 or the contact areas 48 , 50 After applying the coating, these areas can be used when applying the coating 40 , 42 , 44 be left out. That means there is no coating in these areas 40 , 42 , 44 upset. For example, these areas can be masked during an electroplating process.

In the embodiments shown here, the material bumps are 46 each on the second connection element 16 arranged. This has the advantage that an arrangement of the material elevations 46 can be done in such a way that the melted and then hardened material of the material elevations 46 on the ground cable 38 acting forces, in particular tensile forces, can ideally absorb, regardless of the positioning or the alignment of the second connection element 16 on the resistance element 20th (please refer 4th ).

Regardless of this, the material surveys 46 but also on the resistance element 20th be provided.

In particular, the material elevations 46 be arranged so that an ideal load bearing through the melted and then hardened material of the material elevations 46 can be done. In the 5a to 5e are different embodiments for material elevations 46 intended.

In 5a are for example only two, with respect to the prevailing load direction 52 transversely distributed material elevations 46 intended.

In 5b is just a large, circular material bump 46 intended.

In the 5c and 5d is a material survey 46 provided that are transverse or longitudinal to the load direction 52 extends.

In 5e are three material elevations arranged in a triangle 46 intended.

List of reference symbols

10

Battery sensor

12th

first connection element

14th

Battery post clamp

16

second connection element

18th

Cable connection

20th

Resistance element

22nd

casing

24

Resistor assembly

26th

Measuring resistor

28

Connection section

30th

Connection section

32

first pad

34

first pad

36

second pad

38

second pad

40

Coating

42

Coating

44

Coating

46

Material survey

48

Contact area

50

Contact area

52

Load direction

Claims (10)

A method for producing a resistor assembly (24) for a battery sensor (10), the resistor assembly (24) having a first connection element (12), in particular for contacting a battery terminal of a vehicle battery, and a second connection element (16), in particular for contacting a ground line , and a resistance element (20), the first connection element (12) and the second connection element (16) each electrically connected to a first connection surface (32, 34) with a second connection surface (36, 38) provided on the resistance element (20) with the following steps: - Provision of the first connection element (12) and / or the second connection element (16) and the resistance element (20), the first connection element (12), the second connection element (16) and / or the resistance element (20) having a coating (40 , 42, 44), the coating being removed from at least one first connection surface (32, 34) and / or a corresponding second connection surface (36, 38), - Alignment of the first connection element (12) and / or the second connection element (16) and the resistance element (20) so that a first connection surface (32, 34) rests against a second connection surface (36, 38), - Connecting the at least one first connection surface (32, 34) to the adjacent second connection surface (36, 38) using a welding process. Procedure according to Claim 1 , characterized in that the coating (40, 42, 44) on the first connection surface (32, 34) and / or the second connection surface (36, 38) is removed before the alignment. Procedure according to Claim 2 , characterized in that the coating (40, 42, 44) is removed using an abrasive process. Method according to one of the Claims 2 and 3 , characterized in that the coating (40, 42, 44) is removed with a laser. Procedure according to Claim 1 , characterized in that the coating (40, 42, 44) is removed when the coating (40, 42, 44) is applied. Method according to one of the preceding claims, characterized in that at least one material elevation (46) is provided on at least one first connection surface (32, 34) and / or a second connection surface (36, 38), which is melted during the welding process and then solidifies wherein the coating (40, 42, 44) is removed at least in the area of the material elevation (46) and an area of a connection surface (32, 34, 36, 38) opposite the material elevation (46). Procedure according to Claim 6 , characterized in that the welding process is a resistance welding process, in particular the coating (40, 42, 44) in a contact area (48, 50) of the welding electrodes being removed. Method according to one of the preceding claims, characterized in that the coating (40, 42, 44) is an anti-corrosion coating, in particular a tin coating. Resistance assembly (24) for a battery sensor (10), with a first connection element (12), a second connection element (14) and a resistance element (20) which electrically connects the first connection element (12) and the second connection element (16) to one another, wherein the first connection element (12) and / or the second connection element (16) is connected to a first connection surface (32, 34) with a second connection surface (36, 38) provided on the resistance element (20), the resistance assembly (20) with a method according to any one of the preceding claims. Battery sensor (10), in particular for a vehicle, with a resistor assembly (20) according to Claim 9 and with at least one detection device for detecting at least one battery parameter.

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