EP1571731A1 - Method of manufacturing a connection between a plurality of varnish-insulated conductors - Google Patents
Method of manufacturing a connection between a plurality of varnish-insulated conductors Download PDFInfo
- Publication number
- EP1571731A1 EP1571731A1 EP05003715A EP05003715A EP1571731A1 EP 1571731 A1 EP1571731 A1 EP 1571731A1 EP 05003715 A EP05003715 A EP 05003715A EP 05003715 A EP05003715 A EP 05003715A EP 1571731 A1 EP1571731 A1 EP 1571731A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- welding
- metal sleeve
- conductors
- electrical
- connection
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
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Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/02—Soldered or welded connections
- H01R4/026—Soldered or welded connections comprising means for eliminating an insulative layer prior to soldering or welding
Definitions
- the invention relates to a method for producing an electrical Connection between several enamel-insulated electrical conductors.
- soldering is a relatively complex task Method. On the one hand you need appropriate solder, on the other hand also here the cable ends must be stripped before soldering.
- the welding process is preferably in a compacting device carried out.
- a center frequency inverter welding system used.
- the electrical power kept constant.
- a typical time sequence of a welding process proceeds as follows: First, the compacting device is closed and fed to the electrode (s) and built the Kompaktierkraft. Subsequently, the parts are welded, at the beginning of the welding process initially stripping the conductor takes place. In the course of the welding process, a connection between the conductors and the metal sleeve is made. In this case, at the beginning of the welding process, the welding current flows substantially over the metal sleeve, whereby the sleeve is heated and partially evaporated or liquefied the insulating varnish. In the further course of the welding process, the welding current flows essentially over the conductors and welds them together and with the sleeve. The pressure exerted by the welding electrodes of the compacting device on the weld pressure supports the welding process and also ensures the displacement of the insulating paint from the metal sleeve.
- the welding process is carried out in two welding steps.
- a stripping of the conductors is performed.
- the second Welding step a connection between the conductors and the metal sleeve produced.
- a comparatively smaller Welding current e.g. 50 A
- the Welding current flows substantially over the metal sleeve, the sleeve heated and evaporated the insulating varnish.
- a comparatively large welding current e.g. 100 A, with short welding time used, wherein the welding current flows substantially over the conductors and these welded together and with the sleeve.
- the one of the Welding electrodes of the compacting device on the weld applied pressure supports the welding process and also provides for the displacement of the insulating paint from the metal sleeve.
- An advantageous material for the welding electrodes is molybdenum proven, since it has a long service life and good mechanical can process.
- the welding sleeve used is a standard core sleeve, preferably a tinned metal sleeve.
- the material, the wall thickness and the coating (tinning) of the sleeve influence the welding process.
- As a material for the metal sleeve can be used optionally steel, nickel, CuSn or copper. An embodiment of the invention is shown in the drawings.
- the ends of a plurality of copper enameled wires 1 become parallel lying in a metal sleeve 2 threaded.
- This bundle 3 of wires 1 becomes then with the help of an electrical resistance welding process, under Use of preferably a medium frequency inverter - Welding system, welded in a compacting device.
- a plurality of pre-welded bundles 3 of FIG Ladders 1 by means of the sleeves 2, for example, to a contact rail 4 of a Relays are welded.
- welding sleeve 2 is preferably a Standard ferrule used.
Landscapes
- Manufacturing Of Electrical Connectors (AREA)
- Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
- Processing Of Terminals (AREA)
Abstract
Description
Die Erfindung betrifft ein Verfahren zur Herstellung einer elektrischen Verbindung zwischen mehreren lackisolierten elektrischen Leitern.The invention relates to a method for producing an electrical Connection between several enamel-insulated electrical conductors.
Aus dem Stand der Technik sind Pressverbindungen bzw. Crimpverbindungen zur Verbindung von isolierten Leitern bekannt. In der Produktion werden sogenannte Crimpmaschinen eingesetzt, um Kabelenden mit elektrischen Verbindungselementen, beispielsweise Aderendhülsen, zu verbinden. Dabei werden die Kabelenden zunächst in eine Zuführöffnung der Maschine eingeführt, von einer Halteeinrichtung fixiert und anschließend mittels einer Abisoliereinrichtung die Isolierung der Kabelenden eingeschnitten und abgezogen. Bei lackisolierten Drähten ist es bekannt, die Lackschicht an den Drahtenden mittels eines heißen Tauchbades zu entfernen. Anschließend wird eine Aderendhülse auf die abisolierten Kabelenden aufgesetzt und mittels einer Kompaktiereinrichtung bzw. einer Crimpeinrichtung vercrimpt. Mit diesen bekannten Crimpmaschinen lassen sich Crimpverbindungen mit hoher Taktfrequenz und somit mit hoher Produktivität herstellen. Es zeigte sich jedoch, dass die Verbindungen teilweise einen zu großen Übergangswiderstand zwischen den einzelnen Leitern aufweisen. Ein weiterer Nachteil dieser Art der elektrischen Verbindung ist, dass die Leiterenden vor dem Crimpen abisoliert werden müssen.From the prior art press connections or crimp connections known for connecting insulated conductors. In production So-called crimping machines used to cable ends with electrical Connecting elements, such as ferrules to connect. there The cable ends are first in a feed opening of the machine introduced, fixed by a holding device and then by means of a Abisoliereinrichtung the insulation of the cable ends cut in and deducted. In enamel-insulated wires, it is known that the lacquer layer to the To remove wire ends by means of a hot dip. Subsequently, will a wire end ferrule placed on the stripped cable ends and means crimped a compacting device or a crimping device. With these known crimping machines can be crimp connections with high Clock frequency and thus produce high productivity. It was found However, that the connections partly too large Have contact resistance between the individual conductors. Another Disadvantage of this type of electrical connection is that the conductor ends in front must be stripped of the crimping.
Ein anderes wohlbekanntes Verfahren zum Herstellung einer Verbindung zwischen elektrischen Leitern ist das Löten. Löten ist ein relativ aufwändiges Verfahren. Zum einen benötigt man entsprechendes Lötmetall, zum anderen müssen auch hier die Kabelenden vor dem Löten abisoliert werden. Another well-known method for making a compound between electrical conductors is the soldering. Soldering is a relatively complex task Method. On the one hand you need appropriate solder, on the other hand also here the cable ends must be stripped before soldering.
Es ist die Aufgabe der Erfindung, ein Verfahren anzugeben, mit dem mehrere lackisolierte elektrische Leiter ohne vorheriges Abisolieren schnell und zuverlässig miteinander verbunden werden könnenIt is the object of the invention to provide a method with which several lacquer-insulated electrical conductors without prior stripping fast and can be reliably connected to each other
Diese Aufgabe wird erfindungsgemäß durch ein Verfahren gemäß dem
Patentanspruch 1 gelöst.
Vorteilhafte Ausgestaltungen und Merkmale der Erfindung sind in den
abhängigen Ansprüchen angegeben.This object is achieved by a method according to
Advantageous embodiments and features of the invention are indicated in the dependent claims.
Erfindungsgemäß werden die nicht abisolierten Enden der Leiter in eine gemeinsame Metallhülse eingeführt, so dass die Leiter parallel zueinander zu liegen kommen. Nachfolgend werden die Leiter mit der Metallhülse mit Hilfe eines elektrischen Widerstandsschweißverfahrens verschweißt.According to the unstripped ends of the ladder in a common metal sleeve is inserted so that the conductors are parallel to each other come lie. Below are the ladder with the metal sleeve with help welded an electrical resistance welding process.
Durch das erfindungsgemäße Verfahren wird eine Durchkontaktierung sämtlicher Drähte bei geringem Übergangswiderstand zwischen den einzelnen Drähten und der Hülse erreicht.By the method according to the invention is a via all wires with low contact resistance between the achieved individual wires and the sleeve.
Als elektrische Leiter werden vorteilhaft Kupferlackdrähte verwendet.As electrical conductors copper enameled wires are advantageously used.
Der Schweißvorgang wird vorzugsweise in einer Kompaktiereinrichtung durchgeführt. Vorzugsweise wird ein Mittelfrequenz Inverter-Schweißsystem verwendet. Weiterhin wird vorzugsweise während des Schweißvorganges die elektrische Leistung konstant gehalten.The welding process is preferably in a compacting device carried out. Preferably, a center frequency inverter welding system used. Furthermore, preferably during the welding process the electrical power kept constant.
Typische Parameter des Schweißvorganges sind hierbei im folgenden
angegeben. Sie dienen dabei lediglich als Hinweis und sind nicht als
Einschränkung auf diese Werte zu verstehen:
Ein typischer zeitlicher Ablauf eines Schweißvorganges verläuft dabei wie
folgt: Zunächst wird die Kompaktiereinrichtung geschlossen und die
Elektrode(n) zugeführt sowie die Kompaktierkraft aufgebaut. Anschließend
werden die Teile verschweißt, wobei zum Beginn des Schweißvorganges
zunächst ein Abisolieren der Leiter stattfindet. Im weiteren Verlauf des
Schweißvorganges wird eine Verbindung zwischen den Leitern und der
Metallhülse hergestellt.
Dabei fließt zum Beginn des Schweißvorganges der Schweißstrom im
Wesentlichen über die Metallhülse, wodurch die Hülse erhitzt und den
Isolierlack teilweise verdampft bzw. verflüssigt. Im weiteren Verlauf des
Schweißvorganges fließt der Schweißstrom im Wesentlichen über die Leiter
und verschweißt diese miteinander und mit der Hülse. Der von den
Schweißelektroden der Kompaktiereinrichtung auf die Schweißstelle
ausgeübte Druck unterstützt den Schweißvorgang und sorgt darüber hinaus
für die Verdrängung des Isolierlacks aus der Metallhülse.A typical time sequence of a welding process proceeds as follows: First, the compacting device is closed and fed to the electrode (s) and built the Kompaktierkraft. Subsequently, the parts are welded, at the beginning of the welding process initially stripping the conductor takes place. In the course of the welding process, a connection between the conductors and the metal sleeve is made.
In this case, at the beginning of the welding process, the welding current flows substantially over the metal sleeve, whereby the sleeve is heated and partially evaporated or liquefied the insulating varnish. In the further course of the welding process, the welding current flows essentially over the conductors and welds them together and with the sleeve. The pressure exerted by the welding electrodes of the compacting device on the weld pressure supports the welding process and also ensures the displacement of the insulating paint from the metal sleeve.
Nach dem eigentlichen Schweißvorgang wird nach dem Ausschalten des Schweißstromes und vor dem Öffnen der Schweißelektroden eine Haltezeit eingehalten, während dessen sich der Schweißpunkt abkühlt. Anschließend fährt die Elektrode in die Ausgangsstellung und die Vorrichtung öffnet sich und gibt die verschweißten Leiter frei.After the actual welding process, after switching off the Welding current and before opening the welding electrodes a holding time maintained during which the welding point cools down. Subsequently the electrode moves to the starting position and the device opens and releases the welded conductors.
Alternativ wird der Schweißvorgang in zwei Schweißschritten durchgeführt. Im ersten Schweißschritt wird ein Abisolieren der Leiter durchgeführt. Im zweiten Schweißschritt eine Verbindung zwischen den Leitern und der Metallhülse hergestellt. Hierbei wird im ersten Schweißschritt ein vergleichsweise kleiner Schweißstrom, z.B. 50 A, bei langer Schweißzeit verwendet, so dass der Schweißstrom im Wesentlichen über die Metallhülse fließt, die Hülse erhitzt und den Isolierlack verdampft. Im zweiten Schweißschritt wird ein vergleichsweise großer Schweißstrom, z.B. 100 A, bei kurzer Schweißzeit verwendet, wobei der Schweißstrom im Wesentlichen über die Leiter fließt und diese miteinander und mit der Hülse verschweißt. Der von den Schweißelektroden der Kompaktiereinrichtung auf die Schweißstelle ausgeübte Druck unterstützt den Schweißvorgang und sorgt darüber hinaus für die Verdrängung des Isolierlacks aus der Metallhülse.Alternatively, the welding process is carried out in two welding steps. in the first welding step, a stripping of the conductors is performed. In the second Welding step a connection between the conductors and the metal sleeve produced. In this case, in the first welding step, a comparatively smaller Welding current, e.g. 50 A, used at long welding time, so that the Welding current flows substantially over the metal sleeve, the sleeve heated and evaporated the insulating varnish. In the second welding step is a comparatively large welding current, e.g. 100 A, with short welding time used, wherein the welding current flows substantially over the conductors and these welded together and with the sleeve. The one of the Welding electrodes of the compacting device on the weld applied pressure supports the welding process and also provides for the displacement of the insulating paint from the metal sleeve.
Als vorteilhaftes Material für die Schweißelektroden hat sich Molybdän erwiesen, da es eine hohe Standzeit aufweist und sich gut mechanisch verarbeiten lässt.An advantageous material for the welding electrodes is molybdenum proven, since it has a long service life and good mechanical can process.
Als Schweißhülse wird eine Standard- Adernhülse, vorzugsweise eine
verzinnte Metallhülse verwendet. Das Material, die Wandstärke und die
Beschichtung (Verzinnung) der Hülse beeinflussen den Schweißvorgang.
Als Material für die Metallhülse kann wahlweise Stahl, Nickel, CuSn oder
Kupfer verwendet werden.
Ein Ausführungsbeispiel der Erfindung ist in den Zeichnungen dargestellt.The welding sleeve used is a standard core sleeve, preferably a tinned metal sleeve. The material, the wall thickness and the coating (tinning) of the sleeve influence the welding process.
As a material for the metal sleeve can be used optionally steel, nickel, CuSn or copper.
An embodiment of the invention is shown in the drawings.
- Figur 1FIG. 1
- zeigt ein nach dem erfindungsgemäßen Verfahren hergestelltes Bündel aus mehreren miteinander verbundenen Leitern;shows a produced by the process according to the invention Bundles of several interconnected conductors;
- Figur 2FIG. 2
- zeigt eine Verbindung mehrerer Leiterbündel mit einer Kontaktschiene.shows a connection of several conductor bundles with a contact rail.
Gemäß Figur 1 werden die Enden mehrerer Kupferlackdrähte 1 parallel
liegend in eine Metallhülse 2 eingefädelt. Diese Bündel 3 von Drähten 1 wird
dann mit Hilfe eines elektrischen Widerstandsschweißverfahrens, unter
Verwendung von vorzugsweise einem Mittelfrequenz Inverter -
Schweißsystem, in einer Kompaktiereinrichtung verschweißt.According to FIG. 1, the ends of a plurality of copper
Wie in Figur 2 dargestellt ist, können mehrere vorgeschweißte Bündel 3 von
Leitern 1 mittels der Hülsen 2 beispielsweise an eine Kontaktschiene 4 eines
Relais angeschweißt werden. Als Schweißhülse 2 wird vorzugsweise eine
Standard-Aderendhülse verwendet.As shown in FIG. 2, a plurality of pre-welded
Claims (11)
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE200410010723 DE102004010723A1 (en) | 2004-03-05 | 2004-03-05 | Method for producing an electrical connection between a plurality of enamel-insulated conductors |
DE102004010723 | 2004-03-05 |
Publications (1)
Publication Number | Publication Date |
---|---|
EP1571731A1 true EP1571731A1 (en) | 2005-09-07 |
Family
ID=34745395
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP05003715A Withdrawn EP1571731A1 (en) | 2004-03-05 | 2005-02-22 | Method of manufacturing a connection between a plurality of varnish-insulated conductors |
Country Status (3)
Country | Link |
---|---|
EP (1) | EP1571731A1 (en) |
JP (1) | JP2005251744A (en) |
DE (1) | DE102004010723A1 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN103394818A (en) * | 2013-08-21 | 2013-11-20 | 苏州铜盟电气有限公司 | Rope flexible connection welding method |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE102017131371A1 (en) * | 2017-12-28 | 2019-07-04 | Te Connectivity Germany Gmbh | Mechanical connection element, electrical contact device and electrical connector |
Citations (6)
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US4034152A (en) * | 1973-06-18 | 1977-07-05 | Warner Allan S | Termination system for fusing aluminum-type lead wires |
US4396819A (en) * | 1981-09-01 | 1983-08-02 | Muchkin Vadim V | Method of forming a conductive connection |
EP0314319A1 (en) * | 1987-10-09 | 1989-05-03 | Hitachi, Ltd. | Method of joining an insulated wire to a conductive terminal |
GB2232013A (en) * | 1989-04-26 | 1990-11-28 | Shin Kin Enterprises Co Ltd | Welded connection in coaxial plug |
EP0410211A1 (en) * | 1989-07-28 | 1991-01-30 | Siemens Aktiengesellschaft | Process for producing an electrically conductive connection between enamelled copper wires and terminals |
WO1996027220A1 (en) * | 1995-03-02 | 1996-09-06 | Asea Brown Boveri Ab | A method for connection of insulated conductors to a connection member |
Family Cites Families (14)
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US3243501A (en) * | 1965-01-18 | 1966-03-29 | Gen Dynamics Corp | Welded connection for insulated wires |
US3368069A (en) * | 1967-09-14 | 1968-02-06 | David H. Trott | Globe and bulb mounting for signal light |
DE3904213C1 (en) * | 1989-02-13 | 1990-04-05 | Hoesch Stahl Ag, 4600 Dortmund, De | |
DE4118166C3 (en) * | 1991-06-03 | 1995-10-26 | Siemens Ag | Welding method for connecting a winding wire of a coil to a connection element and metal sleeve for use in this method |
JPH05300688A (en) * | 1992-04-21 | 1993-11-12 | Fujitsu General Ltd | Connection of conductor |
JP2842507B2 (en) * | 1994-03-18 | 1999-01-06 | 本田技研工業株式会社 | Connection method and connection structure of conductive wire and connection terminal |
JPH08264256A (en) * | 1995-03-27 | 1996-10-11 | Yazaki Corp | Connecting method for terminal and electric wire, and connecting electrode |
DE19731885A1 (en) * | 1997-07-24 | 1999-01-28 | Odw Elektrik Gmbh | Electrical connection method for lacquer-coated coil winding wire |
DE19956193A1 (en) * | 1999-11-23 | 2001-06-13 | Schunk Kohlenstofftechnik Gmbh | Electrical conductor has contact or plug connector part in form of section of conductor whose shape has been changed and that has been compressed |
JP3566914B2 (en) * | 2000-08-31 | 2004-09-15 | 株式会社日立製作所 | Terminal connection method |
JP3680728B2 (en) * | 2000-11-24 | 2005-08-10 | 株式会社デンソー | Resistance welding apparatus and resistance welding method |
JP2002321068A (en) * | 2001-04-27 | 2002-11-05 | Miyachi Technos Corp | Resistance welding device for covered wire |
DE10123636B4 (en) * | 2001-05-08 | 2009-01-29 | Prettl, Rolf | Press-welded connection, method for producing a press-welded connection and press-welding device |
JP2003010975A (en) * | 2001-06-29 | 2003-01-15 | Dengensha Mfg Co Ltd | Joining method for insulation coat electric wire |
-
2004
- 2004-03-05 DE DE200410010723 patent/DE102004010723A1/en not_active Withdrawn
-
2005
- 2005-02-22 EP EP05003715A patent/EP1571731A1/en not_active Withdrawn
- 2005-02-22 JP JP2005045362A patent/JP2005251744A/en active Pending
Patent Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4034152A (en) * | 1973-06-18 | 1977-07-05 | Warner Allan S | Termination system for fusing aluminum-type lead wires |
US4396819A (en) * | 1981-09-01 | 1983-08-02 | Muchkin Vadim V | Method of forming a conductive connection |
EP0314319A1 (en) * | 1987-10-09 | 1989-05-03 | Hitachi, Ltd. | Method of joining an insulated wire to a conductive terminal |
GB2232013A (en) * | 1989-04-26 | 1990-11-28 | Shin Kin Enterprises Co Ltd | Welded connection in coaxial plug |
EP0410211A1 (en) * | 1989-07-28 | 1991-01-30 | Siemens Aktiengesellschaft | Process for producing an electrically conductive connection between enamelled copper wires and terminals |
WO1996027220A1 (en) * | 1995-03-02 | 1996-09-06 | Asea Brown Boveri Ab | A method for connection of insulated conductors to a connection member |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN103394818A (en) * | 2013-08-21 | 2013-11-20 | 苏州铜盟电气有限公司 | Rope flexible connection welding method |
CN103394818B (en) * | 2013-08-21 | 2015-10-28 | 苏州铜盟电气有限公司 | A kind of rope type is flexible coupling welding method |
Also Published As
Publication number | Publication date |
---|---|
JP2005251744A (en) | 2005-09-15 |
DE102004010723A1 (en) | 2005-09-22 |
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