EP1655804B1 - Device and method for connecting an electrical transfer member to a contact element - Google Patents

Device and method for connecting an electrical transfer member to a contact element Download PDF

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Publication number
EP1655804B1
EP1655804B1 EP20050023401 EP05023401A EP1655804B1 EP 1655804 B1 EP1655804 B1 EP 1655804B1 EP 20050023401 EP20050023401 EP 20050023401 EP 05023401 A EP05023401 A EP 05023401A EP 1655804 B1 EP1655804 B1 EP 1655804B1
Authority
EP
European Patent Office
Prior art keywords
contact element
crimping
contact
electrical
axis
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.)
Not-in-force
Application number
EP20050023401
Other languages
German (de)
French (fr)
Other versions
EP1655804A2 (en
EP1655804A3 (en
Inventor
Uwe Blümmel
Martin Lipp
Horst Müller
Günter Sowa
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
TE Connectivity Germany GmbH
Original Assignee
Tyco Electronics AMP GmbH
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Tyco Electronics AMP GmbH filed Critical Tyco Electronics AMP GmbH
Publication of EP1655804A2 publication Critical patent/EP1655804A2/en
Publication of EP1655804A3 publication Critical patent/EP1655804A3/en
Application granted granted Critical
Publication of EP1655804B1 publication Critical patent/EP1655804B1/en
Not-in-force legal-status Critical Current
Anticipated expiration legal-status Critical

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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
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
    • H01R43/0263—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections for positioning or holding parts during soldering or welding process
    • 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
    • H01R4/10—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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/183—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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section
    • H01R4/184—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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section comprising a U-shaped wire-receiving portion
    • 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
    • H01R4/10—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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/187—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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping combined with soldering or welding
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
    • H01R43/048—Crimping apparatus or processes

Definitions

  • the present invention relates to a method and a device for connecting an electrical transmission element to a contact element, wherein the electrical transmission element has at least one electrical conductor, which is surrounded by a wire sheath.
  • an electrical transmission element for example in the form of an electrical cable
  • a contact element an exposed electrical conductor of the transmission element on the one hand and a conductor sleeve of the transmission element, for example in the form of electrical insulation, on the other hand each connected to the contact element by be crimped by means of a separate crimping of the contact element.
  • a conductor crimping region of the contact element is brought into pressing or crimping contact with the electrical conductor of the transmission element and, on the other hand, the core sheath, for example in the form of insulation, of the electrical transmission element is brought into press or crimp contact with an insulation crimping region of the contact element. to attach the transmission element to the contact element.
  • connection method and a connection arrangement of an electric cable with a contact element are described.
  • the connection method for connecting the electric wire to a contact member after a conductor of the electric wire is crimped, it is connected to a conductor crimping portion of the contact member, the conductor and the conductor crimping portion are welded by passing a laser beam on a bottom wall of the conductor crimping portion.
  • the electrical cable first has to be fed to a conductor crimping area, which first crimps the conductor of the electrical cable to the conductor crimping section of the contact element and the cable sheath of the cable to the insulation crimping area.
  • the electrical cable and contact member connection assembly thus produced is fed to a laser welding apparatus which directs the laser beam to a bottom wall of the cable crimping portion to make the welded joint.
  • the electrical cable and the contact member for performing the crimping operation are first supplied to the crimping apparatus, then the prepared connection assembly must be removed from the crimping apparatus before being supplied to the laser welding apparatus to perform the welding operation in a separate operation.
  • Such a connection method in several separate operations requires a relatively large amount of time in the implementation of the connection method and requires several processing stations with a correspondingly high equipment costs.
  • DE 3017369 A1 a method and an apparatus according to the preambles of claims 1 and 11 is described.
  • the present invention has for its object to provide a method and apparatus for connecting an electrical transmission element with a contact element, which is or is suitable to keep the time required and the equipment costs for performing the connection method comparatively low.
  • the object concerning the method is achieved by a method for connecting an electrical transmission element to a contact element according to claim 1.
  • the object concerning the device is achieved by a device for connecting an electrical transmission element with a contact element according to claim 11.
  • the electrical transmission element and the contact element for connection to a workstation are supplied and remain for a work operation with a certain residence time in the workstation before they are removed from the workstation again.
  • the core sheath of the electrical transmission element which surrounds an electrical conductor, is crimped with at least one crimping element of the contact element.
  • the electrical conductor of the transmission element is welded to a contact region of the contact element.
  • the crimping operation and the welding operation for establishing the connection between the electrical transmission element and the contact element are carried out within a common workstation within a common workstation, so that a common workstation is used for both operations in a common work operation belonging to the same work cycle or the same residence time can be.
  • This makes it possible to achieve a significant reduction in a cycle time for the production of a connection between a transmission element and a contact element, since the transport process of the connection arrangement formed from a crimping device into a separate welding device can be dispensed with according to the invention.
  • the device according to the invention for connecting an electrical transmission element to a contact element contains a feed device for feeding a contact element and a electrical transmission element and a work station, which are supplied to the contact element and the electrical transmission element by the feed device.
  • the workstation is designed in such a way that the elements to be connected remain in the workstation for a certain length of time before they are removed again from the workstation.
  • the workstation includes a crimping device that is configured and operable to crimp the wire sheath of the electrical transmission element with at least one crimping element of the contact element.
  • the workstation includes a welding device that is configured and operable to weld the electrical conductor to a contact region of the contact element.
  • the crimping device and the welding device are adapted to be operated in a common operation for a crimping operation and a welding operation belonging to the same working cycle or the same residence time.
  • the electrical transmission element comprises a plurality of electrical conductors, in particular a Litzendrahtan extract, which are surrounded by a common core sheath
  • at least a portion of the electrical conductors is welded to a contact region of the contact element in the workstation.
  • At least several of the electrical conductors are compacted with each other, i. the individual wires of the strand bundle are welded together to form a bundle.
  • the compacted strand bundle is also welded to the contact element.
  • the electrical conductor is welded to the contact region of the contact element while the insulation crimping tool is in the crimping position.
  • a crimping device is closed, so that the core of the electrical transmission element is crimped with the crimping of the contact element.
  • the electrical conductor is welded to the contact region of the contact element, for example by means of a resistance welding process in which a first welding electrode and a second welding electrode contact the elements to be welded from opposite sides.
  • the transfer element is held by the crimping device.
  • the crimping device is released again, so that the connection arrangement thus formed is released.
  • the electrical conductor is held by a supporting device of the workstation against an evasion tendency during the welding operation.
  • the support device has laterally to the elements to be welded paired support elements, wherein a first of the support elements on a first side and a second of the support elements on an opposite second side of the elements to be welded are arranged.
  • the support elements are designed for example as ceramic jaws, which are placed on both sides next to the elements to be welded in position. In a support position, the support elements are preferably arranged such that they rest without lateral spacing on the respective side of the elements to be welded.
  • the support means is preferably movable along a second axis which is approximately orthogonal to a first axis along which the welding device is moved to approach the elements to be welded, by energizing to carry out the welding process.
  • the welding device is movable along a vertical axis, whereas the individual support elements of the support means are approximated along a horizontal axis laterally to the elements to be welded.
  • the support means is further movable along a third axis which is approximately orthogonal to said two other axes.
  • the support device is moved along the third axis before the welding operation in order to bring the support device between the lined-up contact elements.
  • the support means is laterally approximated along the second axis of the elements to be welded in order to take the support position.
  • the support device can be moved in a direction running at least approximately parallel to the first axis before the support elements are moved along the second axis to the elements to be welded.
  • the two lateral support elements of the support means are locked via a clip or a clasp-like locking element for receiving the lateral forces arising during the welding process.
  • a separating device is included in the workstation to separate the contact element to be welded from a carrier element to which a plurality of processing contact elements are attached.
  • a plurality of contact elements in a row are connected on one side with a carrier strip, which is separated in the workstation from the contact element to be connected.
  • the separating device is brought to the same displacement in a detaching position in which the crimping is brought into crimping position to crimp the wire sheath with the crimping element of the contact element.
  • the separating device has a knife and a movable plunger, which acts in an impact direction on the knife and moves it in the impact direction in order to separate the carrier element from the contact element.
  • the plunger is connected to the crimping device, so that the plunger and the crimping device are moved in synchronism with each other in a traversing operation for approaching the knife or to the contact element.
  • the workstation according to the invention can be arranged in a module rack and formed therein as an exchangeable change tool. This makes it possible to make an adaptation to various types of contact elements and / or various types of electrical transmission elements of a production line. If, for example, after a series of several supplied contact elements of a first type of workstation, a further series of different contact elements supplied thereto, it is possible with the inventive device, the workstation for processing the first series of contact elements against a workstation for processing the second Replacing a series of contact elements with a short disassembly or assembly time.
  • the workstation is, for example, on a support plate, which is mounted by means of a quick-release device on the module frame and can be removed from this. In this way it is possible to disassemble a first workstation quickly and replace it with a second workstation.
  • the electrical transmission element is designed as an electrical cable, in which an electrical conductor is surrounded by a cable sheath as a core sheath.
  • the electrical transmission element may be formed as a single electrical wire within a bundle of a plurality of electrical transmission elements, wherein the bundle is surrounded by a common cable sheath.
  • the electrical conductor of a transmission element is surrounded only by insulation as a buffer tube.
  • the electrical conductor in turn, in one embodiment, as already described above, can be embodied as a unitary wire or as a stranded wire arrangement with a plurality of stranded, electrically conductive wires.
  • FIGS. 1 to 3 Based on FIGS. 1 to 3 the construction of an embodiment of a device according to the invention for connecting an electrical transmission element to a contact element is explained in more detail below.
  • FIG. 1 shows in a three-dimensional view of an embodiment of a workstation 2, the plurality of contact elements 5, which are connected on one side with a carrier strip 53, are fed via a feed device to be connected to an electrical transmission element 6 respectively.
  • Figures 2 and 3 show respective detailed representations of the workstation 2 according to FIG. 1 .
  • the workstation 2 is supplied by the feed device, an electrical transmission element 6, which has an electrical conductor 61 within a wire sheath 62.
  • the wire sheath 62 is designed, for example, as insulation, the electrical conductor 61 comprises, for example, a stranded wire arrangement in which several individual electrically conductive strands are stranded to form an electrical conductor.
  • the transfer element 6 with the exposed conductor 61 is placed on a surface of a support knife 30, above a contact element 5, with which it is to be connected.
  • the contact element 5 has in the present embodiment, two crimping elements in the form of Crimplaschen 51, in particular with reference to FIG. 3 shown in more detail. These Crimplaschen 51 serve to the wire sheath 62 of the transmission element 6 with the contact element 5 are crimped by the crimping tabs 51 with the core sheath 62, so that a pressing or crushing contact between the Crimplaschen 51 and the core sheath 62 is made.
  • the carrier strip 53 has for this purpose transport openings 54 (see, for example FIG. 5 ), in which a feed finger 70 engages to move the carrier strip 53 with an intermittent movement from left to right.
  • the feed finger 70 is for this purpose along the guide rail 72 ( FIG. 5 ), which is mounted on the feed plate 73.
  • To move the feed finger 70 is a pneumatic feed 74, which moves intermittently from left to right and engages with a return movement in a new transport opening 54 by means of the feed finger 70.
  • the workstation 2 has a crimping device comprising a plurality of components.
  • a crimping tool 10 is used to bring the Crimplaschen 51 of the contact element 5 in crimping contact with the buffer tube 62 of the transmission element 6.
  • the crimping tool 10 is moved vertically downwards in a travel path, with the crimping lugs 51 being bent inwards on the basis of the predetermined profile of the lower end of the crimping tool 10 in order to produce the crimping contact.
  • a lifting cylinder 13 For the movement of the crimping tool 10 is a lifting cylinder 13, with which a fastening plate 11 for the crimping tool 10 is moved so that the crimping tool 10 is moved downwards with the fastening plate 11 for a crimping operation.
  • the crimping tool 10 is connected via a crimp height adjustment 12 with the mounting plate 11, which serves to adjust the crimping tool in the final position in its height exactly, so that an adaptation to different diameters of transmission elements is possible.
  • the crimp height adjustment 12 is in the form of an eccentric, which is rotated accordingly to adjust the crimping tool 10 to the desired height.
  • the workstation 2 further includes a welding device configured as a welding device for performing a resistance welding process. It has an upper welding electrode 22 and a lower welding electrode 23, which are supplied with an electrical supply voltage to generate a welding current.
  • the contact element 5 is arranged with the contact region 52 between the electrodes 22 and 23.
  • the upper electrode 22 is held by the electrode holder 21, which is matched to the particular welding electrode used and in turn is attached to a clamp 20 for the electrode holder ( FIG. 9 ).
  • the electrode holder 21 is connected via the clamp 20 with a welding head assembly 4. This welding head assembly 4 serves to vertically position the upper welding electrode 22.
  • the welding current is generated externally and supplied to the welding electrodes 22 and 23 via connecting lines (not shown in the figures). According to FIG.
  • the anvil 14 for the crimping tool 10 by an insulation 15 relative to the lower electrode 23 isolated.
  • a contact support 24 preferably made of electrically non-conductive material, provided to support the contact element 5 during the welding operation downwards.
  • the upper electrode 22 with the electrode holder 21 can be approached along a first axis 81 to the elements to be welded in the form of the electrical conductor 61 and the contact region 52.
  • the axis 81 is in the present embodiment in a vertical arrangement. If the upper electrode 22 is brought to the elements to be welded 61 and 52, the electrodes 22 and 23 are acted upon by an electrical supply voltage, so that a welding current flows through the components 52 and 61 to be welded. These form an electrical resistance to the welding current, so that the elements to be welded become very hot, thus causing welding, i. an intimate connection between the electrical conductor 61 and the contact region 52 of the electrical contact element 5 is brought about.
  • the electrical conductor 61 is a stranded wire assembly of a plurality of stranded strands of wire, at least a portion of these strands of wire are welded to the contact portion 52 and at least a portion of the strands of wire are compacted together, i. the individual wires of the strand bundle are welded together to form a bundle.
  • an intimate connection between the wire strands is produced, so that a good overall contact between the stranded wire arrangement and the contact element is produced.
  • the welding device and crimping device for the connection of the electrical transmission element to the contact element are contained in a common workstation 2, to which the contact element 5 and the electrical transmission element 6 are fed intermittently. These remain in the workstation 2 for an operation with a certain residence time before they are removed again as a connection arrangement of the workstation.
  • the crimping and the welding operation are carried out in the common workstation 2 in one operation, so that a transport operation is omitted by a crimping tool in a separate welding tool.
  • the total time (cycle time) for the common insulation crimping and conductor wire welding per contact element can be considerably reduced to about 1000 to 1500 ms.
  • a support device 40 which serves to support the elements 52 and 61 to be welded during the welding operation against forces exerted by the welding operation on the elements to be welded and a tendency to evasion of the weld metal to the side cause.
  • the support means 40 has laterally to the elements to be welded 52 and 61 paired support members 41 in the form of ceramic jaws, wherein a first ceramic jaw 41 on one side and a second ceramic jaw 41 on an opposite side of the elements to be welded 52 and 61 are arranged.
  • the use of ceramic is advantageous in this context because it is an insulating material that prevents the welding current from flowing through the support.
  • the ceramic jaws 41 along the second axis 82 are movable, which is arranged approximately orthogonal to the first axis 81. This means in the present embodiment that the ceramic jaws 41 are approximated along a horizontal axis laterally to the elements 52 and 61 to be welded.
  • the ceramic jaws 41 are guided by holders 42, which in turn are attached to parallel grippers 43.
  • a feed cylinder 45 is used for movement, more precisely for the forward and reverse thrust of the parallel gripper 43.
  • a locking bracket 44 is movable, which is provided as a bow-shaped or clasp-like locking element to the paired ceramic jaws 41 in its supporting position against To support in the direction of support laterally acting forces that arise as a result of the welding process. This makes it possible to make the ceramic jaws 41 filigree, so that they can be easily moved between the contact elements 5, which are still attached to the carrier strip 53.
  • the support device 40 is moved with the ceramic jaws 41, the holders 42 and the parallel grippers 43 along a third axis 83 in the direction of the carrier strip 53, the third axis 83 approximately orthogonal to the first axis 81 and to the second axis 82 is arranged.
  • the parallel gripper 43 become moved by the feed cylinder 45 for this purpose.
  • the ceramic jaws 41 are brought into a lateral position to the elements to be welded 52 and 61, so that they can then be brought along the second axis 82 to the elements to be welded.
  • the workstation 2 further includes a separating device which serves to separate the contact element 5 to be welded from the carrier strip 53, to which a plurality of contact elements 5 to be processed are mounted side by side.
  • the separating device has a serving both as a separating knife and as a cable carrier support blade 30 and a plunger 31 which is moved for a separation process down.
  • the movable plunger 31 acts on the support blade 30, on the raised, left-hand projection of the support blade 30, so that the support blade 30 is pressed at this point by the plunger 31 down.
  • the support blade 30 is moved in the direction of impact of the plunger 31 down, so that the carrier strip 53 is separated by the support blade 30 from the contact element 5.
  • the plunger 31 is connected via a fastening screw 32 with the crimping tool 10. In this way, the plunger 31 and the crimping tool 10 are moved synchronously with one another in a movement process for approaching the support blade 30 or for approaching the contact element 5.
  • connection process for connecting an electrical transmission element 6 to a contact element 5 will be described below in more detail.
  • the individual contact elements 5 are conveyed by the feed mechanism described intermittently to the workstation 2, wherein the respective contact element 5 to be connected in the welding / crimping of the described workstation 2, where it is supported by the contact support 24.
  • the transmission element 6 is from the front ( FIG. 1 ) or from the left ( FIG. 2 ) approximates the contact element 5 and comes to lie on the right surface portion of the support blade 30.
  • the crimping tool 10 is closed, in which it is lowered onto the anvil 14.
  • the Crimplaschen 51 are pressed to a crimping contact on the buffer tube 62 and synchronously, the contact element 5 is separated from the carrier strip 53 by means of the support blade 30, which is pressed by the plunger 31 down.
  • the ceramic jaws 41 are brought along the axis 83 on both sides next to the contact element 5 in position and closed along the axis 82 to abut without lateral spacing on the respective side of the contact element 5.
  • the holders 42 are advanced for the ceramic jaws 41 from back to front by the parallel gripper 43 are moved by means of the feed cylinder 45 to the front.
  • the holder 42 for the ceramic jaws 41 are still in the open state until they are located on both sides of the respective positioned contact element 5.
  • the ceramic jaws 41 are moved along the axis 82 sideways on the two longitudinal sides of the contact element 5 until they rest thereon.
  • the locking bracket 44 is slipped over the ceramic jaw holder 42 in the closed position in order to prevent lateral deflection of the ceramic jaws 41 as a result of the welding forces. This is during the welding process Crimping tool 10 in the closed state to hold the transmission element 6 in position.
  • the upper welding electrode 22 is moved down to the fixed lower welding electrode 23.
  • the strands of the stranded wire assembly 61 are laterally supported by the ceramic jaws 41.
  • the ceramic jaws 41 are opened along the axis 82 and the crimping tool 10 and the upper welding electrode 22 are moved upwards along the axis 81, so that the transmission element 6 can be removed from the work station 2 with the contact element 5 welded thereto and crimped on.
  • a cooling device 75 which contains a plurality of tubes, in which, for example, cooling medium in the form of a cooling fluid, for example in the form of cooling air or cooling water can be performed.
  • cooling medium in the form of a cooling fluid
  • the cooling water is introduced, for example, at the cooling water inlet 76 into the cooling device 75 and removed again at the cooling water outlet 77 of the cooling device 75. This causes the support plate 71, on which the workstation 2 is arranged, not to overheat and thus deform as a result of the welding operation.
  • FIG. 9 is an embodiment of a device 1 according to the invention with a workstation 2, as shown in FIGS. 1 to 8 described in more detail, shown in more detail in a module frame.
  • the work station 2 (so-called applicator) is on a support plate 71 (see for example FIG. 1 ), which by means of a quick release device, not shown can be mounted on a module frame 3 and disassembled from this.
  • the workstation 2 is arranged in the module frame 3 as an exchangeable change tool and disassembled from this with little effort. This can be done to adapt to various types of contact elements and transmission elements.
  • the welding head assembly 4 with servomotor welding head with welding parameter monitoring remains firmly connected to the module frame 3.
  • the module frame 3 is in turn mounted on a corresponding manufacturing device.
  • the welding electrodes 22 and 23 are changed in accordance with this embodiment, so that a suitable interface to the module frame 3 and the welding head assembly 4 must be provided, with which the welding electrodes can be coupled to a power supply.

Description

Die vorliegende Erfindung betrifft ein Verfahren und eine Vorrichtung zur Verbindung eines elektrischen Übertragungselements mit einem Kontaktelement, wobei das elektrische Übertragungselement wenigstens einen elektrischen Leiter aufweist, der von einer Aderhülle umgeben ist.The present invention relates to a method and a device for connecting an electrical transmission element to a contact element, wherein the electrical transmission element has at least one electrical conductor, which is surrounded by a wire sheath.

Nach einem bekannten Verfahren zur Verbindung eines elektrischen Übertragungselements, beispielsweise in Form eines elektrischen Kabels, mit einem Kontaktelement werden ein freigelegter elektrischer Leiter des Übertragungselements einerseits und eine Aderhülle des Übertragungselements, beispielsweise in Form einer elektrischen Isolierung, andererseits je mit dem Kontaktelement verbunden, indem sie mittels je eines gesonderten Crimpbereichs des Kontaktelements vercrimpt werden. Bei einem solchen Crimpvorgang wird einerseits ein Leitercrimpbereich des Kontaktelements mit dem elektrischen Leiter des Übertragungselements in Press- oder Quetschkontakt gebracht und wird andererseits die Aderhülle, beispielsweise in Form einer Isolierung, des elektrischen Übertragungselements mit einem Isolationscrimpbereich des Kontaktelements in Press- bzw. Quetschkontakt gebracht, um das Übertragungselement am Kontaktelement zu befestigen.According to a known method for connecting an electrical transmission element, for example in the form of an electrical cable, with a contact element, an exposed electrical conductor of the transmission element on the one hand and a conductor sleeve of the transmission element, for example in the form of electrical insulation, on the other hand each connected to the contact element by be crimped by means of a separate crimping of the contact element. In such a crimping process, on the one hand, a conductor crimping region of the contact element is brought into pressing or crimping contact with the electrical conductor of the transmission element and, on the other hand, the core sheath, for example in the form of insulation, of the electrical transmission element is brought into press or crimp contact with an insulation crimping region of the contact element. to attach the transmission element to the contact element.

In DE 103 58 153 A1 sind ein Verbindungsverfahren und eine Verbindungsanordnung eines elektrischen Kabels mit einem Kontaktelement beschrieben. Gemäß dem Verbindungsverfahren zur Verbindung des elektrischen Kabels mit einem Kontaktelement werden, nachdem ein Leiter des elektrischen Kabels vercrimpt wurde, um mit einem Leitercrimpabschnitt des Kontaktelements verbunden zu werden, der Leiter und der Leitercrimpabschnitt verschweißt, indem ein Laserstrahl auf eine Bodenwand des Leitercrimpabschnitts geleitet wird. Zu diesem Zweck muss das elektrische Kabel zunächst einem Leitercrimpbereich zugeführt werden, der zunächst den Leiter des elektrischen Kabels mit dem Leitercrimpabschnitt des Kontaktelements sowie den Kabelmantel des Kabels mit dem Isolationscrimpbereich vercrimpt. Danach wird die so hergestellte Verbindungsanordnung aus elektrischem Kabel und Kontaktelement einer Laser-Schweißvorrichtung zugeführt, welche den Laserstrahl zur Herstellung der Schweißverbindung auf eine Bodenwand des Kabelcrimpabschnitts leitet. Bei einer derartigen Vorgehensweise werden das elektrische Kabel und das Kontaktelement zur Durchführung des Crimpvorgangs zunächst der Crimpvorrichtung zugeführt, anschließend muss die hergestellte Verbindungsanordnung der Crimpvorrichtung entnommen werden, bevor sie der Laser-Schweißvorrichtung zugeführt wird, um in einem separaten Arbeitsvorgang den Schweißvorgang durchzuführen. Ein derartiges Verbindungsverfahren in mehreren separaten Arbeitsvorgängen erfordert einen vergleichsweise hohen Zeitaufwand bei der Durchführung des Verbindungsverfahrens und erfordert mehrere Verarbeitungsstationen mit entsprechend hohem Geräteaufwand. In DE 3017369 A1 ist ein Verfahren und eine Vorrichtung gemäß den Oberbegriffen der Patentansprüche 1 und 11 beschrieben.In DE 103 58 153 A1 For example, a connection method and a connection arrangement of an electric cable with a contact element are described. According to the connection method for connecting the electric wire to a contact member, after a conductor of the electric wire is crimped, it is connected to a conductor crimping portion of the contact member, the conductor and the conductor crimping portion are welded by passing a laser beam on a bottom wall of the conductor crimping portion. For this purpose, the electrical cable first has to be fed to a conductor crimping area, which first crimps the conductor of the electrical cable to the conductor crimping section of the contact element and the cable sheath of the cable to the insulation crimping area. Thereafter, the electrical cable and contact member connection assembly thus produced is fed to a laser welding apparatus which directs the laser beam to a bottom wall of the cable crimping portion to make the welded joint. In such an approach, the electrical cable and the contact member for performing the crimping operation are first supplied to the crimping apparatus, then the prepared connection assembly must be removed from the crimping apparatus before being supplied to the laser welding apparatus to perform the welding operation in a separate operation. Such a connection method in several separate operations requires a relatively large amount of time in the implementation of the connection method and requires several processing stations with a correspondingly high equipment costs. In DE 3017369 A1 a method and an apparatus according to the preambles of claims 1 and 11 is described.

Der vorliegenden Erfindung liegt die Aufgabe zugrunde, ein Verfahren und eine Vorrichtung zur Verbindung eines elektrischen Übertragungselements mit einem Kontaktelement anzugeben, das bzw. die dazu geeignet ist, den Zeitbedarf und den Geräteaufwand zur Durchführung des Verbindungsverfahrens vergleichsweise gering zu halten.The present invention has for its object to provide a method and apparatus for connecting an electrical transmission element with a contact element, which is or is suitable to keep the time required and the equipment costs for performing the connection method comparatively low.

Die Aufgabe betreffend das Verfahren wird gelöst durch ein Verfahren zur Verbindung eines elektrischen Übertragungselements mit einem Kontaktelement gemäß Patentanspruch 1. Die Aufgabe betreffend die Vorrichtung wird gelöst durch eine Vorrichtung zur Verbindung eines elektrischen Übertragungselements mit einem Kontaktelement gemäß Patentanspruch 11.The object concerning the method is achieved by a method for connecting an electrical transmission element to a contact element according to claim 1. The object concerning the device is achieved by a device for connecting an electrical transmission element with a contact element according to claim 11.

Insbesondere werden zur Verbindung eines elektrischen Übertragungselements mit einem Kontaktelement das elektrische Übertragungselement und das Kontaktelement zur Herstellung einer Verbindung einer Arbeitsstation zugeführt und verbleiben für einen Arbeitsvorgang mit einer bestimmten Verweildauer in der Arbeitsstation, bevor sie der Arbeitsstation wieder entnommen werden. In der Arbeitsstation wird die Aderhülle des elektrischen Übertragungselements, die einen elektrischen Leiter umgibt, mit wenigstens einem Crimpelement des Kontaktelements vercrimpt. Während derselben Verweildauer des Kontaktelementes in der Arbeitsstation oder während desselben Arbeitstaktes der Arbeitsstation wird der elektrische Leiter des Übertragungselements mit einem Kontaktbereich des Kontaktelements verschweißt. Nach dem erfindungsgemäßen Verfahren werden also der Crimpvorgang und der Schweißvorgang zur Herstellung der Verbindung zwischen dem elektrischen Übertragungselement und dem Kontaktelement in einem zum selben Arbeitstakt bzw. zur selben Verweildauer gehörenden gemeinsamen Arbeitsvorgang innerhalb einer gemeinsamen Arbeitsstation durchgeführt, so dass für beide Vorgänge eine gemeinsame Arbeitsstation verwendet werden kann. Damit lässt sich eine deutliche Reduzierung einer Zykluszeit für die Herstellung einer Verbindung zwischen einem Übertragungselement und einem Kontaktelement erreichen, da der Transportvorgang der gebildeten Verbindungsanordnung aus einer Crimpvorrichtung in eine separate Schweißvorrichtung erfindungsgemäß entfallen kann.In particular, for connecting an electrical transmission element to a contact element, the electrical transmission element and the contact element for connection to a workstation are supplied and remain for a work operation with a certain residence time in the workstation before they are removed from the workstation again. In the workstation, the core sheath of the electrical transmission element, which surrounds an electrical conductor, is crimped with at least one crimping element of the contact element. During the same dwell time of the contact element in the workstation or during the same work cycle of the workstation, the electrical conductor of the transmission element is welded to a contact region of the contact element. Thus, according to the method of the invention, the crimping operation and the welding operation for establishing the connection between the electrical transmission element and the contact element are carried out within a common workstation within a common workstation, so that a common workstation is used for both operations in a common work operation belonging to the same work cycle or the same residence time can be. This makes it possible to achieve a significant reduction in a cycle time for the production of a connection between a transmission element and a contact element, since the transport process of the connection arrangement formed from a crimping device into a separate welding device can be dispensed with according to the invention.

Die erfindungsgemäße Vorrichtung zur Verbindung eines elektrischen Übertragungselements mit einem Kontaktelement enthält eine Zuführeinrichtung zur Zuführung eines Kontaktelements und eines elektrischen Übertragungselements sowie eine Arbeitsstation, der das Kontaktelement und das elektrische Übertragungselement durch die Zuführeinrichtung zugeführt werden. Die Arbeitsstation ist dabei derart ausgebildet, dass die zu verbindenden Elemente für einen Arbeitsvorgang mit einer bestimmten Verweildauer in der Arbeitsstation verbleiben, bevor sie der Arbeitsstation wieder entnommen werden. Die Arbeitsstation umfasst eine Crimpeinrichtung, die dazu ausgebildet und betreibbar ist, die Aderhülle des elektrischen Übertragungselements mit wenigstens einem Crimpelement des Kontaktelements zu vercrimpen. Weiterhin umfasst die Arbeitsstation eine Schweißvorrichtung, die dazu ausgebildet und betreibbar ist, den elektrischen Leiter mit einem Kontaktbereich des Kontaktelements zu verschweißen. Die Crimpeinrichtung und die Schweißvorrichtung sind dazu eingerichtet, in einem zum selben Arbeitstakt bzw. zur selben Verweildauer gehörenden gemeinsamen Arbeitsvorgang für einen Crimpvorgang und einen Schweißvorgang betätigt zu werden.The device according to the invention for connecting an electrical transmission element to a contact element contains a feed device for feeding a contact element and a electrical transmission element and a work station, which are supplied to the contact element and the electrical transmission element by the feed device. The workstation is designed in such a way that the elements to be connected remain in the workstation for a certain length of time before they are removed again from the workstation. The workstation includes a crimping device that is configured and operable to crimp the wire sheath of the electrical transmission element with at least one crimping element of the contact element. Furthermore, the workstation includes a welding device that is configured and operable to weld the electrical conductor to a contact region of the contact element. The crimping device and the welding device are adapted to be operated in a common operation for a crimping operation and a welding operation belonging to the same working cycle or the same residence time.

Für den Anwendungsfall, dass das elektrische Übertragungselement mehrere elektrische Leiter aufweist, insbesondere eine Litzendrahtanordnung, die von einer gemeinsamen Aderhülle umgeben sind, wird in der Arbeitsstation wenigstens ein Teil der elektrischen Leiter mit einem Kontaktbereich des Kontaktelements verschweißt. Dabei werden wenigstens mehrere der elektrischen Leiter untereinander kompaktiert, d.h. die einzelnen Drähte des Litzenbündels werden miteinander zu einem Bündel verschweißt. Vorzugsweise wird bei dem kompaktierenden Schweißvorgang das kompaktierte Litzenbündel auch an das Kontaktelement angeschweißt.For the application that the electrical transmission element comprises a plurality of electrical conductors, in particular a Litzendrahtanordnung, which are surrounded by a common core sheath, at least a portion of the electrical conductors is welded to a contact region of the contact element in the workstation. At least several of the electrical conductors are compacted with each other, i. the individual wires of the strand bundle are welded together to form a bundle. Preferably, in the compacting welding process, the compacted strand bundle is also welded to the contact element.

Gemäß einer Ausführungsform der Erfindung wird der elektrische Leiter mit dem Kontaktbereich des Kontaktelements verschweißt, während sich das Isolationscrimpwerkzeug in Crimpposition befindet. Dazu wird insbesondere eine Crimpeinrichtung geschlossen, so dass die Aderhülle des elektrischen Übertragungselements mit dem Crimpbereich des Kontaktelements vercrimpt wird. Während des selben Arbeitstaktes oder derselben Verweildauer des Kontaktelementes in der Arbeitsstation wird der elektrische Leiter mit dem Kontaktbereich des Kontaktelements verschweißt, beispielsweise mittels eines Widerstandsschweißverfahrens, bei welchem eine erste Schweißelektrode und eine zweite Schweißelektrode von gegenüberliegenden Seiten die zu verschweißenden Elemente kontaktieren. Während des Schweißvorgangs wird das Übertragungselement von der Crimpeinrichtung festgehalten. Nach dem Beenden des Schweißprozesses wird die Crimpeinrichtung wieder gelöst, so dass die so gebildete Verbindungsanordnung freigegeben wird.According to one embodiment of the invention, the electrical conductor is welded to the contact region of the contact element while the insulation crimping tool is in the crimping position. For this purpose, in particular a crimping device is closed, so that the core of the electrical transmission element is crimped with the crimping of the contact element. During the same working stroke or residence time of the contact element in the work station, the electrical conductor is welded to the contact region of the contact element, for example by means of a resistance welding process in which a first welding electrode and a second welding electrode contact the elements to be welded from opposite sides. During the welding process, the transfer element is held by the crimping device. After completion of the welding process, the crimping device is released again, so that the connection arrangement thus formed is released.

Nach der Erfindung wird der elektrische Leiter während des Schweißvorgangs von einer Stützeinrichtung der Arbeitsstation gegen eine Ausweichtendenz bewirkende Kräfte gehalten. Beispielsweise weist die Stützeinrichtung seitlich zu den zu verschweißenden Elementen paarweise angeordnete Stützelemente auf, wobei ein erstes der Stützelemente auf einer ersten Seite und ein zweites der Stützelemente auf einer gegenüberliegenden zweiten Seite der zu verschweißenden Elemente angeordnet werden. Die Stützelemente sind beispielsweise als Keramikbacken ausgeführt, die beidseits neben die zu verschweißenden Elemente in Position gebracht werden. In einer Stützposition sind die Stützelemente bevorzugt derart angeordnet, dass sie ohne seitlichen Abstand an der jeweiligen Seite der zu verschweißenden Elemente anliegen.According to the invention, the electrical conductor is held by a supporting device of the workstation against an evasion tendency during the welding operation. For example, the support device has laterally to the elements to be welded paired support elements, wherein a first of the support elements on a first side and a second of the support elements on an opposite second side of the elements to be welded are arranged. The support elements are designed for example as ceramic jaws, which are placed on both sides next to the elements to be welded in position. In a support position, the support elements are preferably arranged such that they rest without lateral spacing on the respective side of the elements to be welded.

Um die Stützeinrichtung an die zu verschweißenden Elemente anzunähern, ist die Stützeinrichtung vorzugsweise entlang einer zweiten Achse verfahrbar, die näherungsweise orthogonal zu einer ersten Achse verläuft, entlang welcher die Schweißvorrichtung zur Annäherung an die zu verschweißenden Elemente verfahren wird, um durch eine Energiezufuhr den Schweißvorgang durchzuführen. Beispielsweise ist die Schweißvorrichtung entlang einer vertikalen Achse verfahrbar, wohingegen die einzelnen Stützelemente der Stützeinrichtung entlang einer horizontalen Achse seitlich an die zu verschweißenden Elemente angenähert werden.In order to approximate the support means to the elements to be welded, the support means is preferably movable along a second axis which is approximately orthogonal to a first axis along which the welding device is moved to approach the elements to be welded, by energizing to carry out the welding process. For example, the welding device is movable along a vertical axis, whereas the individual support elements of the support means are approximated along a horizontal axis laterally to the elements to be welded.

Insbesondere für den Fall, in welchem mehrere Kontaktelemente aufgereiht und intermittierend der Arbeitsstation zugeführt werden, ist die Stützeinrichtung des weiteren entlang einer dritten Achse verfahrbar, die näherungsweise orthogonal zu den genannten beiden anderen Achsen angeordnet ist. Gemäß einer Ausführungsform des Verbindungsverfahrens wird die Stützeinrichtung vor dem Schweißvorgang entlang dieser dritten Achse verfahren, um die Stützeinrichtung zwischen die aufgereihten Kontaktelemente zu bringen. Anschließend wird die Stützeinrichtung entlang der zweiten Achse an die zu verschweißenden Elemente seitlich angenähert, um die Stützposition einzunehmen.In particular, in the case where a plurality of contact elements are lined up and intermittently fed to the workstation, the support means is further movable along a third axis which is approximately orthogonal to said two other axes. According to one embodiment of the connection method, the support device is moved along the third axis before the welding operation in order to bring the support device between the lined-up contact elements. Subsequently, the support means is laterally approximated along the second axis of the elements to be welded in order to take the support position.

Alternativ oder zusätzlich zu der Bewegung entlang der dritten Achse kann die Stützeinrichtung in einer mindestens näherungsweise parallel zur ersten Achse verlaufenden Richtung verfahren werden, bevor die Stützelemente entlang der zweiten Achse zu den zu verschweißenden Elementen herangefahren werden.Alternatively or in addition to the movement along the third axis, the support device can be moved in a direction running at least approximately parallel to the first axis before the support elements are moved along the second axis to the elements to be welded.

Bei einer Ausführungsform der Erfindung werden zur Aufnahme der beim Schweißvorgang entstehenden seitlichen Kräfte die beiden seitlichen Stützelemente der Stützeinrichtung über eine Spange oder ein spangenartiges Verriegelungselement verriegelt.In one embodiment of the invention, the two lateral support elements of the support means are locked via a clip or a clasp-like locking element for receiving the lateral forces arising during the welding process.

Gemäß einer weiteren Ausführungsform der Erfindung ist in der Arbeitsstation eine Abtrenneinrichtung enthalten, um das zu verschweißende Kontaktelement von einem Trägerelement zu trennen, an welchem mehrere zu verarbeitende Kontaktelemente angebracht sind. Beispielsweise sind mehrere Kontaktelemente in einer Reihe einseitig mit einem Trägerstreifen verbunden, der in der Arbeitsstation vom zu verbindenden Kontaktelement abgetrennt wird. Bevorzugt wird die Abtrenneinrichtung mit dem gleichen Verfahrvorgang in eine Abtrennposition gebracht, in welchem die Crimpeinrichtung in Crimpposition gebracht wird, um die Aderhülle mit dem Crimpelement des Kontaktelements zu vercrimpen. Dadurch lässt sich wiederum eine deutliche Zeitersparnis während des Verbindungsprozesses erzielen, da mit dem ohnehin durchzuführenden Crimpprozess gleichzeitig der Abtrennprozess durchgeführt wird.According to a further embodiment of the invention, a separating device is included in the workstation to separate the contact element to be welded from a carrier element to which a plurality of processing contact elements are attached. For example, a plurality of contact elements in a row are connected on one side with a carrier strip, which is separated in the workstation from the contact element to be connected. Preferably, the separating device is brought to the same displacement in a detaching position in which the crimping is brought into crimping position to crimp the wire sheath with the crimping element of the contact element. This can in turn achieve a significant time savings during the connection process, since the removal process is carried out simultaneously with the crimping process to be carried out anyway.

In einer Weiterbildung der Erfindung weist die Abtrenneinrichtung ein Messer und einen verfahrbaren Stößel auf, der in einer Stoßrichtung auf das Messer einwirkt und dieses in der Stoßrichtung bewegt, um das Trägerelement vom Kontaktelement abzutrennen. Vorzugsweise wird der Stößel mit der Crimpeinrichtung verbunden, so dass der Stößel und die Crimpeinrichtung in einem Verfahrvorgang zur Annäherung an das Messer bzw. an das Kontaktelement synchron zueinander bewegt werden.In a further development of the invention, the separating device has a knife and a movable plunger, which acts in an impact direction on the knife and moves it in the impact direction in order to separate the carrier element from the contact element. Preferably, the plunger is connected to the crimping device, so that the plunger and the crimping device are moved in synchronism with each other in a traversing operation for approaching the knife or to the contact element.

In einer Weiterbildung der Erfindung ist die erfindungsgemäße Arbeitsstation in einem Modulgestell anordenbar und darin als austauschbares Wechselwerkzeug ausgebildet. Damit ist es ermöglicht, eine Anpassung an verschiedenartige Kontaktelemente und/oder verschiedenartige elektrische Übertragungselemente einer Herstellungslinie vorzunehmen. Wird beispielsweise nach einer Serie von mehreren zugeführten Kontaktelementen einer ersten Art der Arbeitsstation eine weitere Serie dazu unterschiedlicher Kontaktelemente zugeführt, so ist es mit der erfindungsgemäßen Vorrichtung ermöglicht, die Arbeitsstation zur Bearbeitung der ersten Serie von Kontaktelementen gegen eine Arbeitsstation zur Bearbeitung der zweiten Serie von Kontaktelementen mit kurzer Demontage- bzw. Montagezeit auszutauschen.In one embodiment of the invention, the workstation according to the invention can be arranged in a module rack and formed therein as an exchangeable change tool. This makes it possible to make an adaptation to various types of contact elements and / or various types of electrical transmission elements of a production line. If, for example, after a series of several supplied contact elements of a first type of workstation, a further series of different contact elements supplied thereto, it is possible with the inventive device, the workstation for processing the first series of contact elements against a workstation for processing the second Replacing a series of contact elements with a short disassembly or assembly time.

Zu diesem Zweck befindet sich die Arbeitsstation beispielsweise auf einer Trägerplatte, welche mittels einer Schnellspanneinrichtung an dem Modulgestell montierbar und von diesem demontierbar ist. Auf diese Art ist es ermöglicht, eine erste Arbeitsstation schnell zu demontieren und gegen eine zweite Arbeitsstation auszutauschen.For this purpose, the workstation is, for example, on a support plate, which is mounted by means of a quick-release device on the module frame and can be removed from this. In this way it is possible to disassemble a first workstation quickly and replace it with a second workstation.

Mit dem erfindungsgemäßen Verfahren und der erfindungsgemäßen Vorrichtung ist es grundsätzlich möglich, verschiedene Arten von elektrischen Übertragungselementen mit verschiedenen Arten von Kontaktelementen zu verbinden. Beispielsweise ist das elektrische Übertragungselement als elektrisches Kabel ausgebildet, bei welchem ein elektrischer Leiter von einem Kabelmantel als Aderhülle umgeben ist. Des weiteren kann das elektrische Übertragungselement als einzelne elektrische Ader innerhalb eines Bündels mehrerer elektrischer Übertragungselemente ausgebildet sein, wobei das Bündel von einem gemeinsamen Kabelmantel umgeben ist. In letzterem Fall ist der elektrische Leiter eines Übertragungselements lediglich von einer Isolierung als Aderhülle umgeben. Der elektrische Leiter wiederum kann in einer Ausführungsform, wie oben bereits beschrieben, als einheitlicher Draht oder als Litzendrahtanordnung mit mehreren verseilten, elektrisch leitfähigen Drähten ausgeführt sein.With the method according to the invention and the device according to the invention, it is fundamentally possible to connect different types of electrical transmission elements with different types of contact elements. For example, the electrical transmission element is designed as an electrical cable, in which an electrical conductor is surrounded by a cable sheath as a core sheath. Furthermore, the electrical transmission element may be formed as a single electrical wire within a bundle of a plurality of electrical transmission elements, wherein the bundle is surrounded by a common cable sheath. In the latter case, the electrical conductor of a transmission element is surrounded only by insulation as a buffer tube. The electrical conductor, in turn, in one embodiment, as already described above, can be embodied as a unitary wire or as a stranded wire arrangement with a plurality of stranded, electrically conductive wires.

Weitere vorteilhafte Aus- und Weiterbildungen der Erfindung sind in Unteransprüchen angegeben.Further advantageous embodiments and further developments of the invention are specified in subclaims.

Die Erfindung wird im Folgenden anhand der in der Zeichnung dargestellten Figuren, die Ausführungsformen einer erfindungsgemäßen Verbindungsvorrichtung darstellen, näher erläutert. Es zeigen

Figur 1
eine Ausführungsform einer erfindungsgemäßen Vorrichtung zur Verbindung eines elektrischen Übertragungselements mit einem Kontaktelement mit einer Arbeitsstation in einer dreidimensionalen Ansicht,
Figur 2
eine Detaildarstellung einzelner Elemente der Ausführungsform der erfindungsgemäßen Vorrichtung in einer Seitenansicht,
Figur 3
eine weitere Detaildarstellung einzelner Elemente der Ausführungsform der erfindungsgemäßen Vorrichtung in einer dreidimensionalen Ansicht,
Figur 4
eine Darstellung einzelner Elemente der Ausführungsform der erfindungsgemäßen Vorrichtung in einer dreidimensionalen Ansicht,
Figur 5
eine Darstellung einzelner Elemente der Ausführungsform der erfindungsgemäßen Vorrichtung in einer Frontalansicht,
Figur 6
eine weitere Detailansicht von Elementen der Ausführungsform der erfindungsgemäßen Vorrichtung in einer dreidimensionalen Darstellung,
Figur 7
eine weitere Detailansicht von Elementen der Ausführungsform der erfindungsgemäßen Vorrichtung in einer dreidimensionalen Darstellung,
Figur 8
eine Detailansicht einer Kühlvorrichtung der Ausführungsform der erfindungsgemäßen Vorrichtung,
Figur 9
eine Ausführungsform einer erfindungsgemäßen Vorrichtung mit einer Arbeitsstation, die in einem Modulgestell angeordnet ist.
The invention will be explained in more detail below with reference to the figures shown in the drawing, which illustrate embodiments of a connecting device according to the invention. Show it
FIG. 1
An embodiment of a device according to the invention for connecting an electrical transmission element with a contact element with a workstation in a three-dimensional view,
FIG. 2
a detailed representation of individual elements of the embodiment of the device according to the invention in a side view,
FIG. 3
a further detailed representation of individual elements of the embodiment of the device according to the invention in a three-dimensional view,
FIG. 4
a representation of individual elements of the embodiment of the device according to the invention in a three-dimensional view,
FIG. 5
an illustration of individual elements of the embodiment of the device according to the invention in a front view,
FIG. 6
a further detail view of elements of the embodiment of the device according to the invention in a three-dimensional representation,
FIG. 7
a further detail view of elements of the embodiment of the device according to the invention in a three-dimensional representation,
FIG. 8
a detailed view of a cooling device of the embodiment of the device according to the invention,
FIG. 9
an embodiment of a device according to the invention with a workstation which is arranged in a module frame.

Anhand der Figuren 1 bis 3 wird im Folgenden der Aufbau einer Ausführungsform einer erfindungsgemäßen Vorrichtung zur Verbindung eines elektrischen Übertragungselements mit einem Kontaktelement näher erläutert.Based on FIGS. 1 to 3 the construction of an embodiment of a device according to the invention for connecting an electrical transmission element to a contact element is explained in more detail below.

Figur 1 zeigt in einer dreidimensionalen Ansicht eine Ausführungsform einer Arbeitsstation 2, der mehrere Kontaktelemente 5, die einseitig mit einem Trägerstreifen 53 verbunden sind, über eine Zuführeinrichtung zugeführt werden, um jeweils mit einem elektrischen Übertragungselement 6 verbunden zu werden. Figuren 2 und 3 zeigen jeweilige Detaildarstellungen der Arbeitsstation 2 gemäß Figur 1. Wie anhand von Figur 2 näher dargestellt, wird der Arbeitsstation 2 durch die Zuführeinrichtung ein elektrisches Übertragungselement 6 zugeführt, das einen elektrischen Leiter 61 innerhalb einer Aderhülle 62 aufweist. Die Aderhülle 62 ist beispielsweise als Isolierung ausgebildet, der elektrische Leiter 61 umfasst beispielsweise eine Litzendrahtanordnung, bei der mehrere einzelne elektrisch leitfähige Litzen zu einem elektrischen Leiter verseilt sind. Das Übertragungselement 6 mit dem freiliegenden Leiter 61 wird auf einer Fläche eines Tragmessers 30 platziert, oberhalb eines Kontaktelements 5, mit dem es verbunden werden soll. Das Kontaktelement 5 weist im vorliegenden Ausführungsbeispiel zwei Crimpelemente in Form von Crimplaschen 51 auf, wie insbesondere anhand von Figur 3 näher dargestellt. Diese Crimplaschen 51 dienen dazu, die Aderhülle 62 des Übertragungselements 6 mit dem Kontaktelement 5 zu verbinden, indem die Crimplaschen 51 mit der Aderhülle 62 vercrimpt werden, so dass ein Press- oder Quetschkontakt zwischen den Crimplaschen 51 und der Aderhülle 62 hergestellt ist. In diesem Zusammenhang ist es prinzipiell auch möglich, als Crimpelement lediglich nur eine Crimplasche vorzusehen, die mit der Aderhülle inQuetschkontakt gebracht wird. FIG. 1 shows in a three-dimensional view of an embodiment of a workstation 2, the plurality of contact elements 5, which are connected on one side with a carrier strip 53, are fed via a feed device to be connected to an electrical transmission element 6 respectively. Figures 2 and 3 show respective detailed representations of the workstation 2 according to FIG. 1 , As based on FIG. 2 shown in more detail, the workstation 2 is supplied by the feed device, an electrical transmission element 6, which has an electrical conductor 61 within a wire sheath 62. The wire sheath 62 is designed, for example, as insulation, the electrical conductor 61 comprises, for example, a stranded wire arrangement in which several individual electrically conductive strands are stranded to form an electrical conductor. The transfer element 6 with the exposed conductor 61 is placed on a surface of a support knife 30, above a contact element 5, with which it is to be connected. The contact element 5 has in the present embodiment, two crimping elements in the form of Crimplaschen 51, in particular with reference to FIG. 3 shown in more detail. These Crimplaschen 51 serve to the wire sheath 62 of the transmission element 6 with the contact element 5 are crimped by the crimping tabs 51 with the core sheath 62, so that a pressing or crushing contact between the Crimplaschen 51 and the core sheath 62 is made. In this context, it is also possible in principle to provide as crimping element only one crimping plate, which is brought into crimping contact with the core sheath.

Die Kontaktelemente 5, die an dem Trägerstreifen 53 befestigt sind, werden von links nach rechts mittels einer Führungsschiene 72, die auf einer Zuführungsplatte 73 angeordnet ist und zwischen sich und der Zuführungsplatte 73 einen Zuführungsspalt bildet, dem nachfolgenden Bearbeitungsvorgang zur Verbindung mit dem elektrischen Übertragungselement 6 zugeführt. Der Trägerstreifen 53 weist zu diesem Zweck Transportöffnungen 54 auf (siehe beispielsweise Figur 5), in welche ein Vorschubfinger 70 eingreift, um den Trägerstreifen 53 mit einer intermittierenden Bewegung von links nach rechts zu bewegen. Der Vorschubfinger 70 wird zu diesem Zweck entlang der Führungsschiene 72 (Figur 5) geführt, die auf der Zuführungsplatte 73 befestigt ist. Zur Bewegung des Vorschubfingers 70 dient ein pneumatischer Vorschub 74, der sich intermittierend von links nach rechts bewegt und mit einer Rückführbewegung in eine neue Transportöffnung 54 mittels des Vorschubfingers 70 eingreift.The contact elements 5, which are fixed to the carrier strip 53, from left to right by means of a guide rail 72 which is arranged on a feed plate 73 and forms a feed gap between itself and the feed plate 73, the subsequent processing operation for connection to the electrical transmission element. 6 fed. The carrier strip 53 has for this purpose transport openings 54 (see, for example FIG. 5 ), in which a feed finger 70 engages to move the carrier strip 53 with an intermittent movement from left to right. The feed finger 70 is for this purpose along the guide rail 72 ( FIG. 5 ), which is mounted on the feed plate 73. To move the feed finger 70 is a pneumatic feed 74, which moves intermittently from left to right and engages with a return movement in a new transport opening 54 by means of the feed finger 70.

Die Arbeitsstation 2 weist eine Crimpeinrichtung auf, die mehrere Komponenten umfasst. Ein Crimpwerkzeug 10 dient dazu, die Crimplaschen 51 des Kontaktelements 5 in Quetschkontakt mit der Aderhülle 62 des Übertragungselements 6 zu bringen. Dazu wird das Crimpwerkzeug 10 in einem Verfahrweg senkrecht nach unten bewegt, wobei anhand des vorgegebenen Profils des unteren Endes des Crimpwerkzeugs 10 die Crimplaschen 51 nach innen gebogen werden, um den Quetschkontakt herzustellen. Zur Bewegung des Crimpwerkzeugs 10 dient ein Hubzylinder 13, mit dem eine Befestigungsplatte 11 für das Crimpwerkzeug 10 bewegt wird, so dass mit der Befestigungsplatte 11 das Crimpwerkzeug 10 für einen Crimpvorgang nach unten verfahren wird. Das Crimpwerkzeug 10 ist über eine Crimphöhenverstellung 12 mit der Befestigungsplatte 11 verbunden, die dazu dient, das Crimpwerkzeug in der Endposition in seiner Höhe genau einzustellen, so dass eine Anpassung an verschiedene Durchmesser von Übertragungselementen ermöglicht ist. Die Crimphöhenverstellung 12 ist in Form eines Excenters ausgebildet, der entsprechend verdreht wird, um das Crimpwerkzeug 10 mit der gewünschten Höhe einzustellen. Beim Niederdrücken der Crimplaschen 51 durch das Crimpwerkzeug 10 wird eine Gegenkraft durch den Amboss 14 aufgebaut, der das elektrische Kontaktelement 5 an der Position der Crimplaschen 51 gegen das Crimpwerkzeug 10 abstützt.The workstation 2 has a crimping device comprising a plurality of components. A crimping tool 10 is used to bring the Crimplaschen 51 of the contact element 5 in crimping contact with the buffer tube 62 of the transmission element 6. For this purpose, the crimping tool 10 is moved vertically downwards in a travel path, with the crimping lugs 51 being bent inwards on the basis of the predetermined profile of the lower end of the crimping tool 10 in order to produce the crimping contact. For the movement of the crimping tool 10 is a lifting cylinder 13, with which a fastening plate 11 for the crimping tool 10 is moved so that the crimping tool 10 is moved downwards with the fastening plate 11 for a crimping operation. The crimping tool 10 is connected via a crimp height adjustment 12 with the mounting plate 11, which serves to adjust the crimping tool in the final position in its height exactly, so that an adaptation to different diameters of transmission elements is possible. The crimp height adjustment 12 is in the form of an eccentric, which is rotated accordingly to adjust the crimping tool 10 to the desired height. When the crimping lugs 51 are pressed down by the crimping tool 10, a counterforce is built up by the anvil 14, which supports the electrical contact element 5 against the crimping tool 10 at the position of the crimping lugs 51.

Die Arbeitsstation 2 enthält des weiteren eine Schweißvorrichtung, die als Schweißvorrichtung zur Durchführung eines Widerstandsschweißverfahrens ausgebildet ist. Sie besitzt eine obere Schweißelektrode 22 und eine untere Schweißelektrode 23, die mit einer elektrischen Versorgungsspannung beaufschlagt werden, um einen Schweißstrom zu erzeugen. Das Kontaktelement 5 wird mit dem Kontaktbereich 52 zwischen den Elektroden 22 und 23 angeordnet. Die obere Elektrode 22 wird von dem Elektrodenhalter 21 gehalten, der auf die jeweils verwendete Schweißelektrode abgestimmt ist und seinerseits an einer Klemmung 20 für den Elektrodenhalter befestigt ist (Figur 9). Wie anhand von Figur 9 weiter dargestellt, ist der Elektrodenhalter 21 über die Klemmung 20 mit einer Schweißkopfanordnung 4 verbunden. Diese Schweißkopfanordnung 4 dient zur vertikalen Positionierung der oberen Schweißelektrode 22. Der Schweißstrom wird extern erzeugt und den Schweißelektroden 22 und 23 über (in den Figuren nicht gezeigte) Verbindungsleitungen zugeführt. Gemäß Figur 2 ist der Amboss 14 für das Crimpwerkzeug 10 durch eine Isolierung 15 gegenüber der unteren Elektrode 23 isoliert. Neben der unteren Elektrode 23 ist eine Kontaktabstützung 24, vorzugsweise aus elektrisch nicht leitendem Material, vorgesehen, um das Kontaktelement 5 während des Schweißvorgangs nach unten hin abzustützen.The workstation 2 further includes a welding device configured as a welding device for performing a resistance welding process. It has an upper welding electrode 22 and a lower welding electrode 23, which are supplied with an electrical supply voltage to generate a welding current. The contact element 5 is arranged with the contact region 52 between the electrodes 22 and 23. The upper electrode 22 is held by the electrode holder 21, which is matched to the particular welding electrode used and in turn is attached to a clamp 20 for the electrode holder ( FIG. 9 ). As based on FIG. 9 further illustrated, the electrode holder 21 is connected via the clamp 20 with a welding head assembly 4. This welding head assembly 4 serves to vertically position the upper welding electrode 22. The welding current is generated externally and supplied to the welding electrodes 22 and 23 via connecting lines (not shown in the figures). According to FIG. 2 is the anvil 14 for the crimping tool 10 by an insulation 15 relative to the lower electrode 23 isolated. In addition to the lower electrode 23 is a contact support 24, preferably made of electrically non-conductive material, provided to support the contact element 5 during the welding operation downwards.

Die obere Elektrode 22 mit dem Elektrodenhalter 21 ist entlang einer ersten Achse 81 an die zu verschweißenden Elemente in Form des elektrischen Leiters 61 und des Kontaktbereichs 52 annäherbar. Die Achse 81 befindet sich in vorliegender Ausführungsform in vertikaler Anordnung. Ist die obere Elektrode 22 an die zu verschweißenden Elemente 61 und 52 herangeführt, werden die Elektroden 22 und 23 mit einer elektrischen Versorgungsspannung beaufschlagt, so dass ein Schweißstrom durch die zu verschweißenden Komponenten 52 und 61 fließt. Diese bilden einen elektrischen Widerstand für den Schweißstrom, so dass die zu verschweißenden Elemente stark erhitzen und somit eine Verschweißung, d.h. eine innige Verbindung zwischen dem elektrischen Leiter 61 und dem Kontaktbereich 52 des elektrischen Kontaktelements 5 herbeigeführt wird. Handelt es sich bei dem elektrischen Leiter 61 um eine Litzendrahtanordnung aus mehreren miteinander verseilten Drahtlitzen, so wird wenigstens ein Teil dieser Drahtlitzen mit dem Kontaktbereich 52 verschweißt und wird mindestens ein Teil der Drahtlitzen miteinander kompaktiert, d.h. die einzelnen Drähte des Litzenbündels werden miteinander zu einem Bündel verschweißt. Dadurch wird eine innige Verbindung zwischen den Drahtlitzen hergestellt, so dass insgesamt ein guter Kontakt zwischen der Litzendrahtanordnung und dem Kontaktelement hergestellt wird.The upper electrode 22 with the electrode holder 21 can be approached along a first axis 81 to the elements to be welded in the form of the electrical conductor 61 and the contact region 52. The axis 81 is in the present embodiment in a vertical arrangement. If the upper electrode 22 is brought to the elements to be welded 61 and 52, the electrodes 22 and 23 are acted upon by an electrical supply voltage, so that a welding current flows through the components 52 and 61 to be welded. These form an electrical resistance to the welding current, so that the elements to be welded become very hot, thus causing welding, i. an intimate connection between the electrical conductor 61 and the contact region 52 of the electrical contact element 5 is brought about. When the electrical conductor 61 is a stranded wire assembly of a plurality of stranded strands of wire, at least a portion of these strands of wire are welded to the contact portion 52 and at least a portion of the strands of wire are compacted together, i. the individual wires of the strand bundle are welded together to form a bundle. As a result, an intimate connection between the wire strands is produced, so that a good overall contact between the stranded wire arrangement and the contact element is produced.

Im Gegensatz zu dem Verbindungsverfahren gemäß DE 103 58 153 A1 wird keine Vercrimpung des elektrischen Leiters 61 bzw. der Litzendrahtanordnung 61 mit einem Leitercrimbereich des Kontaktelements 5 durchgeführt. Dadurch ist es ermöglicht, den gesamten Kontaktbereich 52 über dessen gesamte Länge hinweg für eine innige Schweißverbindung mit dem bzw. den elektrischen Leitern zu nutzen.In contrast to the connection method according to DE 103 58 153 A1 No crimping of the electrical conductor 61 or the stranded wire arrangement 61 is performed with a conductor crimping region of the contact element 5. This makes it possible, the entire contact area 52 via to use its entire length for an intimate weld with the electrical conductors or the.

Erfindungsgemäß sind also die Schweißvorrichtung und Crimpeinrichtung für die Verbindung des elektrischen Übertragungselements mit dem Kontaktelement in einer gemeinsamen Arbeitsstation 2 enthalten, der das Kontaktelement 5 und das elektrische Übertragungselement 6 intermittierend zugeführt werden. Diese verbleiben für einen Arbeitsvorgang mit einer bestimmten Verweildauer in der Arbeitsstation 2, bevor sie als Verbindungsanordnung der Arbeitsstation wieder entnommen werden. Der Crimpvorgang und der Schweißvorgang werden in der gemeinsamen Arbeitsstation 2 in einem Arbeitsvorgang durchgeführt, so dass ein Transportvorgang von einem Crimpwerkzeug in ein separates Schweißwerkzeug entfällt. Dadurch kann die Gesamtzeit (Zykluszeit) für das gemeinsame Isolationscrimpen und Leiterdrahtschweißen pro Kontaktelement auf ca. 1000 bis 1500 ms beträchtlich reduziert werden.According to the invention, therefore, the welding device and crimping device for the connection of the electrical transmission element to the contact element are contained in a common workstation 2, to which the contact element 5 and the electrical transmission element 6 are fed intermittently. These remain in the workstation 2 for an operation with a certain residence time before they are removed again as a connection arrangement of the workstation. The crimping and the welding operation are carried out in the common workstation 2 in one operation, so that a transport operation is omitted by a crimping tool in a separate welding tool. Thereby, the total time (cycle time) for the common insulation crimping and conductor wire welding per contact element can be considerably reduced to about 1000 to 1500 ms.

Anhand der Darstellungen der Figuren 4 bis 7 wird im weiteren Verlauf der weitere Aufbau einer Ausführungsform der erfindungsgemäßen Verbindungsvorrichtung näher erläutert.Based on the representations of FIGS. 4 to 7 the further construction of an embodiment of the connecting device according to the invention will be explained in more detail below.

In der Arbeitsstation 2 ist neben den bereits beschriebenen Komponenten weiterhin eine Stützeinrichtung 40 vorgesehen, die dazu dient, die zu verschweißenden Elemente 52 und 61 während des Schweißvorgangs gegen Kräfte abzustützen, die durch den Schweißvorgang auf die zu verschweißenden Elemente ausgeübt werden und eine Ausweichtendenz des Schweißgutes zur Seite hin bewirken. Die Stützeinrichtung 40 weist seitlich zu den zu verschweißenden Elementen 52 und 61 paarweise angeordnete Stützelemente 41 in Form von Keramikbacken auf, wobei ein erster Keramikbacken 41 auf einer Seite und ein zweiter Keramikbacken 41 auf einer gegenüberliegenden Seite der zu verschweißenden Elemente 52 und 61 angeordnet werden. Die Verwendung von Keramik ist in diesem Zusammenhang von Vorteil, weil es ein Isoliermaterial darstellt, das verhindert, dass der Schweißstrom durch die Stützeinrichtung hindurch fließt.In the workstation 2, in addition to the already described components, a support device 40 is furthermore provided, which serves to support the elements 52 and 61 to be welded during the welding operation against forces exerted by the welding operation on the elements to be welded and a tendency to evasion of the weld metal to the side cause. The support means 40 has laterally to the elements to be welded 52 and 61 paired support members 41 in the form of ceramic jaws, wherein a first ceramic jaw 41 on one side and a second ceramic jaw 41 on an opposite side of the elements to be welded 52 and 61 are arranged. The use of ceramic is advantageous in this context because it is an insulating material that prevents the welding current from flowing through the support.

Zur Annäherung an die zu verschweißenden Elemente 52 und 61 sind die Keramikbacken 41 entlang der zweiten Achse 82 verfahrbar, welche zur ersten Achse 81 näherungsweise orthogonal angeordnet ist. Das bedeutet bei der vorliegenden Ausführungsform, dass die Keramikbacken 41 entlang einer waagrechten Achse seitlich an die zu verschweißenden Elemente 52 und 61 angenähert werden.To approach the elements to be welded 52 and 61, the ceramic jaws 41 along the second axis 82 are movable, which is arranged approximately orthogonal to the first axis 81. This means in the present embodiment that the ceramic jaws 41 are approximated along a horizontal axis laterally to the elements 52 and 61 to be welded.

Die Keramikbacken 41 werden von Haltern 42 geführt, die ihrerseits an Parallel-Greifern 43 befestigt sind. Ein Vorschubzylinder 45 dient zur Bewegung, genauer für den Vor- und Rückschub der Parallel-Greifer 43. Über einen Zylinder 46 ist ein Verriegelungsbügel 44 bewegbar, der als bügel-oder spangenartiges Verriegelungselement vorgesehen ist, um die paarweise angeordneten Keramikbacken 41 in ihrer Stützposition gegen in Stützrichtung seitlich wirkende Kräfte abzustützen, die in Folge des Schweißvorgangs entstehen. Dadurch ist es ermöglicht, die Keramikbacken 41 filigraner auszuführen, so dass sie zwischen den Kontaktelementen 5, die noch am Trägerstreifen 53 befestigt sind, leichter bewegt werden können.The ceramic jaws 41 are guided by holders 42, which in turn are attached to parallel grippers 43. A feed cylinder 45 is used for movement, more precisely for the forward and reverse thrust of the parallel gripper 43. Via a cylinder 46, a locking bracket 44 is movable, which is provided as a bow-shaped or clasp-like locking element to the paired ceramic jaws 41 in its supporting position against To support in the direction of support laterally acting forces that arise as a result of the welding process. This makes it possible to make the ceramic jaws 41 filigree, so that they can be easily moved between the contact elements 5, which are still attached to the carrier strip 53.

Vor einem Schweißvorgang wird die Stützeinrichtung 40 mit den Keramikbacken 41, den Haltern 42 und den Parallel-Greifern 43 entlang einer dritten Achse 83 in Richtung zum Trägerstreifen 53 verfahren, wobei die dritte Achse 83 näherungsweise orthogonal zu der ersten Achse 81 und zu der zweiten Achse 82 angeordnet ist. Die Parallel-Greifer 43 werden zu diesem Zweck durch den Vorschubzylinder 45 bewegt. Dadurch werden die Keramikbacken 41 in eine seitliche Position zu den zu verschweißenden Elementen 52 und 61 gebracht, so dass sie anschließend entlang der zweiten Achse 82 an die zu verschweißenden Elemente herangeführt werden können.Before a welding operation, the support device 40 is moved with the ceramic jaws 41, the holders 42 and the parallel grippers 43 along a third axis 83 in the direction of the carrier strip 53, the third axis 83 approximately orthogonal to the first axis 81 and to the second axis 82 is arranged. The parallel gripper 43 become moved by the feed cylinder 45 for this purpose. Thereby, the ceramic jaws 41 are brought into a lateral position to the elements to be welded 52 and 61, so that they can then be brought along the second axis 82 to the elements to be welded.

Wie insbesondere anhand der Figuren 1 bis 3 deutlicher ersichtlich, enthält die Arbeitsstation 2 weiterhin eine Abtrenneinrichtung, die dazu dient, das zu verschweißende Kontaktelement 5 von dem Trägerstreifen 53 zu trennen, an welchem mehrere zu verarbeitende Kontaktelemente 5 nebeneinander angebracht sind. Die Abtrenneinrichtung weist ein sowohl als Trennmesser als auch als Kabelträger dienendes Tragmesser 30 und einen Stößel 31 auf, der für einen Abtrennvorgang nach unten bewegt wird. In dieser Stoßrichtung wirkt der verfahrbare Stößel 31 auf das Tragmesser 30 ein, und zwar auf den erhöhten, links angeordneten Vorsprung des Tragmessers 30, so dass das Tragmesser 30 an dieser Stelle durch den Stößel 31 nach unten gedrückt wird. Somit wird das Tragmesser 30 in Stoßrichtung des Stößels 31 nach unten bewegt, so dass der Trägerstreifen 53 durch das Tragmesser 30 vom Kontaktelement 5 abgetrennt wird.As in particular on the basis of FIGS. 1 to 3 more clearly, the workstation 2 further includes a separating device which serves to separate the contact element 5 to be welded from the carrier strip 53, to which a plurality of contact elements 5 to be processed are mounted side by side. The separating device has a serving both as a separating knife and as a cable carrier support blade 30 and a plunger 31 which is moved for a separation process down. In this thrust direction of the movable plunger 31 acts on the support blade 30, on the raised, left-hand projection of the support blade 30, so that the support blade 30 is pressed at this point by the plunger 31 down. Thus, the support blade 30 is moved in the direction of impact of the plunger 31 down, so that the carrier strip 53 is separated by the support blade 30 from the contact element 5.

Gemäß der vorliegenden Ausführungsform ist der Stößel 31 über eine Befestigungsschraube 32 mit dem Crimpwerkzeug 10 verbunden. Damit werden der Stößel 31 und das Crimpwerkzeug 10 in einem Verfahrvorgang zur Annäherung an das Tragmesser 30 bzw. zur Annäherung an das Kontaktelement 5 synchron zueinander bewegt.According to the present embodiment, the plunger 31 is connected via a fastening screw 32 with the crimping tool 10. In this way, the plunger 31 and the crimping tool 10 are moved synchronously with one another in a movement process for approaching the support blade 30 or for approaching the contact element 5.

Im Folgenden wird der Ablauf eines Verbindungsprozesses zur Verbindung eines elektrischen Übertragungselements 6 mit einem Kontaktelement 5 zusammenhängend näher beschrieben.The sequence of a connection process for connecting an electrical transmission element 6 to a contact element 5 will be described below in more detail.

Die einzelnen Kontaktelemente 5 werden durch den beschriebenen Zuführmechanismus intermittierend zu der Arbeitsstation 2 gefördert, wobei das jeweils zu verbindende Kontaktelement 5 in den Schweiß-/Crimpbereich der beschriebenen Arbeitsstation 2 gelangt, wo es von der Kontaktabstützung 24 abgestützt wird. Das Übertragungselement 6 wird von vorne (Figur 1) bzw. von links (Figur 2) an das Kontaktelement 5 angenähert und kommt auf dem rechten Oberflächenteil des Tragmessers 30 zu liegen. Nachfolgend wird das Crimpwerkzeug 10 geschlossen, in dem es auf den Amboss 14 abgesenkt wird. Durch diesen Vorgang werden die Crimplaschen 51 zu einem Quetschkontakt auf die Aderhülle 62 gedrückt und synchron dazu wird das Kontaktelement 5 vom Trägerstreifen 53 abgetrennt mittels des Tragmessers 30, das von dem Stößel 31 nach unten gedrückt wird.The individual contact elements 5 are conveyed by the feed mechanism described intermittently to the workstation 2, wherein the respective contact element 5 to be connected in the welding / crimping of the described workstation 2, where it is supported by the contact support 24. The transmission element 6 is from the front ( FIG. 1 ) or from the left ( FIG. 2 ) approximates the contact element 5 and comes to lie on the right surface portion of the support blade 30. Subsequently, the crimping tool 10 is closed, in which it is lowered onto the anvil 14. By this operation, the Crimplaschen 51 are pressed to a crimping contact on the buffer tube 62 and synchronously, the contact element 5 is separated from the carrier strip 53 by means of the support blade 30, which is pressed by the plunger 31 down.

Nachfolgend werden die Keramikbacken 41 entlang der Achse 83 beidseits neben dem Kontaktelement 5 in Position gebracht und entlang der Achse 82 geschlossen, um ohne seitlichen Abstand an der jeweiligen Seite des Kontaktelements 5 anzuliegen. Dazu werden die Halter 42 für die Keramikbacken 41 von hinten nach vorne vorgefahren, indem die Parallel-Greifer 43 mittels des Vorschubzylinders 45 nach vorne bewegt werden. Hierbei sind die Halter 42 für die Keramikbacken 41 noch im geöffneten Zustand, bis sie sich beidseits des jeweils positionierten Kontaktelements 5 befinden. Sodann werden die Keramikbacken 41 entlang der Achse 82 seitwärts an die beiden Längsseiten des Kontaktelements 5 heranbewegt, bis sie daran anliegen. Vor dem Verschweißvorgang wird der Verriegelungsbügel 44 über die in Schließposition befindlichen Keramikbackenhalter 42 gestülpt, um ein seitliches Ausweichen der Keramikbacken 41 in Folge der Schweißkräfte zu verhindern. Während des Schweißvorgangs ist das Crimpwerkzeug 10 in geschlossenem Zustand, um das Übertragungselement 6 in Position festzuhalten.Subsequently, the ceramic jaws 41 are brought along the axis 83 on both sides next to the contact element 5 in position and closed along the axis 82 to abut without lateral spacing on the respective side of the contact element 5. For this purpose, the holders 42 are advanced for the ceramic jaws 41 from back to front by the parallel gripper 43 are moved by means of the feed cylinder 45 to the front. Here, the holder 42 for the ceramic jaws 41 are still in the open state until they are located on both sides of the respective positioned contact element 5. Then, the ceramic jaws 41 are moved along the axis 82 sideways on the two longitudinal sides of the contact element 5 until they rest thereon. Before the welding process, the locking bracket 44 is slipped over the ceramic jaw holder 42 in the closed position in order to prevent lateral deflection of the ceramic jaws 41 as a result of the welding forces. This is during the welding process Crimping tool 10 in the closed state to hold the transmission element 6 in position.

Für den Schweißvorgang wird die obere Schweißelektrode 22 zur feststehenden unteren Schweißelektrode 23 hin herabbewegt. Während des Schweißvorgangs werden die Litzen der Litzendrahtanordnung 61 seitlich von den Keramikbacken 41 abgestützt. Nach dem Schweißvorgang werden die Keramikbacken 41 entlang der Achse 82 geöffnet sowie das Crimpwerkzeug 10 und die obere Schweißelektrode 22 entlang der Achse 81 nach oben gefahren, so dass das Übertragungselement 6 mit dem daran angeschweißten und angecrimpten Kontaktelement 5 aus der Arbeitsstation 2 entnommen werden kann.For the welding operation, the upper welding electrode 22 is moved down to the fixed lower welding electrode 23. During the welding process, the strands of the stranded wire assembly 61 are laterally supported by the ceramic jaws 41. After the welding operation, the ceramic jaws 41 are opened along the axis 82 and the crimping tool 10 and the upper welding electrode 22 are moved upwards along the axis 81, so that the transmission element 6 can be removed from the work station 2 with the contact element 5 welded thereto and crimped on.

Um die einzelnen Komponenten der Arbeitsstation 2 während des Schweißvorgangs nicht zu stark erhitzen zu lassen, ist gemäß Figur 8 eine Kühlvorrichtung 75 vorgesehen, die mehrere Rohre enthält, in denen beispielsweise Kühlmedium in Form eines Kühlfluids beispielsweise in Form von Kühlluft oder Kühlwasser geführt werden kann. Geht man beispielsweise von einer Ausführungsform mit Kühlwasser als Kühlmedium aus, wird das Kühlwasser beispielsweise an dem Kühlwassereinlass 76 in die Kühlvorrichtung 75 eingeführt und an dem Kühlwasserauslass 77 der Kühlvorrichtung 75 wieder entnommen. Dadurch wird bewirkt, dass sich die Trägerplatte 71, auf welcher die Arbeitsstation 2 angeordnet ist, in Folge des Schweißvorgangs nicht zu stark erhitzt und sich somit verformt.In order not to let the individual components of the workstation 2 during the welding process to overheat, is in accordance FIG. 8 a cooling device 75 is provided, which contains a plurality of tubes, in which, for example, cooling medium in the form of a cooling fluid, for example in the form of cooling air or cooling water can be performed. For example, assuming an embodiment with cooling water as the cooling medium, the cooling water is introduced, for example, at the cooling water inlet 76 into the cooling device 75 and removed again at the cooling water outlet 77 of the cooling device 75. This causes the support plate 71, on which the workstation 2 is arranged, not to overheat and thus deform as a result of the welding operation.

In Figur 9 ist eine Ausführungsform einer erfindungsgemäßen Vorrichtung 1 mit einer Arbeitsstation 2, wie anhand der Figuren 1 bis 8 näher beschrieben, in einem Modulgestell näher gezeigt. Die Arbeitsstation 2 (so genannter Applikator) ist auf einer Trägerplatte 71 (siehe beispielsweise Figur 1) angeordnet, welche mittels einer nicht näher dargestellten Schnellspanneinrichtung an einem Modulgestell 3 montierbar und von diesem demontierbar ist. Somit ist die Arbeitsstation 2 in dem Modulgestell 3 als austauschbares Wechselwerkzeug angeordnet und von diesem mit geringem Aufwand demontierbar. Damit kann eine Anpassung an verschiedenartige Kontaktelemente und Übertragungselemente erfolgen. Die Schweißkopfanordnung 4 mit servomotorischem Schweißkopf mit Schweißparameterüberwachung bleibt dabei mit dem Modulgestell 3 fest verbunden. Das Modulgestell 3 ist seinerseits auf einer entsprechenden Herstellungsvorrichtung montiert. Bei der Auswechslung der Arbeitsstation 2 werden gemäß dieser Ausführungsform die Schweißelektroden 22 und 23 mit gewechselt, so dass eine geeignete Schnittstelle zum Modulgestell 3 bzw. zur Schweißkopfanordnung 4 vorgesehen werden muss, mit der die Schweißelektroden mit einer Spannungsversorgung koppelbar sind.In FIG. 9 is an embodiment of a device 1 according to the invention with a workstation 2, as shown in FIG FIGS. 1 to 8 described in more detail, shown in more detail in a module frame. The work station 2 (so-called applicator) is on a support plate 71 (see for example FIG. 1 ), which by means of a quick release device, not shown can be mounted on a module frame 3 and disassembled from this. Thus, the workstation 2 is arranged in the module frame 3 as an exchangeable change tool and disassembled from this with little effort. This can be done to adapt to various types of contact elements and transmission elements. The welding head assembly 4 with servomotor welding head with welding parameter monitoring remains firmly connected to the module frame 3. The module frame 3 is in turn mounted on a corresponding manufacturing device. In the replacement of the workstation 2, the welding electrodes 22 and 23 are changed in accordance with this embodiment, so that a suitable interface to the module frame 3 and the welding head assembly 4 must be provided, with which the welding electrodes can be coupled to a power supply.

Claims (24)

  1. A method for connecting an electrical transmission element (6) to a contact element (5), wherein the electrical transmission element (6) has at least one electrical conductor (61) which is surrounded by a core sheath (62),
    - in which the electrical transmission element (6) and the contact element (5), in order to produce a connection, are supplied to a work station (2) and remain in the work station (2) for a work operation with a specified holding time before they are removed from the work station again,
    - in which in the work station (2) the core sheath (62) is crimped with at least one crimping element of the contact element (5) and in the same work operation the electrical conductor (61) is welded to a contact region (52) of the contact element (5), characterised in that
    - the at least one electrical conductor (61), during the respective welding operation, is held by a supporting means (40) of the work station (2) against forces which bring about a tendency to yield.
  2. A method according to Claim 1, in which the electrical transmission element (6) has a plurality of electrical conductors (61), in particular a stranded wire arrangement, which are surrounded by a common core sheath (62), with, in the work station (2), at least some of the electrical conductors (61) being welded with a contact region (52) of the contact element (5) and at least several of the electrical conductors (61) being compacted together.
  3. A method according to Claim 1 or 2, in which the electrical connection between the at least one electrical conductor (61) and the contact element (5) is made in a crimp-free manner.
  4. A method according to one of the preceding claims, in which the electrical conductor (61) is welded with the contact region (52) of the contact element (5) while the core sheath (62) is held securely with an insulating crimping region of the contact element (5) by means of a crimping means (10) for crimping the core sheath (62).
  5. A method according to one of Claims 1 to 4, in which
    - the welding takes place by supplying energy along a first axis (81),
    - the electrical conductor or conductors (61) are held by a supporting means (41, 42, 43) which is movable along a second axis (82), the second axis (82) being arranged approximately orthogonally to the first axis (81).
  6. A method according to Claim 5, in which the supporting means (41, 42, 43) before the welding operation is moved along a third axis (83) towards the respective contact element (5), the third axis (83) being arranged approximately orthogonally to the first and second axis (81, 82), and then being moved along the second axis (82) in order to adopt the supporting position.
  7. A method according to Claim 5 or 6, in which the supporting means (41, 42, 43) before the welding operation is moved approximately parallel to the first axis (81) towards the respective contact element (5), and then along the second axis (82) in order to adopt the supporting position.
  8. A method according to one of the preceding claims, in which
    - the contact element (5) upon being supplied to the work station (2) is connected to a carrier element (53),
    - in the work station (2) the contact element (5) is severed from the carrier element (53).
  9. A method according to Claim 8, in which the core sheath (62) is crimped with at least one crimping element of the contact element (5), in that a crimping means (10) is brought into the crimping position in a displacement operation,
    - the contact element (5) is separated from the carrier element (53) by a severing means (30, 31) which is brought into the severing position with the same displacement operation.
  10. A method according to one of the preceding claims, in which a resistance-welding method is used for the welding.
  11. A device for connecting an electrical transmission element (6) to a contact element (5), wherein the electrical transmission element (6) has at least one electrical conductor (61) which is surrounded by a core sheath (62),
    - with a contact-element supply means (70, 72, 73, 74) for supplying a contact element (5),
    - with a work station (2) to which on one hand the electrical transmission element (6), and on the other hand by means of the supply means (70, 72, 73, 74) the contact element (5), are supplied, these remaining in the work station (2) for a work operation with a specific holding time before being removed from the work station again, wherein
    - the work station (2) comprises a crimping means (10) which is designed and can be operated to crimp the core sheath (62) of the electrical transmission element (6) with at least one insulating crimping region of the contact element (5),
    - the work station (2) comprises a welding device (22, 23) which is designed and can be operated to weld the electrical conductor (61) to a contact region (52) of the contact element (5),
    - the crimping means (10) and the welding device (22, 23) are arranged to be actuated in a work operation for a crimping operation and for a welding operation, characterised in that
    - the work station (2) comprises a supporting means (40) which is designed and can be operated such that the elements (52, 61) to be welded during the welding operation are held by the supporting means (40) against forces which bring about a tendency to yield.
  12. A device according to Claim 11, in which a transmission-element supply means (30) is provided, wherein
    - an electrical transmission element (6) can be supplied with a plurality of electrical conductors (61), in particular with a stranded wire arrangement, by the transmission-element supply means, which conductors are surrounded by a common core sheath (62),
    - the welding device (22, 23) is designed and can be operated to weld at least one part of the electrical conductors (61) to a contact region (52) of the contact element (5) and to compact at least several of the electrical conductors (61) together.
  13. A device according to Claim 11 or 12, which is designed and can be operated for the production of a crimp-free electrical connection between the at least one electrical conductor (61) and the contact element (5).
  14. A device according to one of Claims 11 to 13, in which the supporting means (40) has, laterally to the elements (52, 61) to be welded, supporting elements (41) arranged in pairs, a first one of the supporting elements (41) being able to be arranged on a first side, and a second one of the supporting elements (41) on a second side, located opposite, of the elements (52, 61) which are to be welded.
  15. A device according to Claim 14, in which a bolting element (44) is provided which supports the supporting elements (41) which are arranged in pairs in the supporting position counter to forces acting in the supporting direction.
  16. A device according to one of Claims 11 to 15, in which
    - the welding device (22, 23) can be brought closer to the electrical transmission element (6) and the contact element (5) along a first axis (81), in order to perform the welding operation by a supply of energy,
    - the supporting means (40), in order to be brought closer to the elements (52, 61) which are to be welded, can be moved along a second axis (82) which is arranged approximately orthogonally to the first axis (81).
  17. A device according to Claim 16, in which the supporting means (40) is movable along a third axis (83) which is arranged approximately orthogonally to the first and second axis (81, 82), in order to bring the supporting means (40) into a lateral position relative to the elements (52, 61) which are to be welded.
  18. A device according to Claim 16 or 17, in which the supporting means (41, 42, 43) before the welding operation can be moved towards the respective contact element (5) approximately parallel to the first axis (81), in order to bring the supporting means (40) into a lateral position relative to the elements (52, 61) which are to be welded.
  19. A device according to one of Claims 11 to 18, in which the work station (2) has a severing means (30, 31) in order to sever the contact element (5) which is to be welded from a carrier element (53) to which a plurality of contact elements (5) which are to be processed are attached.
  20. A device according to Claim 19, in which the severing means has a blade (30) and a movable tappet (31) which acts on the blade (30) in a direction of impact and moves it in the direction of impact in order to sever the carrier element (53) from the contact element (5).
  21. A device according to Claim 20, in which the tappet (31) is connected to the crimping means (10), so that the tappet (31) and the crimping means (10) in a displacement operation, in order to be brought closer to the blade (30) or the contact element (5), are moved synchronously relative to one another.
  22. A device according to one of Claims 11 to 21, in which the welding device (22, 23) is formed to carry out a resistance-welding operation.
  23. A device according to one of Claims 11 to 22, in which the work station (2) can be arranged in a module frame (3) and is formed therein as a replaceable interchangeable tool.
  24. A device according to Claim 23, in which the work station (2) is arranged on a carrier plate (71) which can be mounted on the module frame (3) and dismounted therefrom by means of a quick-clamping device.
EP20050023401 2004-11-03 2005-10-26 Device and method for connecting an electrical transfer member to a contact element Not-in-force EP1655804B1 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
DE200410053126 DE102004053126A1 (en) 2004-11-03 2004-11-03 Method and device for connecting an electrical transmission element with a contact element

Publications (3)

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EP1655804A2 EP1655804A2 (en) 2006-05-10
EP1655804A3 EP1655804A3 (en) 2008-01-02
EP1655804B1 true EP1655804B1 (en) 2012-09-05

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EP1655804A3 (en) 2008-01-02
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