EP1817781B1 - Inductive component and method for the production of such an inductive component - Google Patents
Inductive component and method for the production of such an inductive component Download PDFInfo
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- EP1817781B1 EP1817781B1 EP05816200.9A EP05816200A EP1817781B1 EP 1817781 B1 EP1817781 B1 EP 1817781B1 EP 05816200 A EP05816200 A EP 05816200A EP 1817781 B1 EP1817781 B1 EP 1817781B1
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- inductive component
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Images
Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/10—Connecting leads to windings
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F38/00—Adaptations of transformers or inductances for specific applications or functions
- H01F38/20—Instruments transformers
- H01F38/22—Instruments transformers for single phase ac
- H01F38/28—Current transformers
- H01F38/30—Constructions
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F17/00—Fixed inductances of the signal type
- H01F17/04—Fixed inductances of the signal type with magnetic core
- H01F17/06—Fixed inductances of the signal type with magnetic core with core substantially closed in itself, e.g. toroid
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F38/00—Adaptations of transformers or inductances for specific applications or functions
- H01F38/20—Instruments transformers
- H01F38/22—Instruments transformers for single phase ac
- H01F38/28—Current transformers
- H01F38/30—Constructions
- H01F2038/305—Constructions with toroidal magnetic core
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
- H01F27/29—Terminals; Tapping arrangements for signal inductances
- H01F27/292—Surface mounted devices
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/4902—Electromagnet, transformer or inductor
Definitions
- the invention relates to an inductive component having a conductor with a non-rectangular cross-section for conducting a current, at least one flat connection conductor for supplying or discharging the current to or from the conductor, wherein the conductor and the connection conductor in the region of a connecting portion of Conductor are connected together to form a conductor arrangement. More particularly, the invention relates to an inductive component having a magnetic module with an opening, wherein the current conductor is passed through the opening.
- the invention also relates to a method for producing a conductor arrangement for such an inductive component.
- a magnetic module current transformer, transformer
- the currently cheapest production of a magnetic component for high-quality current transformers consists in the production of toroidal cores, in particular toroidal cores, and the winding of the isolated or encapsulated cores with the corresponding secondary winding on the basis of enameled copper wire.
- Cores suitable for this purpose are known, for example, from US Pat EP 1 131 830 and EP 1 129 459 , The EP 1 114 429 describes current transformers for such purposes.
- One way of constructing a current transformer is to select the size of the current transformer so that it is possible to pass through a bus bar, for example, the size of 19 x 2.5 mm through the inner hole of the current transformer.
- An optimization is to give the area of the busbar on which the current transformer is to sit, a round cross-section.
- the inner hole of the current transformer can be smaller and used as a result of a smaller ring band core, which is due to the process then cheaper accordingly.
- the smaller the diameter of the core the more favorable are the process steps of a heat treatment and a coating.
- the production of a suitable busbar is done by providing a U-shaped conductor arrangement with different sections. A central connecting portion with a round cross-section serves as an element of the current transformer for passing through the corresponding opening in the core.
- connection conductors with a rectangular cross section are used to connect the conductor in the form of known per se connectors.
- the conductor arrangement thus consists of three metal parts with mutually different cross-sections, wherein the two ends of the round conductor are to be fastened to the flattened surfaces of the rectangular connection conductors.
- the inductive element used in EP 0 389 678 A1 has a winding conductor as a current conductor and two connection conductors on opposite sides of the winding conductor.
- the leads are flattened to provide a pad for use as an SMD component and are joined to pads of a printed circuit board by soldering.
- a method of fabricating an inductive chip with metal terminal strips is known.
- a metallic strip which is provided with slit-shaped openings, equipped with magnetic or non-magnetic cores. These cores are then wound with a wire. Thereafter, the ends of the wire are connected to portions of the metal strip and the core is provided with a housing. The packaged component is then cut off from the metal strip together with the portions of the metal strip so that the portions form terminals of the component, which are finally bent over.
- the US Pat. No. 4,491,818 discloses the preamble of claim 1 and describes a coil having a toroid wound with a wire.
- the coil is mounted standing on a printed circuit board.
- a conductor is passed, the ends of which are soldered to the circuit board. In the area of the opening, the conductor runs parallel to the printed circuit board.
- connection points In addition to soft soldering, which is commonly used to make a connection of SMD components, bonding by means of resistance spot welding or brazing is known for attaching a conductor to a lead.
- both methods require a complex process technology and a high energy input for each connection point to be created.
- the production-accompanying review of the connection points to ensure the quality of the conductor arrangement is to be seen, since in particular the welding in the sense of DIN ISO 9001 is classified as a so-called special process, as is Joining technology, welding technology, DVS publishing house, ISBN 3-87155-786-2, page 328, 2004 , is known.
- Particularly critical are the effects of oxide layers on the connection partners, the wear of the electrodes and the lack of possibility of meaningful, such as optical or electrical testing of the compound.
- the object of the invention is to propose an inductive component, in particular for a current detection device and a method for producing such an inductive component, which provides a simple production with a secure connection and the lowest possible load of other components.
- an inductive component is provided with a current conductor with non-rectangular cross-section for conducting a current to be detected, at least one planar connection conductor for supplying or discharging the current to be detected to or from the conductor, wherein the conductor and the connection conductor in the area of a connection portion of the conductor to form a conductor arrangement are connected to each other, and wherein the conductor in the region of the connecting portion has a flattened, in particular rectangular cross-section and a flat surface of the connecting portion of the conductor is connected to a flat surface of the connecting conductor.
- the device has a magnetic module with an opening through which the conductor is passed.
- the invention comprises a method for producing a conductor arrangement for an inductive component, in particular for use in a current detection device, in which a current conductor with non-rectangular cross-section is connected to a planar connection conductor, wherein the conductor in the cross section in a connecting portion of the conductor ( in particular with rectangular cross-section) is flattened, and the flattened connecting portion of the conductor is connected to the connecting conductor.
- an inductive component can be provided in which the cross section of the current conductor is formed away from the connecting section with an arcuate, in particular round, outer contour, in particular an oval or round cross-sectional shape.
- the inductive component can be designed with two connecting sections on the conductor for connecting the conductor to two connecting conductors.
- the compound is formed as a press connection, in particular as a cold press connection.
- the press connection is designed as a clinching connection.
- the current conductor and the connecting conductor or conductors may be formed as metal parts made of copper or a copper alloy.
- the inductive component according to the invention can be, for example, a magnetic module for current detection.
- the magnetic module can be designed as a current transformer or transformer.
- a current transformer preferably has a toroidal core.
- the ring core is preferably formed as a ring band core.
- the ring core is formed of an amorphous or nanocrystalline alloy.
- the current conductor may have a deformation, in particular compression, for fixing and / or aligning in an opening of the current transformer with respect to the other cross section.
- the contact points can be freed, cleaned and / or plasma-activated in the region of the connection section and / or the connection conductor of metal oxides. Also advantageous is a current detection device, in which the current conductor, the connecting portion and / or the connecting conductor are annealed by means of a heat treatment.
- connection is carried out as a press connection by means of a clinching technique.
- a method is preferably used in which contact points are freed from metal oxides before being combined with a chemical treatment, in particular pickling. The contact points can be cleaned and / or activated on the surface before being connected by means of a plasma treatment. Also advantageous is a method in which the current conductor, its connecting portion and / or the connecting conductor is annealed before joining by means of a heat treatment or are.
- the conductor arrangement thus represents a cost-optimized and long-term stable construction of power line rails.
- the conductor with the non-rectangular cross section, in particular with a round or nearly round cross section on the one hand and on the other hand at least one connecting conductor with a flat surface, in particular a rectangular cross section with each other, which have a stable and durable connection.
- a press connection without the use of heat by, for example, soldering or welding, there is the particular advantage that no heat is transmitted via the conductor to adjacent components of the toroidal core and the like.
- the second connection between the current conductor and a second connection conductor can, for example before the insertion of the conductor in the opening of the current transformer or toroidal be created so that eventually only one such connection is required.
- a cold welding in conjunction with a riveted connection requires a high degree of deformation, so that advantageously a soft metal such as copper or a copper alloy is used.
- a cold welding connection can be further improved with regard to the electrical properties, for example minimum contact resistance and gas tightness.
- the so-called cold pressure welding offers the advantage of a welding process in which a connection is complete, without external thermal energy supplied by pressure alone.
- the clinching represents a riveting, which advantageously without rivet, that is, without foreign materials manages by the material of one partner involved, for example, the conductor is pressed deep into a forming cavity in the other partner, such as the terminal conductor, wherein forms a mushroom-shaped undercut corresponding to the shape of a press-stamp and a die, so that a positive and non-positive connection is achieved.
- connection technology There are a variety of advantages through the connection technology and the structure of the conductor arrangement.
- a mechanically very robust connection is created.
- a simple manufacturing technique allows plant investment of only 30-50% compared to the corresponding welding / brazing technique.
- a simple and inexpensive maintenance of the production facilities is possible in comparison to the welding / brazing technique.
- Compared to the welding / brazing technique when using a cold weld joint, no heating of the metal parts occurs, so that no separate cooling is necessary to protect a plastic coating, for example, a current transformer. Vapors, sparks or chips are avoided.
- a quality assurance is possible by controlling simple mechanical dimensions, for example the thickness in the formed "rivet".
- the energy costs per connection point during manufacture are three to five times lower than in the welding / brazing technique.
- the cost per connection point taking into account even the investment cost, operating cost and tooling cost, is about 5: 1 more favorable when using clinching.
- connection points Since the conductor arrangement serves to transmit an electrical current, heating of the conductor arrangement by the current flow, in particular in the region of the connection points, must also be considered.
- the connection points do not represent a constriction of the cable cross-section. In the case of a poor connection, the temperature there rises significantly above the level of the remaining connection parts due to the higher voltage drop and accelerates the damage or aging of the contact point. This can lead to an increase in the contact resistance.
- the current detection device according to the invention or the described manufacturing method provides a low-resistance connection with simultaneously high mechanical strength, which allows a permanent connection even in the case of heating occurring during operation when using a clinching.
- Fig. 1 shows in various manufacturing steps components of a current detection device, which will be described in the following representative and exemplary of inductive components according to the invention.
- a current conductor 1 As the uppermost a current conductor 1 is shown, which, as shown in the middle, is passed through an opening 20 of a current transformer 2.
- the conductor has a non-rectangular, in particular a round cross-section.
- the cross-section of the conductor 1 in this area may also be slightly deformed, for example slightly flattened or oval instead of circular, to come into clamping engagement with the wall of the opening 20.
- conductors with other cross-sectional shapes can be used as circular cross-sectional shapes.
- cross sections in the form of an octet, square or optionally triangular or cross sections with wavy or serrated outer circumference can be used, which stand out clearly from a flat rectangular shape.
- the end of the current conductor 1 passed through the opening 20 of the current transformer 2 is flattened to form a connecting section 3.
- the flattening is done by squeezing, which is particularly easy, especially in a conductor 1 made of copper or a copper alloy.
- the connecting portion 3 of the conductor 1 has a substantially rectangular Cross-section on. In principle, however, other cross-sections which have a flattening on one side, for example also a flattening by material removal, can advantageously be implemented.
- Fig. 2 shows an output stage of a preferred conductor arrangement of the conductor 1 with connecting portions 3 at both ends, the current transformer 2, through the opening 20 of the conductor 1 passes between the connecting portions 3, and with two connecting conductors 4, which are elongated, flat pins with rectangular or in Substantially rectangular cross-section are formed.
- the connecting portions 3 with the connecting conductors 4 the flattened connecting portions 3 are placed with their flat surface on the flat surface of the connecting conductor 4 and connected together.
- the connection can be made in any manner known per se, for example by soldering or welding. But especially preferred is a cold connection without the supply of heat by means of, for example, cold press welding and / or clinching.
- a guided through one of the two terminal conductor 4 and the corresponding connecting portion 3 in the conductor 1 current is passed through the opening 20 of the current transformer 2 and discharged through the second connecting portion 3 and the second terminal conductor 4.
- the current passed through the current transformer 2 induces in the current transformer 2 a current flow which is conducted via lines 21 of an evaluation circuit for detecting the current flow.
- Fig. 2 is a conductor arrangement shown, in which the two connecting portions 3 of the conductor 1 were generated from the originally round rod-shaped conductor 1 by pressing. When pressing the thickness of the rod is reduced and creates a flat surface. With the help of a connection technique based on the By clinching, the ends of the round bar and the rectangular terminal lugs formed by the terminal conductors 4 are connected to each other. The strong deformation in the region of the connection points of the clinching results in button-shaped rivets 5, so that by means of a cold welding a mechanically stable connection and a good electrical contact for a secure flow of current are generated.
- Figure 4 illustrates a cross-section through an exemplary, by clinching produced connection of a connecting portion 3 and a connecting conductor 4.
- the first tests showed a shear strength of more than 1600 N and a head tensile strength of more than 1500 N.
- Fig. 2 shows an embodiment, each with a clinching point 5 for connecting the corresponding connecting portion 3 with the adjacent terminal conductor 4th
- Fig. 3 shows a further embodiment of a conductor arrangement with also a current conductor 1, the flattened connecting portions 3 are each connected to a terminal conductor 4, wherein for the compounds in each case two clinching points are used. This creates a twist protection of the conductor 1 relative to the two connecting conductors. It is also sketched that the current conductor 1 does not necessarily have to lead straight from one connecting section 3 to the other connecting section 3, but can also have a bend.
- Figure 5 shows an exemplary circuit arrangement of a current detection device 0 for detecting a current flow through three conductors L1, L2, L3.
- a corresponding cable additionally has a neutral conductor N.
- the three conductors L1, L2, L3 are interrupted and each end in a plug contact 6 for insertion of a contact pin in the form of the connecting conductor 4.
- Each of the conductors L1, L2, L3 are thus associated with two female plug-in contact elements 6, in which the two connecting conductors 4 of the conductor arrangement according to, for example Fig. 2 or Fig. 3 be plugged in.
- the current conductor 1 which connects the two connecting conductors 4 via the connecting sections 3 leads through the corresponding opening of a current transformer 2, which, for example, as in FIG Fig. 2 or Fig. 3 can be trained.
- three current transformers 2 are arranged and fastened on a circuit board with electronics for evaluation or current detection.
- the electronics are accommodated in a housing from which correspondingly six such connecting conductors 4 protrude as contact pins for insertion into corresponding plug-in contact sockets 6 and a further connecting conductor as a contact pin for a connection to the neutral conductor N.
- such electronics also have one or more output devices for outputting the detected amount of current.
- the output device is a display device D.
- the display device D or another external interface outputs the quantities of current detected by means of signal processing and optionally analog-to-digital converters in the electronics.
- a current conductor system which serves for the measurement of electrical currents and is formed in particular of three metal parts and a current detection system.
- the current conductor system consists of a middle part as the current conductor 1, which has a preferably round cross-section and in which after plugging the current transformer 2 as a current detection system at least one, in particular both of its ends as a connecting portion 3 are flattened.
- the current conductor system consists of two further parts in the manner of the connecting conductor 4 with a rectangular cross section for the formation of terminal lugs or contact pins for a plug connection.
- connection of the three parts takes place in particular as a cold press connection for forming a mechanically and electrically good connection.
- a cold press connection is preferably made twice on each side, in order to achieve an additional safeguard against twisting while increasing the connection cross section.
- the current detection system preferably consists of a transformer-type current transformer.
- a current transformer is preferably a toroidal core, in particular a toroidal core formed as a toroidal core made of an amorphous or nanocrystalline alloy.
- the round metal rod forming the current conductor 1 preferably has a deformation, in particular a slight compression, in the middle region or in the region which is passed through the opening 20 of the current transformer 2, as a result of which the current transformer 2 is plugged into the current conductor 1 in a desired manner Position fixed and thus secured.
- the contact points are advantageously removed before joining, in particular before the clinching, with a chemical treatment such as pickling of metal oxides.
- the contact points are cleaned or activated before the clinching or other connection, for example, with a treatment in a plasma on the surface. It is also advantageous to soft anneal the metal parts before the clinching by a heat treatment.
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Transformers For Measuring Instruments (AREA)
- Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
Description
Die Erfindung bezieht sich auf eine induktives Bauelement mit einem Stromleiter mit nicht-rechteckigem Querschnitt zum Leiten eines Stromes, zumindest einem flächigen Anschlussleiter zum Zu- oder Abführen des Stromes zu bzw. von dem Stromleiter, wobei der Stromleiter und der Anschlussleiter im Bereich eines Verbindungsabschnittes des Stromleiters unter Ausbildung einer Leiteranordnung miteinander verbunden sind. Die Erfindung bezieht sich insbesondere auf ein induktives Bauelement mit einem magnetischen Modul mit einer Öffnung, wobei der Stromleiter durch die Öffnung geführt ist.The invention relates to an inductive component having a conductor with a non-rectangular cross-section for conducting a current, at least one flat connection conductor for supplying or discharging the current to or from the conductor, wherein the conductor and the connection conductor in the region of a connecting portion of Conductor are connected together to form a conductor arrangement. More particularly, the invention relates to an inductive component having a magnetic module with an opening, wherein the current conductor is passed through the opening.
Die Erfindung bezieht sich auch auf ein Verfahren zum Herstellen einer Leiteranordnung für ein solches induktives Bauelement.The invention also relates to a method for producing a conductor arrangement for such an inductive component.
Zur Stromerfassung sind verschiedenartige elektronische Stromzähler bekannt, welche zunehmend im Industrie- und Haushaltsbereich die mechanischen Ferraris-Zähler ablösen und die Stromerfassung mit unterschiedlich aufgebauten Anordnungen durchführen. Neben einer Stromerfassung mit Mess-Shunts, Rogowski-Spulen oder Hall-Elementen sind auch Stromwandler auf Basis von weichmagnetischen Ringkernen, insbesondere Ringbandkernen, als magnetische Module in elektronischen Zählern verbreitet. Ein magnetisches Modul (Stromwandler, Transformator) bewirkt eine galvanische Netztrennung und liefert eine präzise Messgröße in Form einer Signalspannung an einem Bürdenwiderstand. Die Anforderungen an Amplitudengenauigkeit, Phasengenauigkeit und Linearität werden durch IEC 62053, -21, -23 bzw. vormals 1036 in Europa sowie ANSI C12.xx in den USA festgelegt, und sind beispielsweise dem Firmenprospekt "VAC-Stromtransformatoren für elektronische Energie-Zähler", der Vacuumschmelze, Oktober 1998 zu entnehmen. Stromwandler für elektronische Energie-Zähler sind allgemein auch aus dem Firmenprospekt "Stromtransformatoren für elektronische Energie-Zähler" der Vacuumschmelze 2002 bekannt. Solche Stromwandler verwendende Energie-Zähler (auch Watthour-Meter genannt) dienen als amtlich zugelassenes Messmittel, um den von einem Verbraucher genutzten elektrischen Strom kostenmäßig gegenüber den Energie-Versorgungsunternehmen abzurechnen.For current detection various types of electronic electricity meters are known, which increasingly replace the mechanical Ferrari counters in the industrial and household sector and carry out the current detection with differently constructed arrangements. In addition to current detection with measuring shunts, Rogowski coils or Hall elements, current transformers based on soft-magnetic toroidal cores, in particular toroidal cores, are also widely used as magnetic modules in electronic meters. A magnetic module (current transformer, transformer) provides galvanic isolation and provides a precise measure in the form of a signal voltage at a load resistor. The requirements for amplitude accuracy, phase accuracy and linearity are defined by IEC 62053, -21, -23 or formerly 1036 in Europe and ANSI C12.xx in the USA, and are, for example, in the company brochure "VAC Current Transformers for Electronic Energy Meters", Vacuumschmelze, October 1998 refer. Current transformer for Electronic energy meters are also generally known from the company brochure "Current transformers for electronic energy meters" of Vacuumschmelze 2002. Such energy converters using energy meters (also called Watthour meter) serve as officially approved measuring means to account for the electricity used by a consumer in terms of cost to the energy utility companies.
Bekannt ist ein Aufbau aus Stromschienen und einem dazu passenden Ringkern-Stromwandler zur Erfassung von Verbrauchsströmen in elektronischen Energiezählern. In den USA und anderen Ländern verbreitete steckbare Stromzähler haben auf der Rückseite genormte rechteckige Anschlussfahnen, welche bei einer Montage des Stromzählers in Steckplätze mit passenden Federkontakten eingeschoben werden. Diese Anschlüsse mit einem Querschnitt von ca. a x 2,5 mm dienen der Ein- und Ausleitung des Verbrauchsstromes, welcher bei 110 V-Systemen maximal ca. 200-480 Aeff beträgt. Als Dicke a des Querschnitts wird beispielsweise a=19 mm bei einem maximalen Strom von I-max=320A angesetzt. Üblicherweise werden die Ströme der drei Phasen des Wechselstromnetzes in den Stromzähler hinein, durch ein Stromerfassungs-System hindurch und wieder aus dem Stromzähler heraus geleitet. Eine elektronische Schaltung im Stromzähler erfasst die Ströme der drei Stromerfassungs-Systeme und errechnet aus Stromstärke und Phasenlage die verbrauchte Energie, wie dies beispielsweise aus
Die derzeit preiswerteste Herstellung eines magnetischen Bauteils für hochwertige Stromwandler besteht in der Herstellung von Ringkernen, insbesondere Ringbandkernen, und der Bewicklung der isolierten bzw. gekapselten Kerne mit der entsprechenden Sekundärwicklung auf der Basis von Kupferlackdraht. Dafür geeignete Kerne sind beispielsweise bekannt aus der
Eine Möglichkeit des konstruktiven Aufbaus eines Stromwandlers besteht darin, die Größe des Stromwandlers so auszuwählen, dass es möglich ist, eine Stromschiene beispielsweise der Größe 19 x 2,5 mm durch das Innenloch des Stromwandlers durchzustecken.One way of constructing a current transformer is to select the size of the current transformer so that it is possible to pass through a bus bar, for example, the size of 19 x 2.5 mm through the inner hole of the current transformer.
Eine Optimierung besteht darin, dem Bereich der Stromschiene, auf welcher der Stromwandler sitzen soll, einen runden Querschnitt zu geben. Dadurch kann das Innenloch des Stromwandlers kleiner werden und infolge ein kleinerer Ringbandkern eingesetzt werden, wobei dieser verfahrensbedingt dann entsprechend preiswerter ist. Selbst bei gleichem Einsatz an weichmagnetischem Bandmaterial und gleicher Wickelzeit für den Kern sind die Prozess-Schritte einer Wärmebehandlung und einer Beschichtung umso günstiger, je kleiner der Durchmesser des Kerns ist. Die Herstellung einer dafür geeigneten Stromschiene erfolgt durch die Bereitstellung einer U-förmigen Leiteranordnung mit verschiedenen Abschnitten. Ein zentraler Verbindungsabschnitt mit rundem Querschnitt dient als Element des Stromwandlers zum Hindurchführen durch die entsprechende Öffnung in dem Kern. Zwei Anschlussleiter mit rechteckigem Querschnitt dienen zum Anschließen des Stromleiters in Form der für sich bekannten Steckverbindungen. Die Leiteranordnung besteht somit aus drei Metallteilen mit zueinander verschiedenen Querschnitten, wobei die beiden Enden des runden Stromleiters an den abgeflachten Oberflächen der rechteckigen Anschlussleiter zu befestigen sind.An optimization is to give the area of the busbar on which the current transformer is to sit, a round cross-section. As a result, the inner hole of the current transformer can be smaller and used as a result of a smaller ring band core, which is due to the process then cheaper accordingly. Even with the same use of soft magnetic strip material and the same winding time for the core, the smaller the diameter of the core, the more favorable are the process steps of a heat treatment and a coating. The production of a suitable busbar is done by providing a U-shaped conductor arrangement with different sections. A central connecting portion with a round cross-section serves as an element of the current transformer for passing through the corresponding opening in the core. Two connection conductors with a rectangular cross section are used to connect the conductor in the form of known per se connectors. The conductor arrangement thus consists of three metal parts with mutually different cross-sections, wherein the two ends of the round conductor are to be fastened to the flattened surfaces of the rectangular connection conductors.
Das induktive Element, das in
Aus der
Die
Neben dem Weichlöten, das üblicherweise für die Herstellung einer Verbindung von SMD-Bauteilen verwendet wird, sind zur Befestigung eines Stromleiters an einem Anschlussleiter das Verbinden mittels Widerstands-Punktschweißen oder Hartlöten bekannt. Beide Verfahren erfordern jedoch eine aufwändige Prozesstechnik sowie einen hohen Energieeintrag für jeden zu erstellenden Verbindungspunkt. Als besondere Schwierigkeit ist die fertigungsbegleitende Überprüfung der Verbindungspunkte zur Absicherung der Qualität der Leiteranordnung zu sehen, da insbesondere das Schweißen im Sinne der DIN ISO 9001 als ein sogenannter spezieller Prozess einzustufen ist, wie dies aus
Die Verbindungen einer solchen Leiteranordnung von drei Elementen mit an den Verbindungspunkten jeweils zueinander verschiedenen Querschnitten sollen eine große Lebensdauer von beispielsweise ca. 10-15 Jahren mit großer Zuverlässigkeit ermöglichen, so dass die Fertigung der Leiteranordnung sehr prozesssicher ausgeführt werden muss. Aus Gründen der elektrischen Leitfähigkeit werden entsprechende Stromschienen bzw. Leiteranordnungen überwiegend aus Kupfermaterial aufgebaut. Probleme ergeben sich dabei aber sowohl beim Hartlöten als auch beim Schweißen insbesondere durch die Erwärmung beim Erstellen der Verbindungspunkte, da die Wärme durch den Stromleiter auf den Stromwandler übertragen wird und diesen beschädigen kann.The compounds of such a conductor arrangement of three elements with each other at the connection points different cross-sections should allow a long life of, for example, about 10-15 years with great reliability, so that the production of the conductor arrangement must be performed very reliable process. For reasons of electrical conductivity, corresponding busbars or conductor arrangements are predominantly constructed from copper material. But problems arise both in brazing and welding in particular by the heating when creating the connection points, since the heat is transmitted through the conductor to the current transformer and can damage it.
Allgemein bekannt ist zum Verbinden zweier Metalle das sogenannte Kaltpress-Schweißen, welches beispielsweise beschrieben ist in der Übersicht über den Stand und die Entwicklungstendenzen des Kaltpress-Schweißens,
Die Aufgabe der Erfindung besteht darin, ein induktives Bauelement insbesondere für eine Stromerfassungseinrichtung sowie ein Verfahren zum Herstellen eines solchen induktiven Bauelements vorzuschlagen, welches eine einfache Fertigung bei sicherer Verbindung und möglichst geringer Belastung weiterer Komponenten bereitstellt.The object of the invention is to propose an inductive component, in particular for a current detection device and a method for producing such an inductive component, which provides a simple production with a secure connection and the lowest possible load of other components.
Diese Aufgabe wird durch ein induktives Bauelement mit den Merkmalen des Patentanspruchs 1 und durch ein Verfahren zum Herstellen eines induktiven Bauelements mit den Merkmalen des Patentanspruchs 20 gelöst. Ausgestaltungen und Weiterbildungen des Erfindungsgedankens sind Gegenstand von Unteransprüchen.This object is achieved by an inductive component having the features of
Dem gemäß ist ein induktives Bauelement vorgesehen mit einem Stromleiter mit nicht-rechteckigem Querschnitt zum Leiten eines zu erfassenden Stroms, zumindest einem flächigen Anschlussleiter zum Zu- oder Abführen des zu erfassenden Stromes zu bzw. von dem Stromleiter, wobei der Stromleiter und der Anschlussleiter im Bereich eines Verbindungsabschnittes des Stromleiters unter Ausbildung einer Leiteranordnung miteinander verbunden sind, und wobei der Stromleiter im Bereich des Verbindungsabschnitts einen abgeflachten, insbesondere rechteckigen Querschnitt aufweist und eine flache Fläche des Verbindungsabschnitts des Stromleiters mit einer flachen Fläche des Anschlussleiters verbunden ist. Das Bauelement weist ein magnetisches Modul mit einer Öffnung auf, durch die der Stromleiter geführt ist.Accordingly, an inductive component is provided with a current conductor with non-rectangular cross-section for conducting a current to be detected, at least one planar connection conductor for supplying or discharging the current to be detected to or from the conductor, wherein the conductor and the connection conductor in the area of a connection portion of the conductor to form a conductor arrangement are connected to each other, and wherein the conductor in the region of the connecting portion has a flattened, in particular rectangular cross-section and a flat surface of the connecting portion of the conductor is connected to a flat surface of the connecting conductor. The device has a magnetic module with an opening through which the conductor is passed.
Außerdem umfasst die Erfindung ein Verfahren zum Herstellen einer Leiteranordnung für ein induktives Bauelement, insbesondere zur Anwendung in einer Stromerfassungseinrichtung, bei dem ein Stromleiter mit nicht-rechteckigem Querschnitt mit einem flächigen Anschlussleiter verbunden wird, wobei bei dem Stromleiter der Querschnitt in einem Verbindungsabschnitt des Stromleiters (insbesondere mit rechteckigem Querschnitt) abgeflacht wird, und der abgeflachte Verbindungsabschnitt des Stromleiters mit dem Anschlussleiter verbunden wird.In addition, the invention comprises a method for producing a conductor arrangement for an inductive component, in particular for use in a current detection device, in which a current conductor with non-rectangular cross-section is connected to a planar connection conductor, wherein the conductor in the cross section in a connecting portion of the conductor ( in particular with rectangular cross-section) is flattened, and the flattened connecting portion of the conductor is connected to the connecting conductor.
Es kann zudem ein induktives Bauelement vorgesehen werden, bei welchem der Querschnitt des Stromleiters abseits des Verbindungsabschnitts mit bogenförmiger, insbesondere runder Außenkontur, insbesondere ovaler oder runder Querschnittsform ausgebildet ist.In addition, an inductive component can be provided in which the cross section of the current conductor is formed away from the connecting section with an arcuate, in particular round, outer contour, in particular an oval or round cross-sectional shape.
Das induktive Bauelement kann mit zwei Verbindungsabschnitten am Stromleiter zum Verbinden des Stromleiters mit zwei Anschlussleitern ausgeführt sein.The inductive component can be designed with two connecting sections on the conductor for connecting the conductor to two connecting conductors.
Darüber ist die Verbindung als Pressverbindung, insbesondere als Kaltpressverbindung, ausgebildet.In addition, the compound is formed as a press connection, in particular as a cold press connection.
Vorteilhaft ist insbesondere, wenn bei der die Pressverbindung als Durchsetzfügeverbindung ausgebildet ist.It is particularly advantageous if the press connection is designed as a clinching connection.
Es kann auch ein induktives Bauelement vorgesehen werden, bei dem die Pressverbindung zwischen dem Verbindungsabschnitt und dem Anschlussleiter zweifach ausgebildet ist.It is also possible to provide an inductive component in which the press connection between the connection section and the connection conductor is formed twice.
Des Weiteren kann der Stromleiter und der bzw. die Anschlussleiter als Metallteile aus Kupfer oder einer Kupferlegierung ausgebildet sind.Furthermore, the current conductor and the connecting conductor or conductors may be formed as metal parts made of copper or a copper alloy.
Das erfindungsgemäße induktive Bauelement kann beispielsweise ein magnetisches Modul zur Stromerfassung sein. Das magnetische Modul kann als Stromwandler bzw. Transformator ausgebildet sein.The inductive component according to the invention can be, for example, a magnetic module for current detection. The magnetic module can be designed as a current transformer or transformer.
Insbesondere ein Stromwandler weist bevorzugt einen Ringkern auf. Der Ringkern ist vorzugsweise als Ringbandkern ausgebildet. Vorteilhafterweise ist der Ringkern aus einer amorphen oder nanokristallinen Legierung ausgebildet.In particular, a current transformer preferably has a toroidal core. The ring core is preferably formed as a ring band core. Advantageously, the ring core is formed of an amorphous or nanocrystalline alloy.
Der Stromleiter kann zum Fixieren und/oder Ausrichten in einer Öffnung des Stromwandlers gegenüber dem sonstigen Querschnitt eine Verformung, insbesondere Verpressung aufweisen.The current conductor may have a deformation, in particular compression, for fixing and / or aligning in an opening of the current transformer with respect to the other cross section.
Die Kontaktstellen können im Bereich des Verbindungsabschnitts und/oder des Anschlussleiters von Metalloxiden befreit, gereinigt und/oder plasmaaktiviert sein. Vorteilhaft ist auch eine Stromerfassungseinrichtung, bei welcher der Stromleiter, der Verbindungsabschnitt und/oder der Anschlussleiter mittels einer Wärmebehandlung weichgeglüht sind.The contact points can be freed, cleaned and / or plasma-activated in the region of the connection section and / or the connection conductor of metal oxides. Also advantageous is a current detection device, in which the current conductor, the connecting portion and / or the connecting conductor are annealed by means of a heat treatment.
Vorzugsweise wird die Verbindung als Pressverbindung mit Hilfe einer Durchsetzfügetechnik ausgeführt. Zur Anwendung kommt vorzugsweise ein Verfahren, bei dem Kontaktstellen vor dem Verbinden mit einer chemischen Behandlung, insbesondere Beizen, von Metalloxiden befreit werden. Die Kontaktstellen können dabei vor dem Verbinden mittels einer Plasmabehandlung an der Oberfläche gereinigt und/oder aktiviert werden. Vorteilhaft ist auch ein Verfahren, bei dem der Stromleiter, dessen Verbindungsabschnitt und/oder der Anschlussleiter vor dem Verbinden mittels einer Wärmebehandlung weichgeglüht wird bzw. werden.Preferably, the connection is carried out as a press connection by means of a clinching technique. A method is preferably used in which contact points are freed from metal oxides before being combined with a chemical treatment, in particular pickling. The contact points can be cleaned and / or activated on the surface before being connected by means of a plasma treatment. Also advantageous is a method in which the current conductor, its connecting portion and / or the connecting conductor is annealed before joining by means of a heat treatment or are.
Die Leiteranordnung stellt somit einen kosten-optimierten und langzeitstabilen Aufbau von Stromleitungsschienen dar. Auf einfache Art und Weise wird der Stromleiter mit dem nicht-rechteckigen Querschnitt, insbesondere mit einem runden oder nahezu runden Querschnitt einerseits und andererseits zumindest ein Anschlussleiter mit einer flachen Oberfläche, insbesondere einem rechteckigen Querschnitt miteinander verbunden, wobei diese eine stabile und langlebige Verbindung aufweisen. Bei einer Pressverbindung ohne den Einsatz von Hitze durch beispielsweise Löten oder Schweißen besteht der besondere Vorteil, dass über den Stromleiter keine Hitze an benachbarte Komponenten des Ringkerns und dergleichen übertragen wird. Die zweite Verbindung zwischen dem Stromleiter und einem zweiten Anschlussleiter kann beispielsweise vor dem Einsetzen des Stromleiters in der Öffnung des Stromwandlers bzw. Ringkerns erstellt werden, so dass letztendlich gegebenenfalls nur eine derartige Verbindung erforderlich ist.The conductor arrangement thus represents a cost-optimized and long-term stable construction of power line rails. In a simple manner, the conductor with the non-rectangular cross section, in particular with a round or nearly round cross section on the one hand and on the other hand at least one connecting conductor with a flat surface, in particular a rectangular cross section with each other, which have a stable and durable connection. In a press connection without the use of heat by, for example, soldering or welding, there is the particular advantage that no heat is transmitted via the conductor to adjacent components of the toroidal core and the like. The second connection between the current conductor and a second connection conductor can, for example before the insertion of the conductor in the opening of the current transformer or toroidal be created so that eventually only one such connection is required.
Durch das Flachpressen der Enden einer Rundstange als Stromleiter, worauf der Stromwandler sitzt, werden flache Bereiche geschaffen, welche nach dem Übereinanderlegen mit den flachen Anschlussfahnen durch eine Kaltpressverbindung, z.B. Durchsatzfügen bzw. Clinchen dauerhaft und mit geringstem Übertragungswiderstand verbunden werden bzw. sind. Natürlich muss das Abflachen des Stromleiters nicht zwingend an den Enden erfolgen, sondern kann auch in einem sonstigen Bereich benachbart des Ringkerns bzw. Stromwandlers erfolgen.By flat pressing the ends of a round bar as a current conductor, whereupon the current transformer sits, flat areas are created, which after being superimposed with the flat terminal lugs by a cold press connection, e.g. Durchsatzfügen or clinching are connected permanently and with minimal transmission resistance or are. Of course, the flattening of the conductor does not necessarily take place at the ends, but can also be done in another area adjacent to the toroidal core or current transformer.
Insbesondere eine Kaltverschweißung in Verbindung mit einer genieteten Verbindung erfordert einen hohen Umformungsgrad, so dass vorteilhafter Weise ein weiches Metall wie beispielsweise Kupfer oder eine Kupferlegierung verwendet wird. Durch eine entsprechende Vorbehandlung der Verbindungspartner, das heißt des Stromleiters und des bzw. der Anschlussleiter kann eine Kaltschweißverbindung bezüglich der elektrischen Eigenschaften, beispielsweise minimalem Übergangswiderstand und der Gasdichtigkeit weiter verbessert werden. Das sogenannte Kaltpressschweißen bietet den Vorteil eines Schweißverfahrens, bei dem eine Verbindung vollständig, ohne von außen zugeführter thermischer Energie allein durch Druckkraft zustande kommt. Das Durchsetzfügen stellt eine Vernietung dar, welche vorteilhafter Weise ohne Niet-, das heißt ohne Fremdwerkstoffe auskommt, indem der Werkstoff des einen beteiligten Partners, beispielsweise des Stromleiters, tief in eine sich bildende Aushöhlung in dem anderen Partner, beispielsweise dem Anschlussleiter, gepresst wird, wobei sich entsprechend der Form eines Press-Stempels und einer Matrize eine pilzförmige Hinterschneidung ausbildet, so dass eine form- und kraftschlüssige Verbindung erzielt wird.In particular, a cold welding in conjunction with a riveted connection requires a high degree of deformation, so that advantageously a soft metal such as copper or a copper alloy is used. By means of a corresponding pretreatment of the connection partners, that is to say of the current conductor and of the connecting conductor or conductors, a cold welding connection can be further improved with regard to the electrical properties, for example minimum contact resistance and gas tightness. The so-called cold pressure welding offers the advantage of a welding process in which a connection is complete, without external thermal energy supplied by pressure alone. The clinching represents a riveting, which advantageously without rivet, that is, without foreign materials manages by the material of one partner involved, for example, the conductor is pressed deep into a forming cavity in the other partner, such as the terminal conductor, wherein forms a mushroom-shaped undercut corresponding to the shape of a press-stamp and a die, so that a positive and non-positive connection is achieved.
Es bietet sich eine Vielzahl von Vorteilen durch die Verbindungstechnik bzw. den Aufbau der Leiteranordnung. Neben guten elektrischen Eigenschaften entsteht eine mechanisch sehr robuste Verbindung. Eine einfache Herstelltechnik ermöglicht Anlagen-Investitionen von nur 30-50% im Vergleich zu der entsprechenden Schweiß-/Hartlöt-Technik. Möglich ist eine einfache und preiswerte Wartung der Fertigungsanlagen im Vergleich zur Schweiß-/Hartlöt-Technik. Gegenüber der Schweiß-/Hartlöt-Technik erfolgt beim Einsatz einer Kaltschweiß-Verbindung keine Erwärmung der Metallteile, so dass keine gesonderte Kühlung notwendig ist, um einen Kunststoffüberzug beispielsweise eines Stromwandlers zu schützen. Dämpfe, Funken oder Späne werden vermieden. Eine Qualitätssicherung ist durch die Kontrolle einfacher mechanischer Maße, beispielsweise der Dicke im ausgebildeten "Niet" möglich. Weiterhin sind die Energiekosten pro Verbindungsstelle bei der Herstellung drei- bis fünffach geringer als bei der schweiß-/Hartlöt-Technik. Im Vergleich der Punktschweißtechnik zur Durchsetzfügetechnik sind die Kosten pro Verbindungspunkt unter der Berücksichtigung sogar der Investitionskosten, der Betriebskosten und der Werkzeugkosten im Verhältnis von etwa 5:1 beim Einsatz des Durchsetzfügens günstiger.There are a variety of advantages through the connection technology and the structure of the conductor arrangement. In addition to good electrical properties, a mechanically very robust connection is created. A simple manufacturing technique allows plant investment of only 30-50% compared to the corresponding welding / brazing technique. A simple and inexpensive maintenance of the production facilities is possible in comparison to the welding / brazing technique. Compared to the welding / brazing technique, when using a cold weld joint, no heating of the metal parts occurs, so that no separate cooling is necessary to protect a plastic coating, for example, a current transformer. Vapors, sparks or chips are avoided. A quality assurance is possible by controlling simple mechanical dimensions, for example the thickness in the formed "rivet". Furthermore, the energy costs per connection point during manufacture are three to five times lower than in the welding / brazing technique. Compared to the spot-weld technique of clinch-clinching, the cost per connection point, taking into account even the investment cost, operating cost and tooling cost, is about 5: 1 more favorable when using clinching.
Da die Leiteranordnung zum Übertragen eines elektrischen Stroms dient, sind auch Erhitzungen der Leiteranordnung durch den Stromfluss insbesondere im Bereich der Verbindungspunkte zu berücksichtigen. Der elektrische Widerstand einer typischen U-förmigen Stromschiene beträgt etwa 100µ Ohm. Bei einem Strom von etwa 200 A entsteht gemäß Pv=I2×R in der Einheit eine Verlustleistung von 4 W, welche eine Erwärmung zur Folge hat. Dabei ist zu beachten, dass die Verbindungsstellen keine Einschnürung des Leitungs-Querschnittes darstellen. Bei einer schlechten Verbindung steigt die Temperatur dort bedingt durch den höheren Spannungsabfall deutlich über das Niveau der restlichen Anschlussteile und beschleunigt die Schädigung bzw. Alterung der Kontaktstelle. Dabei kann es zu einer Erhöhung des Übergangswiderstandes kommen. Dies ist ein kumulativer Prozess, der in weiter steigenden Temperaturen und schließlich in dem Versagen der Verbindungsstelle münden kann. Im Falle einer geschweißten oder insbesondere einer gelöteten Verbindung kann dies zum partiellen oder vollständigen Aufschmelzen des Verbindungspunktes durch Überhitzung führen. Ob Löt- oder Schweißbrücken langzeit-stabil sind, ist daher in der Regel sehr unsicher. Ein im Endstadium eines solchen Ausfall-Szenarios auftretender Lichtbogen kann die völlige Unterbrechung der elektrischen Verbindung zur Folge haben. Als Anforderung an die Verbindungsstelle muss daher eine niederohmige Verbindung mit gleichzeitig hoher mechanischer Festigkeit gefordert werden, so dass sich der Übergangswiderstand durch Erschütterungen, Vibration oder Stöße bei der Montage oder im späteren Einsatz nicht merklich erhöht.Since the conductor arrangement serves to transmit an electrical current, heating of the conductor arrangement by the current flow, in particular in the region of the connection points, must also be considered. The electrical resistance of a typical U-shaped busbar is about 100μ ohms. At a current of about 200 A, a power dissipation of 4 W is produced in the unit according to Pv = I 2 × R, which results in heating. It should be noted that the connection points do not represent a constriction of the cable cross-section. In the case of a poor connection, the temperature there rises significantly above the level of the remaining connection parts due to the higher voltage drop and accelerates the damage or aging of the contact point. This can lead to an increase in the contact resistance. This is a cumulative process, which may result in further increasing temperatures and eventually failure of the joint. In the case of a welded or in particular a soldered connection, this can lead to partial or complete melting of the connection point due to overheating. Whether soldering or welding bridges are long-term stable, is therefore usually very uncertain. An arc occurring in the final stage of such a failure scenario can result in the complete interruption of the electrical connection. As a requirement for the connection point, therefore, a low-resistance connection with simultaneously high mechanical strength must be required, so that the contact resistance by vibration, vibration or shock during assembly or during subsequent use does not increase significantly.
Vorteilhafterweise bietet die erfindungsgemäße Stromerfassungseinrichtung bzw. das beschriebene Fertigungsverfahren eine niederohmige Verbindung mit gleichzeitig hoher mechanischer Festigkeit, welche selbst im Falle einer im Betrieb auftretenden Erhitzung beim Einsatz einer Durchsetzfügung eine trotzdem dauerhafte Verbindung ermöglicht.Advantageously, the current detection device according to the invention or the described manufacturing method provides a low-resistance connection with simultaneously high mechanical strength, which allows a permanent connection even in the case of heating occurring during operation when using a clinching.
Die Erfindung wird nachfolgend anhand der in den Figuren der Zeichnung dargestellten Ausführungsbeispiele näher erläutert. Es zeigt:
- Fig. 1
- einzelne Fertigungsschritte bei der Fertigung eines erfindungsgemäßen induktiven Bauteils;
- Fig. 2
- montierte Komponenten eines induktiven Bauelements gemäß einer ersten Ausführungsform;
- Fig. 3
- montierte Komponenten eines induktiven Bauelements gemäß einer zweiten Ausführungsform;
- Fig. 4
- einen Querschnitt durch einen Durchsetzfügepunkt; und
- Fig. 5
- eine beispielhafte für sich bekannte SchaltungsAnordnung, bei welcher derartige Bauelemente eingesetzt werden können.
- Fig. 1
- individual production steps in the manufacture of an inductive component according to the invention;
- Fig. 2
- mounted components of an inductive component according to a first embodiment;
- Fig. 3
- mounted components of an inductive component according to a second embodiment;
- Fig. 4
- a cross section through a clinching point; and
- Fig. 5
- an exemplary circuit arrangement known per se, in which such components can be used.
Nach dem Durchführen des Stromleiters 1 durch die Öffnung 20 des Stromwandlers 2 wird das durch die Öffnung 20 des Stromwandlers 2 hindurchgeführte Ende des Stromleiters 1 zur Ausbildung eines Verbindungsabschnittes 3 abgeflacht. Auf besonders einfache Art und Weise erfolgt die Abflachung durch ein Quetschen, was insbesondere bei einem Stromleiter 1 aus Kupfer oder einer Kupferlegierung besonders einfach möglich ist. Bei der dargestellten Ausführungsform weist der Verbindungsabschnitt 3 des Stromleiters 1 einen im Wesentlichen rechteckförmigen Querschnitt auf. Vorteilhaft umsetzbar sind prinzipiell aber auch andere Querschnitte, welche auf einer Seite eine Abflachung aufweisen, beispielsweise auch eine Abflachung durch Materialabtragung.After passing through the
Ein über einen der beiden Anschlussleiter 4 und den entsprechenden Verbindungsabschnitt 3 in den Stromleiter 1 geführter Strom wird durch die Öffnung 20 des Stromwandlers 2 hindurchgeleitet und über den zweiten Verbindungsabschnitt 3 und den zweiten Anschlussleiter 4 abgeführt. Der durch den Stromwandler 2 hindurchgeführte Strom induziert in dem Stromwandler 2 einen Stromfluss, welcher über Leitungen 21 einer Auswerteschaltung zum Erfassen des geflossenen Stromes geführt wird.A guided through one of the two
Bei der Ausführungsform gemäß
Bei einem Durchsetzfügepunkt der beispielhaften Größe von 8 mm zwischen zwei Kupferteilen mit den Dicken von je 2,4 mm ergab sich in ersten Versuchen eine Scherfestigkeit von mehr als 1600 N und eine Kopfzugfestigkeit von mehr als 1500 N.At a clinching point of the exemplary size of 8 mm between two copper parts with the thicknesses of 2.4 mm each, the first tests showed a shear strength of more than 1600 N and a head tensile strength of more than 1500 N.
Zum Beispiel sind drei Stromwandler 2 mit jeweils einer derart durchgeführten Leiteranordnung auf einer Platine mit einer Elektronik zur Auswertung bzw. Stromerfassung angeordnet und befestigt. Üblicherweise ist die Elektronik in einem Gehäuse aufgenommen, aus welchem entsprechend sechs solche Anschlussleiter 4 als Kontaktstifte zum Einstecken in entsprechende Steckkontakt-Buchsen 6 sowie ein weiterer Anschlussleiter als Kontaktstift für eine Verbindung mit dem neutralen Leiter N herausragen. Üblicherweise weist eine solche Elektronik auch eine oder mehrere Ausgabeeinrichtungen zum Ausgeben der erfassten Strommenge auf. Beispielsweise handelt es sich bei der Ausgabeeinrichtung um eine Anzeigeeinrichtung D. Auf der Anzeigeeinrichtung D oder einer sonstigen externen Schnittstelle werden die mittels Signalverarbeitung und gegebenenfalls Analog-/Digital-Wandlern in der Elektronik erfassten Strommengen ausgegeben.For example, three
Bei dem dargestellten Prinzip-Schaltbild eines elektronischen Stromzählers als Stromerfassungseinrichtung 0 wird somit mit drei Durchsteck-Stromwandlern aus den zu messenden drei Strömen mittels einer 1:N-Transformation und über Lastwiderstände jeweils ein individuelles Spannungs-Signal für eine AuswerteElektronik erzeugt und dieser zugeführt. Danach erfolgt die Anzeige der berechneten Energie mittels einer Ausgabeeinrichtung.In the illustrated circuit diagram of an electronic electricity meter as a current detection device 0 is thus with three push-through current transformers from the three currents to be measured By means of a 1: N transformation and via load resistances in each case generates an individual voltage signal for a AuswerteElektronik and supplied to this. Thereafter, the display of the calculated energy by means of an output device.
Bevorzugt wird somit ein Stromleiter-System bereitgestellt, welches zur Messung von elektrischen Strömen dient und aus insbesondere drei Metallteilen und einem Stromerfassungs-System ausgebildet ist. Das Stromleiter-System besteht dabei aus einem mittleren Teil als dem Stromleiter 1, welcher einen vorzugsweise runden Querschnitt hat und bei dem nach dem Aufstecken des Stromwandlers 2 als einem Stromerfassungs-System zumindest eines, insbesondere beide seiner Enden als Verbindungsabschnitt 3 flachgedrückt werden. Außerdem besteht das Stromleiter-System aus zwei weiteren Teilen in Art der Anschlussleiter 4 mit rechteckförmigem Querschnitt zur Ausbildung von Anschlussfahnen bzw. Kontaktstiften für eine Steckverbindung.Thus, a current conductor system is preferably provided, which serves for the measurement of electrical currents and is formed in particular of three metal parts and a current detection system. The current conductor system consists of a middle part as the
Die Verbindung der drei Teile erfolgt insbesondere als Kaltpress-Verbindung zum Ausbilden einer mechanisch und elektrisch guten Verbindung. Eine Kaltpress-Verbindung wird dabei vorzugsweise auf jeder Seite zweifach hergestellt, um somit bei gleichzeitiger Erhöhung des VerbindungsQuerschnittes eine zusätzliche Sicherung gegen Verdrehen zu erreichen. Vorzugsweise besteht das Stromerfassungs-System aus einem transformatorisch arbeitenden Stromwandler. Bevorzugt wird als Stromwandler ein Ringkern, insbesondere ein als Ringbandkern ausgebildeter Ringkern aus einer amorphen oder nanokristallinen Legierung. Die den Stromleiter 1 ausbildende runde Metallstange besitzt im mittleren Bereich bzw. in dem Bereich, welcher durch die Öffnung 20 des Stromwandlers 2 hindurchgeführt wird, vorzugsweise eine Verformung, insbesondere eine leichte Verpressung, wodurch der Stromwandler 2 beim Aufstecken auf den Stromleiter 1 in einer gewünschten Lage fixiert und damit befestigt wird.The connection of the three parts takes place in particular as a cold press connection for forming a mechanically and electrically good connection. A cold press connection is preferably made twice on each side, in order to achieve an additional safeguard against twisting while increasing the connection cross section. The current detection system preferably consists of a transformer-type current transformer. A current transformer is preferably a toroidal core, in particular a toroidal core formed as a toroidal core made of an amorphous or nanocrystalline alloy. The round metal rod forming the
Zur Verbesserung der Verbindung werden die Kontaktstellen vor dem Verbinden, insbesondere vor dem Durchsetzfügen in vorteilhafter Weise mit einer chemischen Behandlung wie Beizen von Metalloxiden befreit. Die Kontaktstellen werden vor dem Durchsetzfügen oder sonstigen Verbindung beispielsweise mit einer Behandlung in einem Plasma an der Oberfläche gereinigt bzw. aktiviert. Vorteilhaft ist auch, die Metallteile vor dem Durchsetzfügen durch eine Wärmebehandlung weich zu glühen.To improve the connection, the contact points are advantageously removed before joining, in particular before the clinching, with a chemical treatment such as pickling of metal oxides. The contact points are cleaned or activated before the clinching or other connection, for example, with a treatment in a plasma on the surface. It is also advantageous to soft anneal the metal parts before the clinching by a heat treatment.
Obwohl in den obigen Ausführungsbeispielen auf Stromerfassungseinrichtungen Bezug genommen wird, können selbstredend beliebige induktive Bauelemente, wie etwa Drosseln, Transformatoren und andere Arten von magnetischen Modulen, erfindungsgemäß ausgebildet und hergestellt werden.Although current detection devices are referred to in the above embodiments, it should be understood that any of the inductive components, such as chokes, transformers and other types of magnetic modules, may be designed and manufactured in accordance with the present invention.
Claims (25)
- Inductive component (0) with a current conductor (1) for conducting a current, with at least one flat connecting conductor (4) for supplying or discharging a current to or from the current conductor (1), wherein the current conductor (1) and the connecting conductor (4), in the area of the connection section (3) of the current conductor (1), are connected to one another with formation of a conductor arrangement, wherein the inductive component (0) comprises a magnetic module with an opening (20) through which the current conductor (1) is led, and the current conductor (1), to the side of the connection section (3), is formed as a straight or curved rod with non-rectangular cross section,
characterized in that
the current conductor (1) has a flattened cross section in the area of the connection section (3), a flat surface of the connection section (3) of the current conductor (1) is connected to a flat surface of the connecting conductor (4), and the connection is formed as a press fit connection. - Inductive component according to Claim 1, in which the cross section of the current conductor (1) to the side of the connection section (3) is formed with a curved outer contour.
- Inductive component according to Claim 2, in which the cross section of the current conductor (1) to the side of the connection section (3) is formed with rounded outer contour.
- Inductive component according to Claim 2, in which the cross section of the current conductor (1) to the side of the connection section (3) is formed with oval outer contour.
- Inductive component according to a previous claim, with two connection sections (3) on the current conductor (1) for connecting the current conductor (1) to two connecting conductors (4).
- Inductive component according to a previous claim, wherein the connection is formed as a cold press fit connection.
- Inductive component according to one of Claims 1 to 5, wherein the press fit connection is formed as a press joint connection (5).
- Inductive component according to one of Claims 1 to 5, wherein the press fit connection between the connection section (3) and the connecting conductor (4) is formed in duplicate.
- Inductive component according to a previous claim, wherein the current conductor (1) and the connecting conductor(s) (4) are formed as metal parts made of copper or of a copper alloy.
- Inductive component according to a previous claim, in which the inductive component comprises a magnetic module with an opening (20), wherein the current conductor (1) is led through the opening (20).
- Inductive component according to a previous claim, wherein the magnetic module is formed as a transformer.
- Inductive component according to Claim 11, wherein the transformer (2) comprises an annular core.
- Inductive component according to Claim 12, wherein the annular core is formed as an annular strip core.
- Inductive component according to Claim 12 or 13, wherein the annular core is formed from an amorphous or nanocrystalline alloy.
- Inductive component according to a previous claim, wherein the current conductor (1) has a deformation relative to the rest of the cross section, for the attachment and/or alignment in an opening (20) of the current transformer (2).
- Inductive component according to Claim 15, wherein the deformation is a pressing.
- Inductive component according to a previous claim, wherein contact positions in the area of the connection section (3) and/or of the connecting conductor (4) are freed of metal oxides, cleaned and/or plasma activated.
- Inductive component according to a previous claim, wherein the current conductor (1), the connection section (3) and/or the connecting conductor (4) are soft annealed by means of a heat treatment.
- Inductive component according to a previous claim, in which the current conductor (1) has a rectangular cross section in its flattened section.
- Method for producing an inductive component (0) according to one of Claims 1 to 19, in which a current conductor (1) formed as straight or curved rod with non-rectangular cross section to the side of the connection section (3) and led through the opening (20) of a current module is connected to a flat connecting conductor (4), characterized in that, in the case of the current conductor (1), the cross section is flattened in a connection section (3) of the current conductor (1), the flattened connection section (3) of the current conductor (1) is connected to the connecting conductor (4), and the connection is formed as a press fit connection.
- Method according to Claim 21, in which the connection is implemented as a press fit connection using a press joining technique.
- Method according to Claim 20 or 21, in which contact positions are freed of metal oxides by a chemical treatment before the connection.
- Method according to Claim 22, in which contact positions are freed of metal oxides by acid cleaning before the connection.
- Method according to one of Claims 20 to 23, in which contact positions are cleansed and/or activated by means of a plasma treatment on the surface before the connection.
- Method according to one of Claims 20 to 24, in which the current conductor (1), its connection section (3) and/or the connecting conductor (4) is/are soft annealed by means of a heat treatment before the connection.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE102004058452A DE102004058452A1 (en) | 2004-12-03 | 2004-12-03 | Current detection device and method for producing such a current detection device |
PCT/EP2005/012850 WO2006058750A1 (en) | 2004-12-03 | 2005-12-01 | Inductive component and method for the production of such an inductive component |
Publications (2)
Publication Number | Publication Date |
---|---|
EP1817781A1 EP1817781A1 (en) | 2007-08-15 |
EP1817781B1 true EP1817781B1 (en) | 2014-10-29 |
Family
ID=35610130
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP05816200.9A Expired - Fee Related EP1817781B1 (en) | 2004-12-03 | 2005-12-01 | Inductive component and method for the production of such an inductive component |
Country Status (5)
Country | Link |
---|---|
US (1) | US7692526B2 (en) |
EP (1) | EP1817781B1 (en) |
CN (1) | CN101069251B (en) |
DE (1) | DE102004058452A1 (en) |
WO (1) | WO2006058750A1 (en) |
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DE102006059384B4 (en) * | 2006-12-15 | 2013-02-21 | Siemens Aktiengesellschaft | Device with a current transformer for detecting a current flowing through a current conductor and terminal / current transformer module for such a device |
DE102007037058B4 (en) * | 2007-08-03 | 2015-07-30 | Siemens Aktiengesellschaft | Current transformer module for an energy and / or power meter and energy and / or power meter with current transformer module |
DE102008051561B4 (en) | 2008-10-14 | 2013-06-20 | Vacuumschmelze Gmbh & Co. Kg | Method for producing a current detection device |
DE102009000827A1 (en) | 2009-02-13 | 2010-08-19 | Robert Bosch Gmbh | Device and method for connecting at least two electrical connections |
US20100306999A1 (en) * | 2009-06-05 | 2010-12-09 | Szu-Chi Huang | Current terminal structure |
DE102010004223B4 (en) | 2010-01-08 | 2013-12-05 | Vacuumschmelze Gmbh & Co. Kg | Method for producing a current detection device |
JP5533441B2 (en) * | 2010-08-26 | 2014-06-25 | 株式会社オートネットワーク技術研究所 | Current detection device and manufacturing method thereof |
CN102231320B (en) * | 2011-04-15 | 2013-07-17 | 安徽千恩智能科技股份有限公司 | Heavy current mutual inductor for electronic circular electric energy meter and production method thereof |
JP2012242203A (en) * | 2011-05-18 | 2012-12-10 | Auto Network Gijutsu Kenkyusho:Kk | Current detection device |
JP2012255725A (en) * | 2011-06-09 | 2012-12-27 | Sumitomo Wiring Syst Ltd | Current detecting device |
JP2013015425A (en) * | 2011-07-05 | 2013-01-24 | Sumitomo Wiring Syst Ltd | Current detecting device |
JP2013015431A (en) * | 2011-07-05 | 2013-01-24 | Sumitomo Wiring Syst Ltd | Current detecting device |
WO2013023455A1 (en) * | 2011-08-12 | 2013-02-21 | 浙江永泰隆电子有限公司 | Connection structure between sampling device and wire connecting terminal |
DE102012202999B4 (en) * | 2012-02-28 | 2021-05-06 | Lisa Dräxlmaier GmbH | Connection between electrically conductive components |
CN103943343B (en) * | 2013-01-22 | 2016-08-17 | 上海雷博司电气股份有限公司 | Current transformer for ring main unit |
JP6187420B2 (en) * | 2014-09-11 | 2017-08-30 | 中国電力株式会社 | Current transformer |
DE102015205632A1 (en) * | 2015-03-27 | 2016-09-29 | Siemens Aktiengesellschaft | Current transformer and current measuring device |
JP2020134191A (en) * | 2019-02-14 | 2020-08-31 | 三菱電機エンジニアリング株式会社 | Characteristics measuring device |
CN112164567A (en) * | 2020-10-27 | 2021-01-01 | 衡阳华瑞电气有限公司 | Quick assembly mechanism for outdoor type current transformer and quick assembly method thereof |
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- 2005-12-01 CN CN200580041584.6A patent/CN101069251B/en not_active Expired - Fee Related
- 2005-12-01 WO PCT/EP2005/012850 patent/WO2006058750A1/en active Application Filing
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Also Published As
Publication number | Publication date |
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US20080048815A1 (en) | 2008-02-28 |
DE102004058452A1 (en) | 2006-06-08 |
US7692526B2 (en) | 2010-04-06 |
WO2006058750A1 (en) | 2006-06-08 |
CN101069251B (en) | 2011-07-13 |
CN101069251A (en) | 2007-11-07 |
EP1817781A1 (en) | 2007-08-15 |
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