EP2544316A1 - Method for attaching a connector to a braided cable - Google Patents
Method for attaching a connector to a braided cable Download PDFInfo
- Publication number
- EP2544316A1 EP2544316A1 EP12172416A EP12172416A EP2544316A1 EP 2544316 A1 EP2544316 A1 EP 2544316A1 EP 12172416 A EP12172416 A EP 12172416A EP 12172416 A EP12172416 A EP 12172416A EP 2544316 A1 EP2544316 A1 EP 2544316A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- stranded cable
- end portion
- plug
- connector
- stripped end
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
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
- H01R43/0207—Ultrasonic-, H.F.-, cold- or impact 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
- H01R43/28—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for wire processing before connecting to contact members, not provided for in groups H01R43/02 - H01R43/26
Definitions
- the present invention relates to a method for connecting a plug to a stranded cable according to claim 1.
- the most common way to connect a plug to a stranded cable is to crimp a plug that serves as a crimp barrel, the stranded wire, or the flexible litz wire cable.
- Object of the present invention is therefore to provide a method for connecting a plug with a Litzentent that ensures a high joint strength, a low contact resistance and the gentlest possible production of the compound and in particular regardless of the cross section of the stranded cable applicable.
- the invention is based on the idea to create a positive and cohesive connection after compaction of the stranded cable between the stranded cable and the plug receiving the stranded cable, in particular different metals of the flexible stranded cable (copper, aluminum or similar conductive material) on one side and the metal present at least in the connecting portion of the plug are provided.
- a compaction or precompacting of the stripped end portion of the stranded cable leads to a reduction of the required energy and an improvement of the particularly intimate, positive and cohesive connection between the stranded cable and the plug.
- the interior of the stranded cable, ie the heddle core is compacted by the precompacting. As a result, the consumption of additional energy in the production of the positive or cohesive connection is avoided.
- the invention also provides a helium-tight and / or gas-tight connection.
- the preparation of the compound comprises a, in particular radial, pressurization, which is suitable for producing a positive and cohesive connection
- the connection in particular without welding, and thus particularly independent of the cross section, in particular for larger cross sections (> 20 mm 2 cross-sectional area ) be used.
- magnet forming in particular by means of electromagnetic pulse technology, that is, an electrodynamic Hochenergyumformungs vide.
- electrodynamic Hochenergyformungs vide in particular cold forming of the electrically conductive materials or sections of the stranded cable and the plug, namely the stripped end section of the stranded cable and of the metallic connection section of the plug, takes place.
- the advantage of the magnetic forming consists in a very precise adjustability of the pressure or pressing forces and a very homogeneous distribution of forces on the circumference, so that the radial pressurization after joining the, in particular sleeve-shaped, metallic connecting portion of the connector with the end portion of the stranded cable particularly homogeneous on Scope can be distributed.
- the magnetic field for the magnetic deformation through substances such as glass, ceramic and plastic act through, so that an application under vacuum to avoid oxidation and thus with better material consistency is feasible.
- a protective gas atmosphere or clean room conditions are also conceivable.
- magnet forming offers very high repeatability and extremely short process life and independence from thermal processes.
- the method according to the invention initially consists of precompacting / compacting the stripped end section of the stranded cable, which consists in particular of a plurality of copper strands.
- the magnetic forming takes place to produce a positive and cohesive connection between the connecting section and the end section.
- the stranded cable will strip exactly the length corresponding to the insertion depth of the end section into the connecting section of the plug.
- the particularly intimate cohesive connection in particular by covalent bonds between the materials of the stranded cable on one side and the connector on the other side leads to a high joint strength, in particular the strength of the softer material of the stranded cable / plug accordingly.
- the inventive method also prevents damage to nearby components after joining the plug with the stranded cable, since no welding is provided after the joining.
Abstract
Description
Die vorliegende Erfindung betrifft ein Verfahren zum Verbinden eines Steckers mit einem Litzenkabel gemäß Patentanspruch 1.The present invention relates to a method for connecting a plug to a stranded cable according to claim 1.
Die häufigste Herstellungsweise für die Verbindung eines Steckers mit einem Litzenkabel ist das Vercrimpen eines Steckers, der als Crimphülse dient, mit der Litze beziehungsweise dem flexiblen Litzenkabel.The most common way to connect a plug to a stranded cable is to crimp a plug that serves as a crimp barrel, the stranded wire, or the flexible litz wire cable.
Technische Anforderungen sind dabei insbesondere eine hohe Fügestellenfestigkeit sowie ein möglichst niedriger Übergangswiderstand zwischen den häufig unterschiedlichen Materialien.Technical requirements are in particular a high joint strength and the lowest possible contact resistance between the often different materials.
Insbesondere bei größeren Querschnitten von mehr als 25 mm2 Flächenquerschnitt bereitet das Verbinden durch Schweißen erhebliche Probleme, zumal mit Schweißen häufig eine Beschädigung anderer Komponenten, insbesondere im Umgebungsbereich der Schweißstellen, unvermeidbar einhergeht.In particular, with larger cross sections of more than 25 mm 2 area cross-section, the joining by welding causes considerable problems, especially as with welding often damage to other components, especially in the surrounding area of the welds, inevitably goes along.
Aufgabe der vorliegenden Erfindung ist es daher, ein Verfahren zum Verbinden eines Steckers mit einem Litzenkabel anzugeben, das eine hohe Fügestellenfestigkeit, einen niedrigen Übergangswiderstand und eine möglichst schonende Herstellung der Verbindung gewährleistet und insbesondere unabhängig vom Querschnitt des Litzenkabels anwendbar ist.Object of the present invention is therefore to provide a method for connecting a plug with a Litzenkabel that ensures a high joint strength, a low contact resistance and the gentlest possible production of the compound and in particular regardless of the cross section of the stranded cable applicable.
Die vorliegende Aufgabe wird mit den Merkmalen des Patentanspruchs 1 gelöst. Vorteilhafte Weiterbildungen der Erfindung sind in den Unteransprüchen angegeben. In den Rahmen der Erfindung fallen auch sämtliche Kombinationen aus zumindest zwei in der Beschreibung, den Ansprüchen und/oder den Zeichnungen angegebenen Merkmalen. Bei angegebenen Wertebereichen sollen auch innerhalb der genannten Grenzen liegende Werte als Grenzwerte offenbart gelten und in beliebiger Kombination beanspruchbar sein.The present object is solved with the features of claim 1. Advantageous developments of the invention are specified in the subclaims. All combinations of at least two features specified in the description, the claims and / or the drawings also fall within the scope of the invention. For specified value ranges, values lying within the stated limits should also be disclosed as limit values and may be claimed in any combination.
Der Erfindung liegt der Gedanke zugrunde, zwischen dem Litzenkabel und dem das Litzenkabel aufnehmenden Stecker eine form- und stoffschlüssige Verbindung nach einer Kompaktierung des Litzenkabels zu schaffen, wobei insbesondere unterschiedliche Metalle des flexiblen Litzenkabels (Kupfer, Aluminium oder ähnliches leitendes Material) auf der einen Seite und des zumindest im Verbindungsabschnitt des Steckers vorliegenden Metalls vorgesehen sind. Insbesondere eine Kompaktierung beziehungsweise Vorkompaktierung des abisolierten Endabschnitts des Litzenkabels, beispielsweise durch Ultraschall und/oder Widerstandsschweißen, führt zu einer Reduzierung der benötigten Energie und einer Verbesserung der besonders innigen, form- und stoffschlüssigen Verbindung zwischen dem Litzenkabel und dem Stecker. Dabei ist besonders vorteilhaft, wenn durch die Vorkompaktierung das Innere des Litzenkabels, also der Litzenkern, verdichtet wird. Hierdurch wird der Verbrauch zusätzlicher Energie bei der Herstellung der form- oder stoffschlüssigen Verbindung vermieden. Durch die Erfindung wird außerdem eine heliumdichte und/oder gasdichte Verbindung geschaffen.The invention is based on the idea to create a positive and cohesive connection after compaction of the stranded cable between the stranded cable and the plug receiving the stranded cable, in particular different metals of the flexible stranded cable (copper, aluminum or similar conductive material) on one side and the metal present at least in the connecting portion of the plug are provided. In particular, a compaction or precompacting of the stripped end portion of the stranded cable, for example by ultrasound and / or resistance welding, leads to a reduction of the required energy and an improvement of the particularly intimate, positive and cohesive connection between the stranded cable and the plug. It is particularly advantageous if the interior of the stranded cable, ie the heddle core, is compacted by the precompacting. As a result, the consumption of additional energy in the production of the positive or cohesive connection is avoided. By the invention also provides a helium-tight and / or gas-tight connection.
Soweit die Herstellung der Verbindung eine, insbesondere radiale, Druckbeaufschlagung umfasst, die zur Herstellung einer form- und stoffschlüssigen Verbindung geeignet ist, kann die Verbindung, insbesondere ohne Schweißung, und damit besonders unabhängig vom Querschnitt, insbesondere für größere Querschnitte (> 20 mm2 Querschnittsfläche) verwendet werden.As far as the preparation of the compound comprises a, in particular radial, pressurization, which is suitable for producing a positive and cohesive connection, the connection, in particular without welding, and thus particularly independent of the cross section, in particular for larger cross sections (> 20 mm 2 cross-sectional area ) be used.
Besonders geeignet für die Herstellung einer form- und stoffschlüssigen Verbindung ist erfindungsgemäß die Magnetumformung, insbesondere mittels elektromagnetischer Pulstechnologie, also ein elektrodynamisches Hochenergieumformungsverfahren. Dabei findet erfindungsgemäß insbesondere eine Kaltumformung der elektrisch leitfähigen Materialien beziehungsweise Abschnitte des Litzenkabels und des Steckers, nämlich des abisolierten Endabschnitts des Litzenkabels und des metallischen Verbindungsabschnitts des Steckers, statt.Particularly suitable for the production of a positive and cohesive connection according to the invention is the magnet forming, in particular by means of electromagnetic pulse technology, that is, an electrodynamic Hochenergieumformungsverfahren. According to the invention, in particular cold forming of the electrically conductive materials or sections of the stranded cable and the plug, namely the stripped end section of the stranded cable and of the metallic connection section of the plug, takes place.
Der Vorteil der Magnetumformung besteht in einer sehr genauen Einstellbarkeit der Druck- beziehungsweise Presskräfte sowie einer sehr homogenen Verteilung der Kräfte am Umfang, so dass die radiale Druckbeaufschlagung nach dem Fügen des, insbesondere hülsenförmigen, metallischen Verbindungsabschnitts des Steckers mit dem Endabschnitt des Litzenkabels besonders homogen am Umfang verteilt erfolgen kann.The advantage of the magnetic forming consists in a very precise adjustability of the pressure or pressing forces and a very homogeneous distribution of forces on the circumference, so that the radial pressurization after joining the, in particular sleeve-shaped, metallic connecting portion of the connector with the end portion of the stranded cable particularly homogeneous on Scope can be distributed.
Darüber hinaus kann das Magnetfeld für die Magnetumformung auch durch Stoffe wie Glas, Keramik und Kunststoff hindurch wirken, so dass eine Beaufschlagung unter Vakuum zur Vermeidung von Oxidation und damit mit besserem Stoffschluss durchführbar ist. Auch eine Schutzgasatmosphäre oder Reinraumbedingungen sind denkbar.In addition, the magnetic field for the magnetic deformation through substances such as glass, ceramic and plastic act through, so that an application under vacuum to avoid oxidation and thus with better material consistency is feasible. A protective gas atmosphere or clean room conditions are also conceivable.
Durch die Vermeidung eines mechanischen Kontakts zwischen der Magnetumformanlage und dem Werkstück, hier dem hülsenförmigen Stecker, treten weder Oberflächenverunreinigungen noch Werkzeugabdrücke auf.By avoiding mechanical contact between the magnetic forming machine and the workpiece, in this case the sleeve-shaped plug, neither surface contamination nor tool marks occur.
Schließlich bietet die Magnetumformung eine sehr hohe Wiederholgenauigkeit und eine äußerst kurze Prozessfertigungsdauer und die Unabhängigkeit von thermischen Prozessen.Finally, magnet forming offers very high repeatability and extremely short process life and independence from thermal processes.
Das erfindungsgemäße Verfahren besteht demnach zunächst aus einer Vorkompaktierung/Kompaktierung des abisolierten Endabschnitts des Litzenkabels, das insbesondere aus einer Vielzahl von Kupferlitzen besteht. Durch die Kompaktierung wird gleichzeitig das sich an die Kompaktierung anschließende Fügen des metallischen Verbindungsabschnitts des Steckers in Form einer Hülse mit dem Abschnitt des Litzenkabels vereinfacht.Accordingly, the method according to the invention initially consists of precompacting / compacting the stripped end section of the stranded cable, which consists in particular of a plurality of copper strands. By compacting the adjoining the compaction joining of the metallic connecting portion of the plug in the form of a sleeve with the portion of the stranded cable is simplified at the same time.
Nach dem Fügen erfolgt die Magnetumformung zur Herstellung einer form-und stoffschlüssigen Verbindung zwischen dem Verbindungsabschnitt und dem Endabschnitt.After joining, the magnetic forming takes place to produce a positive and cohesive connection between the connecting section and the end section.
Idealerweise wird von dem Litzenkabel genau die Länge abisoliert, die der Stecktiefe des Endabschnitts in den Verbindungsabschnitt des Steckers entspricht.Ideally, the stranded cable will strip exactly the length corresponding to the insertion depth of the end section into the connecting section of the plug.
Durch die so geschaffene form- und stoffschlüssige Verbindung wird ein sehr niedriger Übergangswiderstand von < 0,1 mOhm, vorzugsweise < 0,05 mOhm erreicht. Darüber hinaus führt die besonders innige, stoffschlüssige Verbindung, insbesondere durch kovalente Bindungen zwischen den Materialien des Litzenkabels auf der einen Seite und des Steckers auf der anderen Seite zu einer hohen Fügestellenfestigkeit, insbesondere der Festigkeit des weicheren Materials des Litzenkabels/Steckers entsprechend.By the thus created positive and cohesive connection a very low contact resistance of <0.1 mOhm, preferably <0.05 mOhm is achieved. In addition, the particularly intimate cohesive connection, in particular by covalent bonds between the materials of the stranded cable on one side and the connector on the other side leads to a high joint strength, in particular the strength of the softer material of the stranded cable / plug accordingly.
Durch das erfindungsgemäße Verfahren wird außerdem eine Schädigung von naheliegenden Komponenten nach dem Fügen des Steckers mit dem Litzenkabel vermieden, da nach dem Fügen keine Schweißung mehr vorgesehen ist.The inventive method also prevents damage to nearby components after joining the plug with the stranded cable, since no welding is provided after the joining.
Claims (5)
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE201110051643 DE102011051643B3 (en) | 2011-07-07 | 2011-07-07 | Method for connecting a plug to a stranded cable |
Publications (1)
Publication Number | Publication Date |
---|---|
EP2544316A1 true EP2544316A1 (en) | 2013-01-09 |
Family
ID=46514093
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP12172416A Withdrawn EP2544316A1 (en) | 2011-07-07 | 2012-06-18 | Method for attaching a connector to a braided cable |
Country Status (2)
Country | Link |
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EP (1) | EP2544316A1 (en) |
DE (1) | DE102011051643B3 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US10923834B1 (en) | 2019-07-31 | 2021-02-16 | Te Connectivity Germany Gmbh | Intermediate product and method for crimping an electrical conductor |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
AT513003B1 (en) | 2012-06-06 | 2014-05-15 | Gebauer & Griller | Connection of an electrical cable with a contact part |
DE102013015140A1 (en) * | 2013-09-13 | 2015-03-19 | Lisa Dräxlmaier GmbH | Device for connecting a stranded conductor to an electrical conductor by means of magnetic forming technology |
Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2008104668A1 (en) * | 2007-01-31 | 2008-09-04 | Powerconn | Process for manufacturing a cable for connecting the poles of a battery, an installation for implementing said process, and the cable obtained |
DE102009059307A1 (en) * | 2009-12-23 | 2011-06-30 | Schunk Sonosystems GmbH, 35435 | Method for the electrically conductive connection of wires |
Family Cites Families (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE19956193A1 (en) * | 1999-11-23 | 2001-06-13 | Schunk Kohlenstofftechnik Gmbh | Electrical conductor has contact or plug connector part in form of section of conductor whose shape has been changed and that has been compressed |
DE202004001363U1 (en) * | 2003-02-11 | 2004-04-15 | Neumann-Henneberg, Wolf | Connector for flexible electric cable, has a plug element that is pressed into a main body that receives a blade connection pin |
-
2011
- 2011-07-07 DE DE201110051643 patent/DE102011051643B3/en not_active Expired - Fee Related
-
2012
- 2012-06-18 EP EP12172416A patent/EP2544316A1/en not_active Withdrawn
Patent Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2008104668A1 (en) * | 2007-01-31 | 2008-09-04 | Powerconn | Process for manufacturing a cable for connecting the poles of a battery, an installation for implementing said process, and the cable obtained |
DE102009059307A1 (en) * | 2009-12-23 | 2011-06-30 | Schunk Sonosystems GmbH, 35435 | Method for the electrically conductive connection of wires |
Non-Patent Citations (1)
Title |
---|
RALPH SCHÄFER ET AL: "Elektromagnetische Pulsumformtechnologie im industiellen Einsatz", WWW.PSTPRODUCTS.COM, 9 May 2009 (2009-05-09), XP055035660, Retrieved from the Internet <URL:http://web.archive.org/web/20090509035725/http://www.pstproducts.com/UKD2009_PSTproducts_rs.pdf> [retrieved on 20120816] * |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US10923834B1 (en) | 2019-07-31 | 2021-02-16 | Te Connectivity Germany Gmbh | Intermediate product and method for crimping an electrical conductor |
Also Published As
Publication number | Publication date |
---|---|
DE102011051643B3 (en) | 2012-10-31 |
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