EP2706616A1 - Verfahren zum Zusammenbau einer Verbindungsvorrichtung auf einem blanken Endstück eines Elektrokabels, und Einheit, die eine solche fest auf einem Kabelendstück montierte Vorrichtung umfasst - Google Patents

Verfahren zum Zusammenbau einer Verbindungsvorrichtung auf einem blanken Endstück eines Elektrokabels, und Einheit, die eine solche fest auf einem Kabelendstück montierte Vorrichtung umfasst Download PDF

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Publication number
EP2706616A1
EP2706616A1 EP13183148.9A EP13183148A EP2706616A1 EP 2706616 A1 EP2706616 A1 EP 2706616A1 EP 13183148 A EP13183148 A EP 13183148A EP 2706616 A1 EP2706616 A1 EP 2706616A1
Authority
EP
European Patent Office
Prior art keywords
zone
tubular portion
stripped end
compression ratio
section
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.)
Granted
Application number
EP13183148.9A
Other languages
English (en)
French (fr)
Other versions
EP2706616B1 (de
Inventor
Eric Gery
Jonathan Brette
Jérôme Jeambrun
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Mecatraction SAS
Original Assignee
Mecatraction SAS
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Mecatraction SAS filed Critical Mecatraction SAS
Priority to PL13183148T priority Critical patent/PL2706616T3/pl
Publication of EP2706616A1 publication Critical patent/EP2706616A1/de
Application granted granted Critical
Publication of EP2706616B1 publication Critical patent/EP2706616B1/de
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/183—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/20—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping using a crimping sleeve
    • H01R4/203—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping using a crimping sleeve having an uneven wire-receiving surface to improve the contact
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
    • H01R43/048—Crimping apparatus or processes
    • H01R43/0482—Crimping apparatus or processes combined with contact member manufacturing mechanism
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R11/00—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
    • H01R11/11—End pieces or tapping pieces for wires, supported by the wire and for facilitating electrical connection to some other wire, terminal or conductive member
    • H01R11/12—End pieces terminating in an eye, hook, or fork
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R2201/00—Connectors or connections adapted for particular applications
    • H01R2201/26—Connectors or connections adapted for particular applications for vehicles
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/58—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation characterised by the form or material of the contacting members
    • H01R4/62—Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
    • H01R43/048—Crimping apparatus or processes
    • H01R43/0484—Crimping apparatus or processes for eyelet contact members
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
    • H01R43/058—Crimping mandrels
    • H01R43/0585—Crimping mandrels for crimping apparatus with more than two radially actuated mandrels
    • 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
    • Y10T29/49117—Conductor or circuit manufacturing
    • Y10T29/49174—Assembling terminal to elongated conductor
    • Y10T29/49181—Assembling terminal to elongated conductor by deforming
    • Y10T29/49183—Assembling terminal to elongated conductor by deforming of ferrule about conductor and terminal

Definitions

  • the invention relates to methods of assembling a connection device on a terminal section stripped of an electric cable.
  • the invention also relates to assemblies comprising such a connection device integrally assembled on such a terminal section stripped of an electric cable.
  • the cable is introduced, at a stripped end section, into the tubular portion of the connection device and is integrally joined by crimping this tubular portion on this denuded terminal section.
  • the assembly method of this device on this bare end section comprises a single crimping step performed using a crimping device provided with two jaws, including a substantially flat lower jaw and an upper jaw comprising several bearings.
  • the stripped end portion and the tubular portion are crimped together in stages, with the stripped end section having a variable and gradual compression ratio between a portion farthest from an opening opening in the tubular portion and a portion closest to this opening, but not in the immediate vicinity of the latter.
  • the invention aims to improve the methods of assembling a connection device on a terminal section stripped of an electric cable while being particularly simple, convenient and economical to implement.
  • the crimping of the first zone of the tubular portion on the first portion of the stripped end portion which is implemented with first predetermined crimping parameters, makes it possible to hold this first portion firmly in the connection device, without worrying about any flexibility of this first portion relative to the connection device.
  • the first portion of the stripped end portion is locked in the first zone of the tubular portion and has a first compression ratio said mean means.
  • the crimping of the second zone of the tubular portion on the second portion of the stripped end section makes it possible to maintain this second portion in the connecting device, while ensuring a certain flexibility of this second portion relative to the connection device.
  • the second portion of the bare terminal section is fixed in the second zone of the tubular portion while allowing the electrical cable to be folded at and in the immediate vicinity of this second portion, the latter portion having a second compression ratio, which is said to be low here.
  • the punching of the third zone of the tubular portion on the third portion of the stripped end section which is implemented with predetermined punching parameters, makes it possible to compact (more than with a crimping) the material of the tubular portion forming this third zone together with the material of the electric cable forming the third portion.
  • the third portion of the stripped end section is compacted with the third zone of the tubular portion and has a third compression ratio said strong here; so as to ensure permanent electrical contact between the connection device and the electrical cable.
  • the method according to the invention therefore provides a particularly effective mechanical and electrical fastening between the connecting device and the electric cable by means of a double crimping, performed under predetermined crimping parameters which are distinct, respectively to distance and near the introduction opening, combined with a punching, made between the two zones and crimped portions under predetermined punching parameters which are distinct from the predetermined crimping parameters.
  • the compactness of a zone / punched portion has an external perimeter ratio of this zone / portion on the smallest height passing through the center of gravity (here the geometric center) of this zone / portion, which is greater than or equal to about 6; while the compactness of a crimped area / portion has an outer perimeter ratio of this area / portion on the smallest height passing through the center of gravity of that area / portion, which is less than about 6.
  • the crimping and / or punching parameters are defined in particular by a closing edge of crimping and / or punching devices and by the imprint shape of such devices. It is these parameters that characterize the compression ratios obtained, also called section reduction rate. These parameters of course also depend on the diameter of the conductive core of the electric cable.
  • the first and the second crimping already performed when the punching is done, maintain longitudinally the end section of the electric cable. Therefore, during punching, the terminal section of the electric cable can not flow outside the punching area, or in any case can only flow in a particularly limited manner.
  • the end section of the electrical cable in the punching zone is subjected to intense deformation, which favors the quality of the electrical connection, particularly when the electrical cable is made of aluminum, since the fracture is then particularly effective.
  • the alumina layer present on the surface.
  • the subject of the invention is also, in a second aspect, an assembly comprising a connection device integrally assembled on a terminal section stripped of an electric cable, said connection device comprising a conductive element having a tubular portion and an opening of introduction by which said stripped end portion is introduced into said tubular portion, said assembly being characterized in that said tubular portion comprises a first crimped area with a first portion of said stripped end portion being in said first area, said first area being the most remote from said introductory opening, and with said first portion having a first predetermined compression ratio; said tubular portion further comprises a second zone crimped with a second portion of said stripped end section located in said second zone, said second zone being closest to said introducing opening, and with said second portion having a second predetermined compression ratio less than said first predetermined compression ratio; and said tubular portion further comprises a third punched area with a third portion of said stripped end portion in said third area, said third area being between said first and second areas, and with said third portion having a third predetermined compression ratio greater than said first predetermined compression
  • the first compression ratio, referred to herein as the mean, of the first portion of the stripped end portion is indicative of the crimping of the first zone of the tubular portion on this first portion, which is implemented with predetermined first crimping parameters, and the maintenance integral with this first portion in the connection device, without being concerned about any flexibility of this first portion relative to the connection device.
  • the first portion of the stripped end portion is locked in the first zone of the tubular portion.
  • the second so-called low compression ratio of the second portion of the stripped end section is indicative of the crimping of the second zone of the tubular portion on this second portion, which is implemented with predetermined second crimping parameters, and the maintenance of this second portion in the connection device, while ensuring a certain flexibility of this second portion relative to the connection device.
  • the second portion of the bare end section is fixed in the second zone of the tubular portion while allowing the folding of the electric cable at and in the immediate vicinity of this second portion.
  • the third compression ratio, referred to here as the loudness, of the third portion of the stripped end section is indicative of the punching of the third zone of the tubular portion on this third portion which is implemented with predetermined punching parameters, and compaction ( stronger than with crimping) the material of the tubular portion forming this third zone together with the material of the electric cable forming the third portion.
  • the third portion of the bare end portion is compacted with the third zone of the tubular portion so as to ensure permanent electrical contact between the connection device and the electrical cable.
  • the assembly according to the invention thus has a particularly powerful mechanical and electrical fastening between the connecting device and the electric cable thanks to a double crimping, providing two predetermined and distinct compression ratios, respectively at a distance and near the opening introduction, combined with punching, performed between the two zones and crimped portions and providing a predetermined compression ratio and greater than the two compression ratios resulting from crimping.
  • the crimping and / or punching parameters are defined in particular by a closing edge of crimping and / or punching devices and by the imprint shape of such devices. It is these parameters that characterize the compression ratios obtained, also called section reduction rate. These parameters of course also depend on the diameter of the conductive core of the electric cable.
  • the figure 1 schematically represents a motor vehicle 100 of the heavy truck type, comprising a starter 5 configured to launch a ring of a heat engine (not shown) of the vehicle 100, which starter 5 is formed by a rotating electrical machine connected to a battery 2 via an electrical connection assembly 1.
  • the electrical connection assembly 1 is here provided with two connection lugs 3 and an electric cable 4 with a conductive core 35 of aluminum ( figure 7 ) on which are integrally assembled the two connection terminals 3.
  • the conductive core 35 here comprises a plurality of strands ( figure 8 ) in aluminium.
  • the cable 4 has two opposite ends each forming a stripped end portion 6 ( figure 7 ) where the pods are crimped and punched 3.
  • the lug 3 comprises a conductive element 7 and a metallic tubular insert monobloc 9.
  • the conductive element 7 comprises a tubular portion 13 extending in a longitudinal general direction, a flat portion 15 connected to the tubular portion 13 by a transition portion 14 and an insertion opening 16 opposite the portion of transition 14.
  • the tubular portion 13 is hollow and provided with an outer face 18 and an inner face 19, which delimits an internal space 20 of the tubular portion 13.
  • the tubular portion 13 further comprises a first tubular section 22 having a large internal diameter, also called second internal diameter, a second tubular section 23 having a small internal diameter, also called first internal diameter, which is smaller than the second internal diameter, and an annular shoulder 17 connecting the first tubular section 22 to the second tubular section 23.
  • the first tubular section 22 is situated between the annular shoulder 17 and the insertion opening 16.
  • the second tubular section 23 is located between the annular shoulder 17 and the transition portion 14.
  • the second tubular section 23 here has a length less than the first internal diameter and the first tubular section 22 here has a length greater than the second internal diameter.
  • the tubular portion 13 comprises an insertion chamfer 24 formed on the first tubular section 22, at the level of the insertion opening 16.
  • the transition portion 14 connects the second tubular section 23 of the tubular portion 13 to the flat portion 15.
  • This transition portion 14 forms a bottom wall of the tubular portion 13, which bottom wall has an inner face 21 facing the internal space 20.
  • the bottom wall is here straight, substantially perpendicular to the longitudinal general direction of the tubular portion 13 and substantially perpendicular to the flat portion 15.
  • the flat portion 15 forms a mechanical and electrical contact pad configured to cooperate with a predetermined electrical terminal (not shown).
  • This predetermined electrical terminal belongs here to either the battery 2 or the starter 5.
  • the flat portion 15 has a generally parallelepipedal shape, has a predetermined width, and is provided with a hole 12 formed centrally and configured to receive a fastener (not shown), for example a bolt having a screw and a nut.
  • a fastener for example a bolt having a screw and a nut.
  • this bolt belongs, in one case to the battery 2 and in the other case to the starter 5.
  • the one-piece tubular insert 9 comprises a sheath 32 and a flared ring 39 located at one end of the sheath 32.
  • the sheath 32 is located in the internal space 20 of the tubular portion 13, at the level of the first tubular section 22.
  • the sheath 32 comprises a split body 60 having a generally cylindrical shape ( figure 6 ).
  • the body 60 has an external diameter (when this body 60 is not subjected to any stress) substantially similar to or even slightly greater than the second internal diameter of the first tubular section 22 of the tubular portion 13 ( figure 6 ).
  • the body 60 has an inner face 33 and an outer face 34, which comes into contact with the inner face 19 of the tubular portion 13.
  • the body 60 is mounted slightly compressed in the inner space 20 of the tubular portion 13 (through the slot).
  • the sheath 32 also has a plurality of perforations 59 formed in the body 60.
  • this sheath 32 is configured to deform the bare terminal section 6, with the conductive core 35 ( figure 7 ) of aluminum cable 4 which is embedded in these perforations 59 (see below).
  • the flared ring 39 is located at the end of the sheath 32 in the immediate vicinity of the insertion opening 16 and thus of the insertion chamfer 24.
  • the flared ring 39 has a profile similar to that of the introduction chamfer 24, against which this flared ring 39 bears.
  • the flared ring 39 delimits the insertion opening 16 of the conductive element 7.
  • flared ring 39 is configured to facilitate the introduction of the stripped terminal section 6 of the cable 4 into the internal space 20 of the tubular portion 13.
  • a predetermined amount of contact grease 10 is introduced into the inner space 20 of the tubular portion 13 at and against the bottom wall thereof.
  • This contact grease 10 is configured to improve the electrical conductivity between the conductive core 35 ( figure 7 ) of the cable 4, the insert 9 and the conductive element 7.
  • the plug 8 is mounted on the outer face 18 of the tubular portion 13, at the first tubular section 22 and facing the opening 16, so as to plug the internal space 20 of the tubular portion 13.
  • the conductive element 7 is made from an initial cylindrical metal tube having a predetermined internal diameter corresponding to the first internal diameter of the second tubular section 23 of the tubular portion 13.
  • Two opposite walls of the cylindrical tube are flattened (brought together until contacting) at an end opposite to the insertion opening 16 so as to form the flat portion 15.
  • This flattening creates a first configuration of the transition portion 14 (inclined orientation of the bottom wall) and thus closes the internal space 20 of the opposite side to the insertion opening 16.
  • the tubular portion 13 is formed by expansion over a predetermined length to form, on the one hand the first tubular section 22 having the second internal diameter, and on the other hand the annular shoulder 17 (on the inner face 19), which shoulder delimits the first and second sections 22 and 23 of the tubular portion 13.
  • transition portion 14 is deformed so that the bottom wall of the tubular portion 13 is straightened from the inclined orientation that it had at the end of the flattening step to the straight orientation visible on the drawings.
  • deformations are carried out with a deformation spindle 25 ( Figures 4 and 5 ), here an expansion pin, configured to be inserted into the internal space 20 of the tubular portion 13 by its insertion opening 16.
  • a deformation spindle 25 ( Figures 4 and 5 ), here an expansion pin, configured to be inserted into the internal space 20 of the tubular portion 13 by its insertion opening 16.
  • This expansion pin 25 comprises a body provided with a first cylindrical portion 26 having a first outer diameter greater than the second internal diameter of the first tubular section 22, a second cylindrical portion 27 having a second similar external diameter (at the introductory game near) to the second internal diameter of the first tubular section 22 and a third cylindrical portion 28 having a third similar outer diameter (to the introductory clearance near) to the first internal diameter of the second tubular section 23.
  • the first cylindrical portion 26 is connected to the second cylindrical portion 27 by a first annular shoulder 29 and the third cylindrical portion 28 is connected to the second cylindrical portion 27 by a second annular shoulder 30.
  • the third cylindrical portion 28 has at its end which is on the opposite side to the side connected to the second shoulder 30, a face 31 which is flat.
  • the second shoulder 30 is configured to form, together with the matrix, the shoulder 17 of the tubular portion 13.
  • plane face 31 is configured to form the internal face 21 of the bottom wall of the tubular portion 13.
  • the deformation step by expansion with the spindle 25 is carried out by introduction of this pin 25 with the second cylindrical portion 27 which comes into contact with the inner face 19 at its first tubular portion 22 to expand the latter, with the shoulder 29 which comes into contact with the inner face 19 near the insertion opening 16 to create the insertion chamfer 24, with the shoulder 30 which forms the shoulder 17, and with the flat face 31 which comes against the transition portion 14 to straighten it and thus form the right bottom wall and thus the inner face 21.
  • the conductive element 7 is therefore mainly formed by deformation and expansion of the initial cylindrical tube via the expansion pin 25 and the die (not shown).
  • the expansion pin 25 leaves on the bottom wall 21 a flat zone, generally of length at least equal to one third of the diameter of the bottom wall 21 (see the part of the face 31 in contact with the wall of FIG. bottom 21 on the figure 5 ).
  • the bottom wall 21 extends substantially perpendicular to the longitudinal direction of the tubular portion 13 when a flat area of length at least equal to one third of the diameter of the bottom wall 21 has an angle with respect to the longitudinal direction of the tubular portion 13 in the range [80 °; 100 °].
  • the one-piece tubular insert 9 (provided with the sheath 32 and the flared ring 39) is then supplied and introduced into the internal space 20 of the tubular portion 13 through the insertion opening 16.
  • this insert 9 is facilitated by the introduction chamfer 24.
  • the insert 9 is introduced until it comes into abutment on the annular shoulder 17, and with the flared ring 39 which takes place in the insertion chamfer 24.
  • the inner face 19 of the tubular portion 13 is opposite the outer face 34 of the sheath 32.
  • a predetermined quantity of contact grease 10 is introduced into the internal space 20 against the inner face 21.
  • the electric cable 4 further comprises the conductive core 35 provided with a plurality of aluminum strands, an insulating sheath 36 of a predetermined thickness enveloping the conductive core 35.
  • the electric cable 4 comprises an isolated section 37, provided with the core 35 and the sheath 36, and a stripped end section 6 situated at the end of the isolated section 37, which stripped terminal section 6 is devoid of sheath 36.
  • the stripped end section 6 has a substantially flat end face 38 opposite the insulated section 37.
  • the tubular portion 13 has, along what was initially its first tubular section 22 located between the insertion opening 16 and the annular shoulder 17, a first crimped zone 40, a second crimped zone 41 and a third punched zone 42.
  • the first zone 40 is furthest from the introduction opening 16 while the second zone 41 is closest to it.
  • the third zone 42 is located between the first zone 40 and the second zone 41.
  • the stripped terminal section 6 has a first portion 43 at a distance from the insertion opening 16, a second portion 44 near this introduction opening 16 and a third portion 56 located between the first portion 43 and the second portion 43. portion 44.
  • the first zone 40 is crimped on the first portion 43, which has a first compression ratio, also called section reduction ratio (TRS).
  • TRS section reduction ratio
  • This first compression ratio is here in the range [10%; 30%]. Note that this is an average compression ratio.
  • the first zone 40 and the first portion 43 have, in section, a general shape in B.
  • the compactness of the assembly formed of the first zone 40 and crimped portion 43 here has an external perimeter ratio P of these zone and portion on height H the smallest passing through the center of gravity G (here the geometric center) of these area and portion, which is less than about 6, significant of a first crimping.
  • the second zone 41 is crimped on the second portion 44, which has a second compression ratio which is lower than the first compression ratio.
  • This second compression ratio is here in the range [2%; 20%]. Note that this is a low compression ratio.
  • the second zone 41 and the second portion 44 have, in section, a hexagonal shape.
  • the compactness of the assembly formed of the second zone 41 and crimped portion 44 here has an external perimeter ratio P of these zone and portion on height H the smallest passing through the center of gravity G (here the geometric center) of these area and portion, which is less than about 6, significant of a second crimping.
  • the third zone 42 is punched with the third portion 56, which has a third compression ratio which is greater than the first and second compression ratio.
  • This third compression ratio is here in the range [25%; 45%]. Note that this is a strong compression ratio.
  • the third punched zone 42 and the third portion 56 have, in section, a crescent shape.
  • the compactness of the assembly formed of the third zone 42 and the portion 56 punched here has an external perimeter ratio P of these zone and portion on height H the smallest passing through the center of gravity G (here the geometric center) of these area and portion, which is greater than about 6, significant of a punching.
  • the stripped terminal section 6 is introduced into the terminal 3 until the end face 38 of the cable 4 comes opposite the internal face 21 of the bottom wall of the tubular portion 13.
  • a layer of contact grease 10 separates this inner face 21 from the end face 38.
  • the right bottom wall of the tubular portion 13 allows, once the end face 38 of the cable 4 facing the inner face 21 of this tubular portion 13, to return with good distribution a portion of the contact grease 10 around the first, second and third portions 43, 44 and 56 of the bare terminal section 6.
  • the conductive core 35 has a diameter substantially equal to the first internal diameter of the second tubular section 23, which makes it possible to guide the stripped terminal section 6 into the internal space 20.
  • the first zone 40 and the second zone 41 of the first tubular section 22 of the tubular portion 13 are crimped in a single step respectively on the first and second portions 43 and 44 of the stripped end portion 6, by means of a single crimping device 45 configured to obtain distinct compression ratios of the crimped strands of the denuded terminal section 6.
  • This crimping device 45 has a first lower jaw 46, a first upper jaw 47 opposite the first one. lower jaw 46, a second lower jaw 49 distinct from the first lower jaw 46 and a second upper jaw 50 distinct from the first upper jaw 47 and opposite the second lower jaw 49.
  • the first lower jaw 46 and the first upper jaw 47 form a first pair of crimping jaws 46, 47, while the second lower jaw 49 and the second upper jaw 50 form a second pair of crimping jaws 49, 50.
  • the first pair of crimping jaws 46, 47 has a B-shaped recess and is disposed plumb with the outer face 18 of the tubular portion 13, with the B-shaped recess facing the first tubular section 22 , close to the shoulder 17 (in other words away from the insertion opening 16).
  • This first pair of crimping jaws 46, 47 is configured to crimp the first zone 40 of the tubular portion 13 on the first portion 43 of the stripped end portion 6 according to predetermined first crimping parameters so as to provide the first portion 43 with the first predetermined compression ratio, and to provide the first zone 40 and portion 43, in section, a shape in B.
  • the second pair of crimping jaws 49, 50 has a hexagon-shaped imprint and is disposed plumb with the outer face 18 of the tubular portion 13, with the hexagon-shaped imprint facing the first section tubular 22, close to the insertion opening 16 (ie away from the shoulder 17).
  • This second pair of crimping jaws 49, 50 is configured to crimp the second zone 41 of the tubular portion 13 on the second portion 44 of the stripped end portion 6 according to second predetermined crimping parameters so as to provide the second portion 44 with the second predetermined compression ratio (lower than the first compression ratio), and to provide the second zone 41 and portion 44, in section, a hexagonal shape.
  • the third zone 42 of the first tubular section 22 of the tubular portion 13 is then punched with the third portion 56 of the stripped end section 6, by means of a punching device 51 configured to obtain a strong compression ratio of the punched strands of the bare terminal section. 6.
  • This punching device 51 comprises a punch 52 and a punching die 53 facing the punch 52.
  • the punch 52 and the die 53 have a crescent-shaped punching footprint and are arranged in line with the outer face 18 of the tubular portion 13, with the crescent-shaped imprint facing the first tubular section 22, between its first and second zones 40 and 41.
  • This punch 52 and this die 53 are configured to punch the third zone 42 of the tubular portion 13 on the third portion 56 of the stripped end portion 6 according to predetermined punching parameters so as to provide the third portion 56 with the third compression ratio predetermined (greater than the first and second compression ratio), and to provide the third zone 42 and portion 56, in section, a crescent shape.
  • the sleeve 32 is crushed by the crimping and punching steps on the stripped end section 6, which is thus deformed and the conductive core 35 is embedded in the perforations 59 of the sleeve 32.
  • these crimping and / or punching parameters are defined in particular by the closing edge of the crimping and / or punching devices 45 and 51 and by the shape of the imprints thereof. These parameters of course also depend on the diameter of the conductive core 35 of the electric cable 4.
  • this step of deformation of the transition portion is not implemented; and the invention relates to a method of manufacturing a crimp connection device on a stripped end section of electrical cable, comprising the step of providing a conductive element made in one piece and having a tubular portion, an opening of introduction by which it is intended to introduce in said tubular portion said stripped end portion and a flat portion configured to cooperate with a predetermined electrical terminal, said tubular portion being connected at an end opposite said insertion opening, by a transition portion at said flat portion; said method comprising the step of providing a conductive cylindrical tube having a predetermined first internal diameter and having said introduction opening, and the step of at least partially expanding said conductive cylindrical tube to form said tubular portion, which is provided at least a first tubular section having a second internal diameter greater than said first predetermined internal diameter.
  • the method just described comprises a step of deformation of the transition portion until said transition portion forms a substantially straight bottom wall of the tubular portion, wherein said bottom wall extends substantially perpendicular to the longitudinal general direction of the tubular portion.
EP13183148.9A 2012-09-07 2013-09-05 Verfahren zum Zusammenbau einer Verbindungsvorrichtung auf einem blanken Endstück eines Elektrokabels, und Einheit, die eine solche fest auf einem Kabelendstück montierte Vorrichtung umfasst Active EP2706616B1 (de)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PL13183148T PL2706616T3 (pl) 2012-09-07 2013-09-05 Sposób montażu urządzenia łączącego na odsłoniętym odcinku końcowym kabla elektrycznego i zespół zawierający takie urządzenie zamontowane sztywno na takim odcinku kabla

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
FR1258423A FR2995459B1 (fr) 2012-09-07 2012-09-07 Procede d'assemblage d'un dispositif de connexion sur un troncon terminal denude d'un cable electrique et ensemble comportant un tel dispositif assemble solidairement sur un tel troncon de cable

Publications (2)

Publication Number Publication Date
EP2706616A1 true EP2706616A1 (de) 2014-03-12
EP2706616B1 EP2706616B1 (de) 2018-08-01

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EP13183148.9A Active EP2706616B1 (de) 2012-09-07 2013-09-05 Verfahren zum Zusammenbau einer Verbindungsvorrichtung auf einem blanken Endstück eines Elektrokabels, und Einheit, die eine solche fest auf einem Kabelendstück montierte Vorrichtung umfasst

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US (1) US9196971B2 (de)
EP (1) EP2706616B1 (de)
FR (1) FR2995459B1 (de)
PL (1) PL2706616T3 (de)

Cited By (2)

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EP3096404A1 (de) * 2015-05-21 2016-11-23 Delphi Technologies, Inc. Crimpverbindungssystem für elektrische kabel mit einer befestigungshülse
FR3050579A1 (fr) * 2016-04-25 2017-10-27 A M C Dispositif et procede de reparation des cosses de connexion electroqie

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US9853367B2 (en) * 2013-11-01 2017-12-26 Furukawa Electric Co., Ltd. Wire harness, method of connecting terminal and coated wire, and mold
DE102015012906A1 (de) * 2015-02-27 2016-09-01 Gentherm Gmbh Hülse, Kontaktier-Einrichtung und Verfahren zum Schweißen von dünnen strangförmigen Leitern mittels Ultraschall
US10033117B1 (en) * 2017-01-23 2018-07-24 Te Connectivity Corporation Connecting insert for a terminal assembly
US20180219303A1 (en) * 2017-02-02 2018-08-02 Hubbell Incorporated Terminal connectors
FR3063392B1 (fr) 2017-02-28 2019-04-19 Mecatraction Dispositif de connexion a sertir sur un troncon terminal de cable, comportant une enveloppe conductrice pourvue d’une paroi separant deux logements
DE102017215970B3 (de) * 2017-09-11 2018-07-26 Strunk Connect automated solutions GmbH & Co. KG Verfahren zum Verbinden einer elektrischen Aluminiumleitung mit einem Aluminiumrohr
JP6762338B2 (ja) * 2018-05-21 2020-09-30 矢崎総業株式会社 端子の圧着方法及び圧着構造
JP2020119865A (ja) * 2019-01-28 2020-08-06 日立金属株式会社 端子付電線、端子付電線の製造方法及び端子付電線が有する端子
FR3095086B1 (fr) * 2019-04-12 2021-04-16 Aptiv Tech Ltd Procédé de fabrication d’un contact de puissance mâle et contact de puissance mâle
CN114430127A (zh) * 2021-12-31 2022-05-03 中国航空工业集团公司西安飞机设计研究所 一种防水型整体式压接端子

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US3955044A (en) * 1970-12-03 1976-05-04 Amp Incorporated Corrosion proof terminal for aluminum wire
WO1998054790A1 (en) * 1997-05-26 1998-12-03 The Whitaker Corporation Crimp connection for large conductors

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US2276140A (en) * 1940-04-18 1942-03-10 Artos Engineering Co Conductor terminal
US2810897A (en) * 1953-03-27 1957-10-22 Ideal Ind Crimp connector

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GB1164100A (en) * 1967-09-13 1969-09-10 Amp Inc Terminal for Connection to Aluminium Wire
US3955044A (en) * 1970-12-03 1976-05-04 Amp Incorporated Corrosion proof terminal for aluminum wire
WO1998054790A1 (en) * 1997-05-26 1998-12-03 The Whitaker Corporation Crimp connection for large conductors

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3096404A1 (de) * 2015-05-21 2016-11-23 Delphi Technologies, Inc. Crimpverbindungssystem für elektrische kabel mit einer befestigungshülse
WO2016184914A1 (en) * 2015-05-21 2016-11-24 Delphi Technologies, Inc. Crimp connection system for electrical cables, comprising a fastening sleeve
US10424849B2 (en) 2015-05-21 2019-09-24 Aptiv Technologies Limited Crimp connection system for electrical cables comprising a fastening sleeve
FR3050579A1 (fr) * 2016-04-25 2017-10-27 A M C Dispositif et procede de reparation des cosses de connexion electroqie

Also Published As

Publication number Publication date
FR2995459A1 (fr) 2014-03-14
US20140073205A1 (en) 2014-03-13
FR2995459B1 (fr) 2014-10-10
US9196971B2 (en) 2015-11-24
PL2706616T3 (pl) 2019-02-28
EP2706616B1 (de) 2018-08-01

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