EP2777096B1 - Multi-pole plug connection unit for three-phase alternating current systems - Google Patents

Description

The invention relates to a multi-pin plug connection unit for three-phase AC systems with two complementary kinking nesting plug connector parts and with a plug connector parts in assembled state against each other axially locking locking sleeve, each plug connector is constructed as a monolithic insulator in which a plurality of electrical plug contacts are axially locked.

Such a multipolar connector unit is known from DE 10 2006 025 134 A1 known. The plug-in connection unit has two connector parts that are complementary to each other for a kink-proof nesting, in which mutually complementary electrical plug contacts are provided. Both plug connection parts have an insulating body, in which the respective electrical plug contacts are accommodated.

Another multi-pin connector unit is from the EP 1 936 752 A2 known. The known plug-in connection unit has two plug-in connection parts constructed in each case in several parts, which can be locked against one another via a locking sleeve which is likewise constructed in several parts. Each connector part is provided with electrical plug contacts, which are designed as individual pins or as individual sockets. Both the individual pins and the individual sockets are integrated in insulating sleeves, which in turn merge into a plastic insulating body. The insulating body is inserted into a metallic hollow body, which is also part of the respective connector part.

The object of the invention is to provide a multi-pin connector unit of the type mentioned, which is designed to be inexpensive to manufacture and miniaturized and yet can transmit large voltage and current levels.

This object is solved by the features of claim 1. The combination of these features creates a miniaturized circular connector module that can transmit high voltages and currents. The solution according to the invention is particularly suitable for energy transmission between machine tools and control units or control cabinets. The reverse rotation prevents unintentional turning back the locking sleeve from the locked state in the release state, in which the connector between the connector parts can be separated.

In an embodiment of the invention, electrical cable cores of a cable are connected to the electrical plug contacts whose core cross section is 2.5 mm ² . Despite miniaturization with a diameter of the connector unit of less than 23 mm, the use of large cable cross-sections is possible, which in turn allow high energy transfer values.

In a further embodiment of the invention, the electrical plug contacts comprise at least three contacts, which are designed for maximum voltage and current ranges of 630V / 16A.

In a further embodiment, the electrical plug contacts comprise at least two additional contacts, which are designed for minimum voltage and current ranges from 63 V / 10 A. The additional contacts form auxiliary contacts. In addition, the electrical plug contacts comprise at least one protective conductor contact.

In a further embodiment of the invention, each insulating body is encapsulated by a protective sheath, which consists of an elastic plastic material and comprises a cable surrounding the cable of the respective connector part strain relief. The protective sheath is integral with the Isolierköper by being sprayed by an injection molding process on the already completed insulator. The strain relief is created by corresponding ring or sleeve-like sections of the protective casing.

In a further embodiment of the invention, each insulator is provided in an insertion of the cable cores with a cable cores enclosing closure element, the rear receiving areas of the insulating body for the plug contacts seals. This embodiment is advantageously suitable for miniaturized circular connector modules, in which an outer diameter of the connector parts and the locking sleeve is smaller than 23 mm. The embodiment is also preferably suitable for transmitting high electrical voltages and current strengths, so that voltage and current ranges up to 630 V / 16 A can preferably be transmitted despite miniaturization of the circular connector module. The embodiment described can also be provided in a multi-pin connector unit, in which each connector part comprises a monolithic insulating body in which a plurality of electrical plug contacts are axially locked without additional miniaturization and / or the transmission of large voltage and current ranges are provided. By the described embodiment, the rear insertion of each insulating body, in which the receiving areas are provided for the axial insertion and locking of the electrical plug contacts, sealed, so that potting compound, which is required for the protective casing of each insulator, not in the receiving areas for the electrical plug contacts can penetrate. Thus, the rear receiving areas for the electrical plug contacts in each insulator remain free of potting material, so that each electrical plug-in contact in its latched in the receiving area of the insulating state limited in certain tolerances is radially movable. The axial latching forms a floating bearing for the electrical plug contacts, since they can move, in particular in the radial direction within certain limits within the receiving areas of each insulator. This floating bearing and the limited mobility allow a secure connection between the electrical plug contacts during mating of the two insulator. In addition, by this configuration, each cable core in the region of the rear end face of the associated insulating in a defined orientation and positioning by the corresponding Held closing element, so that the respective cable core is aligned together with the end face in particular by crimping electrical plug contact substantially coaxially within the respective receiving area of the associated insulating body. The respective closure element for each of the two insulating body is preferably designed disk-shaped or plate-shaped and has on the cross sections of the receiving areas of the respective insulator coordinated plug-in profiles, which can be attached non-positively to the corresponding rear end side of the insulator. Alternatively or additionally, it is provided to bond the closure element with the end face of the insulating body or to achieve a positive securing of the closure element on the rear end face of the respective insulating body by externally encapsulating the protective jacket for the insulating body. The closure element is produced as a one-piece plastic component, preferably of the same material as the associated insulating body. Alternatively, it is possible to produce the corresponding closure element from an elastomer or a thermoplastic elastomer.

In a further embodiment of the invention, an outer sheath of each insulating body is provided with profilings to achieve an additional positive connection for the sprayed protective sheath. As a result, in addition to a corresponding material connection between the protective casing and the insulating body, a positive connection is also achieved.

In a further embodiment of the invention, the plug connection parts and the locking sleeve are designed as circular connector, wherein the outer contours of the connector parts and the locking sleeve in mated condition at least largely aligned with each other. As a result, a substantially cylindrical circular connector created in mated condition of the connector parts and the locking sleeve.

In a further embodiment of the invention, the plug connection parts are designed as plug / socket combination, as angled plug / angle socket combination, as couplings or as feedthroughs. As a result, the plug connection unit can be designed for different purposes. As couplings or bushings in particular mounting or Einschraubkupplungen or - are provided.

Fig. 1

zeigt eine Explosionsdarstellung einer Ausführungsform einer erfindungsgemäßen Steckverbindungseinheit,

Fig. 2

einen als Stecker ausgebildeten Steckverbindungsteil der Steckverbindungseinheit nach Fig. 1, jedoch ohne Schutzummantelung,

Fig. 3

einen zu dem Steckverbindungsteil nach Fig. 2 komplementären, als Buchse ausgebildeten Steckverbindungsteil,

Fig. 4

eine Längsschnittdarstellung des Steckverbindungsteiles nach Fig. 2,

Fig. 5

eine Längsschnittdarstellung des Steckverbindungsteiles nach Fig. 3, mit montierter Verriegelungshülse,

Fig. 6

den als Stecker ausgeführten Steckverbindungsteil nach Fig. 2, aber mit aufgespritzter Schutzummantelung,

Fig. 7

den als Buchse ausgeführten Steckverbindungsteil nach Fig. 3, aber mit umspritzter Schutzummantelung und mit montierter Verriegelungshülse,

Fig. 8

einen Längsschnitt durch die Steckverbindungseinheit nach Fig. 1,

Fig. 9

in vergrößerter Darstellung einen Ausschnitt des Längsschnittes nach Fig. 8,

Fig. 10

die Steckverbindungseinheit nach Fig. 1 in gestecktem, aber unverriegeltem Zustand,

Fig. 11

die Steckverbindungseinheit nach Fig. 10 in gestecktem und verriegeltem Zustand,

Fig. 12

eine Explosionsdarstellung einer weiteren Ausführungsform einer erfindungsgemäßen Steckverbindungseinheit,

Fig. 13

in vergrößerter Längsschnittdarstellung die Steckverbindungseinheit nach Fig. 12 in zusammengestecktem Funktionszustand,

Fig. 14

einen als Stecker ausgebildeten Steckverbindungsteil der Steckverbindungseinheit nach Fig. 13, ohne Schutzummantelung und ohne Kabeladern,

Fig. 15

den zu dem Steckverbindungsteil nach Fig. 14 korrespondierenden Steckverbindungsteil der Steckverbindungseinheit nach den Fig. 12 und 13 mit Verriegelungshülse, aber ohne Schutzummantelung und

Fig. 16

in vergrößerter Darstellung einen Ausschnitt der Steckverbindungseinheit nach Fig. 13.

Further advantages and features of the invention will become apparent from the claims. Hereinafter, a preferred embodiment is described and illustrated with reference to the drawings.

Fig. 1

shows an exploded view of an embodiment of a plug connection unit according to the invention,

Fig. 2

designed as a plug connector part of the connector unit after Fig. 1 but without protective coating,

Fig. 3

one to the connector part after Fig. 2 complementary, designed as a socket connector part,

Fig. 4

a longitudinal sectional view of the connector part after Fig. 2 .

Fig. 5

a longitudinal sectional view of the connector part after Fig. 3 , with mounted locking sleeve,

Fig. 6

the connector part designed as a connector Fig. 2 but with sprayed protective coating,

Fig. 7

the plug-in connector designed as socket Fig. 3 , but with overmoulded protective coating and with mounted locking sleeve,

Fig. 8

a longitudinal section through the connector unit after Fig. 1 .

Fig. 9

in an enlarged view a section of the longitudinal section after Fig. 8 .

Fig. 10

the connector unit after Fig. 1 in plugged but unlocked condition,

Fig. 11

the connector unit after Fig. 10 in plugged and locked state,

Fig. 12

an exploded view of another embodiment of a connector unit according to the invention,

Fig. 13

in enlarged longitudinal sectional view of the connector unit after Fig. 12 in assembled functional state,

Fig. 14

designed as a plug connector part of the connector unit after Fig. 13 , without protective coating and without cable wires,

Fig. 15

the to the connector part after Fig. 14 corresponding connector part of the connector unit after the Fig. 12 and 13 with locking sleeve, but without protective coating and

Fig. 16

in an enlarged view a section of the connector unit after Fig. 13 ,

A multipolar connector assembly for three-phase AC systems according to the Fig. 1 to 11 is composed of a plug connector designed as a first connector part 2a, 4, made of a designed as a socket second connector part 2b, 4 and a locking sleeve 3, which is captively connected to the socket connector 2b, 4 designed as a socket. The multipole plug connection unit is provided for signal and energy transmission between a machine tool and a control unit or a control cabinet. The connector unit is miniaturized and has in the assembled state after the Fig. 5 and 8 to 11 a diameter of about 21 mm. Preferably, the diameter of the plug connection unit is less than 23 mm and in a preferred embodiment 20.5 mm. Each plug connection part is composed of a monolithic insulating body 2a, 2b, a certain number of metallic, electrical plug contacts 5a, 5b and a sprayed protective casing 4, which is provided with a molded strain relief for a cable harness of lines, with their connecting strands with the metallic , electrical plug contacts 5a, 5b are connected. The one monolithic insulating body 2b is designed as a socket. The other monolithic insulating body 2a is designed as a plug. In each insulating body 2a, 2b shots for the axial mechanical engagement of a total of 6 electrical plug contacts 5a, 5b are provided, which are designed as a round pin. The plug contacts 5a, which are also referred to as contact pins, are designed as plug pins. The also known as contact pins electrical plug contacts 5b are as socket-shaped or sleeve-shaped contact pins executed. The corresponding receptacles in the respective insulator 2 a, 2 b are profiled in such a way that the contact pins 5 a, 5 b can be inserted axially from a rear side of the respective insulator 2 a, 2 b and positively lock in their functional position in the receptacles. This is based on the 4 and 5 good to see. Each monolithic insulating body 2a, 2b is made of a plastic material, preferably of polyamide.

Three of the plug contacts 5a, 5b in each insulating body 2a, 2b are designed for an energy transfer of up to 630 volts / 16 amperes. Two further plug contacts in the form of contact pins of each insulator 2 a, 2 b are designed as auxiliary contacts for a minimum voltage of 63 volts and a minimum current of 10 amperes. In addition, the six plug contacts 5a, 5b of each insulating body 2a, 2b each comprise a protective conductor contact. The three plug contacts, which are designed for a maximum of 630 volts / 16 amperes, are designed for the connection of copper cables of corresponding connection cables, which have a cable cross-section of up to 2.5 mm ² .

Each plug connection part is provided with a protective sheathing 4 applied to the respective insulating body 2a, 2b by an injection molding process, which comprises a strain relief for the cable strands, which depart from the respective electrical plug contacts 5a, 5b. The protective cover is made of a suitable elastic and flexible plastic material which has a good adhesion and good tactile properties. In order to improve the cohesive connection by the injection molding process between insulator 2a, 2b and protective casing 4, an outer sheath of each insulator is provided in a cylindrical connecting portion with profilings in the form of recesses 8, in which the injection molding material of the protective sheath 4 form-fitting flow during the manufacturing process can. The respective protective casing 4 terminates in the region of an unspecified annular flange of each insulating body 2a, 2b, starting from the direction in the insertion direction of the respective connecting portion of each insulator 2a, 2b attaches. Each connecting portion of the respective insulating body 2a, 2b is composed of an axial connector portion 9a, 9b and an unspecified peripheral portion which is provided for the axial locking of the two connector parts together via the locking sleeve 3, as soon as the two insulating body 2a, 2b are plugged together. The one connector portion 9a of the insulator 2a is formed in a plug shape. The other connector portion 9b of the insulating body 2b is made in a female form. For this purpose, the female form of the insulating body 2b has three plug-in sleeves protruding axially from one another and a triple plug, in which three plug contacts (female contacts) are accommodated and which is designed as a monolithic composite. Corresponding to this, the socket-shaped connector portion 9a of the insulator 2a on three cylindrical receptacles into which the cylindrical sockets of the connector portions 9b are inserted. Die beiden Steckverbindungsabschnitte 9b bzw. In addition, a receptacle adapted to the dome-like triple plug of the insulating body 2 is provided, into which the triple plug-in dome can be inserted axially. The sockets of the connector sections 9b form simple, cylindrical plug-in dome. The axial insertion depth of the connector portions of the two insulating body 2a, 2b is chosen so large that a kink and tilt safety in the region of the connector in collapsed condition of the insulating body 2a, 2b is given. As based on the Fig. 4 to 9 can be seen, in the corresponding connector portions, which are made of the plastic material of the respective monolithic insulating body 2a, 2b, respectively, the metallic, electrical plug contacts aligned, the inevitably when plugging the insulator 2a, 2b their experience mutual electrical contact. The corresponding plug-in profiling of the connector sections 9a, 9b are designed so accurate that after mating a backlash-free seat is ensured with high contact forces.

In order to prevent the assembled insulating body 2a, 2b from loosening again, the locking sleeve 3 is provided, which is held captive on the insulating body 2b, but rotatably. For this purpose, the locking sleeve 3 is snapped in a simple manner to a corresponding profiling on the outer circumference of the connecting portion of the insulating body 2b. In addition, a small leaf spring 7 is provided, which serves as a reverse rotation for the locking sleeve 3 in the locked state of the connector parts 2a, 2b, 4 together ( Fig. 11 ). For interlocking axial locking of the two connector parts 2a, 2b, 4 with each other, the locking sleeve 3 is provided with cams 13 which are formed in bayonet-like recesses 12 (FIG. Fig. 6 ) immerse axially on the other insulating body 2a and achieve the desired axial positive locking by turning.

To seal the connector parts 2a, 2b, 4 together in a plugged state an additional O-ring seal 6 is provided in the region of the locking sleeve 3, which in the assembled state as shown in the Fig. 5 and 9 is positioned. The connector unit 1 is dustproof and waterproof overall and meets the protection class IP65.

An unlocked or locked state of the connector unit 1 is clearly visible to a viewer from the outside. Once the connector parts 2a, 2b, 4 of the connector unit 1 are axially plugged together, but not yet locked, planar surface portions of the insulating body 2a, 2b and the locking sleeve 3 are aligned with each other, as Fig. 10 can be seen. The plane surface sections are on all three components increased radially to the plug-in axis of the connector unit, as based on the Fig. 10 is apparent. By simple rotation of the locking sleeve 3, the plug connection unit is transferred into its axially locked state in which the arranged on the inside of the locking sleeve 3 cam 13 in the circumferentially extending pockets of the recesses 12. As a result of this rotation, the plane surface section of the locking sleeve 3 is offset in the circumferential direction relative to the planar surface sections of the adjacent insulating bodies 2 a, 2 b (FIG. Fig. 11 ). This makes it clear to a viewer that the connector unit 1 is in its locked state.

The multipolar connector unit after the Fig. 12 to 16 is essentially the same as previously Fig. 1 to 11 described in detail connector unit. To avoid repetition is therefore on the comments on the connector unit after the Fig. 1 to 11 directed. Functionally identical components and sections of the connector unit according to Fig. 12 to 16 have the same reference numerals but with the addition of one. In the embodiment of the Fig. 12 to 16 In addition, corresponding connection cables for the two plug-in connection parts 2'a, 2'b are provided, which are provided with a plurality of cable cores K for contacting each with an electrical plug-in contact 5'a, 5'b. The connection of the cable cores K with the corresponding electrical plug contacts 5'a, 5'b takes place in the illustrated example via crimping. In the same way, connection and contacting of the connection cable to the connector unit according to the Fig. 1 to 11 although this is not shown there.

The following is on the differences of the connector unit after the Fig. 12 to 16 relative to the connector unit after the Fig. 1 to 11 received.

As a reverse rotation lock for the locking sleeve 3 'is in the embodiment of the Fig. 12 to 16 instead of a separate small leaf spring, a latching nose combination 15 is provided, corresponding latching lugs being provided on the locking sleeve 3 'and on the plug connection part 2'b. The corresponding locking lugs are integrally formed on the locking sleeve 3 'and on the insulating body of the connector part 2'b.

Both plug connection parts each have a monolithic insulating body 2'a, 2'b, which are each provided with a total of six receiving areas 16a, 16b, which open towards a rear end side of the respective insulating body 2'a, 2'b, viewed in the plug connection direction are. The receiving areas 16a, 16b are used for axial insertion of the corresponding female or male electrical plug contacts 5'a, 5'b from the back to allow the axial locking within the respective insulator 2'a, 2'b. Each electrical plug-in contact 5'a, 5'b is connected by crimping in each case with a cable core K of a cable harness of the respective electrical connection cable. Each of the cable cores K has been previously pulled through a corresponding recess of serving as a closure element closure plate 14a, 14b. The recesses are matched to the respective insulating sheath of the corresponding cable core in such a way that each recess tightly encloses the respective cable core K after being pulled through by the closure disk 14a, 14b. For this purpose, the recesses each have a circular cross-section. The closure plate 14a, 14b is also provided on both end sides in the edge region of each recess with an integrally formed, annular thickening, which serves as a plug-in profiling for insertion into the corresponding receiving area 16a, 16b. The thickenings in the form of extending around the recesses annular webs are in their dimensions so on the cross sections matched to the receiving areas 16a, 16b, that they axially so far from the respective rear end side of the respective insulating 2'a, 2'b ago in the receiving areas 16a, 16b inserted so far until the flat end face of the respective shutter disc 14a, 14b flush with the Front side of the corresponding insulating body 2'a, 2'b rests. Based on Fig. 13 It can be seen that in this way the cable cores K, which were connected with their frontal strands with the corresponding plug contacts 5'a, 5'b, by serving as a back stopper for the receiving areas 16a, 16b of the insulator 2'a, 2'b closure disc 14a, 14b are positioned substantially coaxially aligned with the receiving areas 16a, 16b of the insulating body 2'a, 2'b.

After this pre-assembly, the encapsulation with the protective coating 4 'takes place by means of a suitable plastic material, preferably a thermoplastic elastomer. Due to the dense overlay of the closure disks 14a, 14b on the respective rear end side of the insulating body 2'a, 2'b, no potting compound of this protective coating 4 'can penetrate into the receiving regions 16a, 16b of the insulating body 2'a, 2'b. Rather, between the cable cores K and the inner walls of the receiving areas 16a, 16b remains a free space, which allows a certain radial play and thus a certain mobility of the cable cores K within the receiving areas 16a, 16b. The fact that the electrical plug contacts 5'a, 5'b are axially locked only in a central region, the electrical plug contacts 5'a, 5'b can make oblique to the storage in the region of the latches in certain tolerances and yield. As a result, a subsequent plug connection process is facilitated with the corresponding connector part. For the socket-and plug-shaped plug-in contacts 5a, 5'b, which are to be connected in pairs, can be limited in their alignment with each other, which facilitates the axially brought-in plug-in operation. The shutter disc 14a, 14b becomes on the one hand non-positively due to the connections of the ring lands in the recesses with the receiving areas 16a, 16b and on the other form and / or cohesively by the overmolded protective casing 4 'at the respective rear end face of the insulating 2'a, 2'b held.

Claims (9)

1. Multipole plug-type connection unit for three-phase alternating current (AC) systems, comprising two plug-type connection parts (2'a, 2'b) which are complementary to one another for plugging one inside the other without bending, and comprising a locking sleeve (3') which secures the plug-type connection parts (2'a, 2'b) axially against one another in the plugged-together state, each plug-type connection part (2'a, 2'b) being designed as a monolithic insulating body, in which a plurality of electrical plug-type contacts (5'a, 5'b) are latched axially,
   characterized in that
   an outer diameter of the plug-type connection parts (2'a, 2'b) and of the locking sleeve (3') is less than 23 mm, in that the plug-type connection unit (1) is designed to transmit voltage and current intensity ranges of up to 630 volts/16 amperes, and in that a reverse rotation prevention means, which is designed as a latching lug combination (15), is assigned to the locking sleeve (3'), wherein corresponding latching lugs are integrally molded to the locking sleeve (3') and/or the insulating body.
2. Multipole plug-type connection unit according to claim 1, characterized in that electrical cable wires of a cable having a wire cross section of up to 2.5 mm² are connected to the electrical plug-type contacts (5'a, 5'b).
3. Multipole plug-type connection unit according to claim 2, characterized in that the electrical plug-type contacts (5'a, 5'b) comprise at least three contacts, which are designed for maximum voltage and current intensity ranges of up to 630 V/16 A.
4. Multipole plug-type connection unit according to claim 2 or 3, characterized in that the electrical plug-type contacts (5'a, 5'b) comprise at least two additional contacts, which are designed for minimum voltage and current intensity ranges above 63 V/10 A.
5. Multipole plug-type connection unit according to claim 1, characterized in that each insulating body is encapsulated by injection molding with a protective sheath (4'), which sheath consists of an elastic plastics material and comprises a strain relief means surrounding the cable of the respective plug-type connection part (2'a, 2'b).
6. Multipole plug-type connection unit according to claim 5, characterized in that each insulating body (2'a, 2'b) is provided with a sealing element (14a, 14b) enclosing the cable wires (K) in an insertion region of the cable wires (K), said sealing element sealing off the rear receiving regions (16a, 16b) of the insulating body (2'a, 2'b) for the plug-type contacts (5'a, 5'b).
7. Multipole plug-type connection unit according to claim 5, characterized in that an outer jacket of each insulating body is provided with profiled portions (8) for achieving an additional form-fitting connection for the protective sheath (4') applied by injection molding.
8. Multipole plug-type connection unit according to at least one of the preceding claims, characterized in that the plug-type connection parts (2'a, 2'b) and the locking sleeve (3') are configured as a circular plug-type connection, wherein the outer contours of the plug-type connection parts and of the locking sleeve are at least substantially aligned with one another in the plugged-together state.
9. Multipole plug-type connection unit according to at least one of the preceding claims, characterized in that the plug-type connection parts are configured as a male connector/female connector combination, as a male elbow connector/female elbow connector combination, as couplings, or as bushings.

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