EP3172742B1 - Verfahren zur herstellung einer elektrischen leitung, elektrische leitung sowie kraftfahrzeug-bordnetz mit einer entsprechenden elektrischen leitung - Google Patents

Verfahren zur herstellung einer elektrischen leitung, elektrische leitung sowie kraftfahrzeug-bordnetz mit einer entsprechenden elektrischen leitung Download PDF

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Publication number
EP3172742B1
EP3172742B1 EP15752932.2A EP15752932A EP3172742B1 EP 3172742 B1 EP3172742 B1 EP 3172742B1 EP 15752932 A EP15752932 A EP 15752932A EP 3172742 B1 EP3172742 B1 EP 3172742B1
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EP
European Patent Office
Prior art keywords
wire bundle
individual wires
shaping element
wire
electrical line
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.)
Active
Application number
EP15752932.2A
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German (de)
English (en)
French (fr)
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EP3172742A1 (de
Inventor
Erwin Köppendörfer
Markus Schill
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.)
Leoni Kabel GmbH
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Leoni Kabel GmbH
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Filing date
Publication date
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Publication of EP3172742A1 publication Critical patent/EP3172742A1/de
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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/0006—Apparatus or processes specially adapted for manufacturing conductors or cables for reducing the size of conductors or cables
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C23/00—Extruding metal; Impact extrusion
    • B21C23/22—Making metal-coated products; Making products from two or more metals
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/06—Insulating conductors or cables
    • H01B13/14—Insulating conductors or cables by extrusion
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/02—Disposition of insulation

Definitions

  • the invention relates to a method for producing an electrical line with at least one wire, which has a wire bundle made up of a number of individual wires and an insulating sheathing surrounding the wire bundle.
  • the invention also relates to such an electrical line and a vehicle electrical system with a corresponding electrical line.
  • Such a method and such an electrical line are for example from U.S. 4,471,161 refer to. It describes a stranded wire and its manufacture, in which a plurality of individual wires are twisted together to form a strand with the aid of a stranding machine. The stranded wire produced in this way is also surrounded by an extruded sheathing to form the core.
  • cores with stranded conductors are used in particular for applications in which a high degree of flexibility of the line is desired. Due to the large number of individual wires in the stranded conductor, there is such flexibility compared, for example, to cores with a solid wire as the conductor.
  • the US4426837 B shows a stranding machine for the production of stranded individual wires with opposing lay (SZ stranding).
  • SZ stranding stranded individual wires with opposing lay
  • the individual wires are twisted together with an elongated tube within which they are routed. Due to the rotation of the tube, the individual wires are stranded together as they exit the tube and are then fed to an extruder for the application of a sheath.
  • stranded conductors In the production of stranded conductors, for example, it is from the DE 689 15 881 T2 , from the EP 1 191 545 A1 , from the JPS5622008 A , from the U.S. 2002/0050395 A1 or also from the US5449861B known in principle to compact the stranded conductors, i.e. to press the individual wires against one another.
  • the individual wires are regularly twisted during the stranding or stranding process or else bundles of individual wires are first fed to a stranding element, for example a stranding nipple or a stranding disk.
  • the stranding nipple is designed accordingly, for example, so that compacting takes place as a result.
  • the use of a drawing die is known.
  • the wire bundle brought together in this way is fed to a stranding machine, at the end of which the stranded wire bundle is wound onto a take-up spool.
  • the insulating covering is usually applied around the stranded wire bundle afterwards in a separate process step.
  • the design of the stranded conductors is also typically adapted to specific standards, such as can be found in JIS C 3406-1987 or JASO D 611-94 .
  • the stranded conductors in the automotive sector are typically designed for low voltages. As a rule, they should be as compact as possible and also light. With regard to the most compact configuration possible, it is known, for example from JASO D 611-94, to compact the stranded conductors in order to press the stranded assembly in particular into a circular shape. To reduce weight, lines with reduced, thin-walled insulation, so-called FLRY lines, are known.
  • Stranded conductors for the automotive sector for low voltages and low currents typically have a stranding element made up of a large number of individual wires, usually 7-70, in particular 7-37, each of which has an individual wire diameter in the range from 0.18 to 0.32 mm, see above that the stranded conductor has a diameter in the range of about 0.8mm to 2mm.
  • the invention is based on the object of enabling a cost-effective production of a flexible line.
  • the method is used here to produce a cable with a wire bundle made up of a number of individual wires and with an insulating sheath.
  • the sheathing is produced by means of an extruder, for which purpose the wire bundle made up of long individual wires is fed continuously to the extruder in a feed area.
  • the wire bundle is guided through a shaping element in the feed area directly in front of the extruder along a central longitudinal axis, with the shaping element rotating about its central longitudinal axis and the wire bundle.
  • the insulating sheathing is applied to the wire bundle by means of the extruder. There is therefore a relative rotational movement of the shaping element around the bundle of wires.
  • the desired cross-sectional shape of the wire bundle in the finished strand is set by the shaping element.
  • the individual wires of the wire bundle which are in particular loose, are brought together in the radial direction.
  • the wire bundle is thus quasi prepared immediately before the extruder in the feed area for treatment in the extruder, which, among other things, facilitates the application of the insulating sheathing to the wire bundle.
  • This configuration is based on the basic idea of dispensing with the expensive stranding using a stranding machine and feeding the wire bundle to the extruder without being stranded, or at least without a targeted stranding.
  • the shaping element thus only serves to bring the wire bundle into a desired, for example, circular shape.
  • the wire bundle does not rotate with the rotating shaping element, nor does the individual wires twist relative to one another with the aid of the rotating shaping element.
  • the wire bundle becomes in this shape impressed on the wire bundle by the shaping element then fed directly to the extruder, so that the insulation applied by the extrusion process keeps the wire bundle in the specified desired geometry. “Immediately following” is therefore understood to mean that the geometry predetermined by the shaping element is still retained and is fixed directly in an extrusion step that immediately follows both in terms of time and space.
  • the rotating shaping element It is of particular importance for the rotating shaping element that it rotates about its central longitudinal axis, ie usually about a direction in which the individual wires are fed. As a result, forces that act on the individual wires when the individual wires are passed through the shaping element are better distributed, since the shaping element rotates relative to the wire bundle. As a result, the stress on the individual wire is reduced and the risk of the wire tearing off while the individual wires are being guided through the shaping element is reduced.
  • stranding is generally understood to mean any targeted twisting or twisting of the individual wires relative to one another about a central longitudinal axis after they have been unwound from a drum.
  • stranding is also understood in a broader sense as so-called twisting, in which the individual wires in the bundle are twisted about a central longitudinal axis, with this twisting not achieving a defined position of the individual wires, as is the case in the classic stranding process.
  • the line produced in this way is manufactured in a continuous process as a quasi endless product with a length of typically several hundred meters. After the sheathing has been applied, the cable is therefore typically also rolled up on a drum.
  • such a targeted twisting or stranding and in particular a stranding machine is therefore complete omitted and the individual wires are in the wire bundle untwisted or at least largely untwisted.
  • the individual wires therefore run parallel to one another to a good approximation. They are fed to the shaping element at least essentially and preferably exactly in parallel and are also carried on in parallel therein and leave the shaping element untwisted.
  • lay length describes the length in which the wire bundle rotates once through 360° around its own central longitudinal axis.
  • a feed that is not exactly parallel of this kind results at most from the wire bundle being unwound from a, in particular, stationary drum.
  • the arrangement of the shaping unit directly in front of the extruder can also be used with stranded conductors.
  • the shaping element rotates around the bundle of wires, as a result of which the stress on the individual wires is kept low. In this case, therefore, an already stranded wire bundle is fed to the shaping element. This is in turn carried out by the rotating shaping element without it rotating with it.
  • a desired shape takes place, so that the finished line has good roundness and the subsequently applied sheathing has a high degree of concentricity with the wire bundle.
  • the wire bundle is brought into the desired shape, in particular rounded, by the shaping element after the stranding process and, for example, after several deflections.
  • the individual wires in the non-stranded embodiment variant are usually unwound as a more or less loose bundle from a supply, in particular a drum, and fed to the shaping element. If necessary, several individual wires or bundles of individual wires are first brought together before the shaping element from several stocks and are combined in the shaping element to form a wire bundle.
  • a particular advantage of the large to infinite lay length can also be seen in the material and weight savings due to the large or infinite lay length, which is of particular importance for the intended field of application in the automotive sector. Compared to conventional stranded conductors, savings of around 1% can be achieved through this alone.
  • the wire bundle is prepared with the aid of the shaping element directly in front of the extruder.
  • the shaping element in which the wire bundle is prepared is positioned preferably less than 2 m and in particular less than 0.5 m away from the extruder, ie quasi the extruder inlet.
  • the shaping element is also used to form the individual wires transversely to the longitudinal direction of the individual wires to apply to each other, thereby typically forming a wire bundle with approximately cylinder jacket-shaped surface.
  • a wire bundle is created which has the smallest possible thickness or the smallest possible diameter.
  • the individual wires are not deformed here. The individual wires placed against one another in this way are immediately subsequently covered in the extruder with the insulating sheath, typically a plastic, so that the wire bundle is held by the sheath in its shape specified by the shaping element.
  • the shaping element is advantageously designed as a shaping sleeve, i.e. as a body that is at least partially in the shape of a hollow cylinder and/or a truncated cone, through which the wire bundle is guided in the feed area immediately in front of the extruder.
  • the dimensions of the shaping sleeve are selected in such a way that the individual wires in the wire bundle are deformed in their relative position to the longitudinal axis of the wire bundle, but are not deformed geometrically.
  • the shaping element not only results in a type of alignment or repositioning of the individual wires in the wire bundle, but also a compression of the wire bundle, in which the individual wires in the wire bundle are pressed together as they are pulled through the shaping element, in order to increase the thickness of the wire bundle or to further reduce the diameter of the wire bundle.
  • the shaping element has a conical inlet area and tapers to a final diameter which is dimensioned in such a way that the desired compression takes place. Compression is understood here to mean a reduction in the diameter of the wire bundle of, for example, 1% to 3%, based on a diameter in the most compact possible arrangement of the individual wires without deformation of the individual wires themselves.
  • the particular advantage of compression is that of better rounding , so that the surface of the wire bundle is further approximated to a cylinder surface. This creates the cladding material required for extrusion and for cladding kept low. Furthermore, the wire bundle is held together at least somewhat by the compression, so that the individual wires do not diverge on the way to the extruder.
  • the shaping element rotates about the central longitudinal axis.
  • the individual wires lying on the outside are highly stressed in the longitudinal direction. Under certain circumstances, this can lead to the individual wires being torn off. Due to the rotation of the shaping element, the longitudinal forces that occur are now diverted laterally, as a result of which the stress on the individual wire is reduced.
  • the rotation speed is preferably several 100 rpm and more preferably greater than 500 rpm.
  • the shaping element is usually actively driven.
  • the risk of such a wire tearing off is also present in particular as a result of the usually very small cross sections of the individual wires.
  • the individual wires which usually consist of copper or a copper alloy, typically have a diameter of ⁇ 1 mm, in particular also ⁇ 0.5 mm.
  • comparatively small cables are produced, for example according to the standards mentioned at the beginning, in which the diameter of the entire wire bundle within the core is a maximum in the range of 2 mm to 4 mm lies.
  • the diameter of the entire wire bundle within the core is a maximum in the range of 2 mm to 4 mm lies.
  • only a limited number of individual wires usually less than 60, preferably less than 20, individual wires is provided.
  • the individual wires typically have a diameter in the range from 0.11 to 0.40 mm or even up to 0.60 mm.
  • a wire manufactured in this way has a comparable level of resistance to breakage as a classic stranded conductor in which the individual wires are twisted together.
  • the manufacturing effort is lower than with a classic stranded conductor, which means that the production costs are also lower.
  • Such a cable thus represents a kind of intermediate solution between a solid wire conductor and a classic stranded conductor, which is advantageous for various areas of application.
  • lines are preferably produced with at least one such core with a wire bundle made up of a number of individual wires that are not twisted.
  • Such a core is used in particular for single-core lines but also for multi-core lines.
  • the individual cores are preferably combined by a common cable sheath.
  • the individual cores are connected to one another, for example in the manner of a (raster) ribbon cable.
  • Such single-core or multi-core cables are used in particular in the motor vehicle sector.
  • the method described here with the direct arrangement of the shaping element immediately before the extrusion process is used in particular for non-stranded, ie untwisted, wire bundles. In principle, however, this method can also be used in the case of stranded wire bundles, ie stranded wire bundles and, in particular, also in the case of twisted wire bundles.
  • the wire bundle is compacted with the aid of the compacting unit, ie in particular the shaping sleeve.
  • each wire bundle 6 consists of seven individual wires 10 with a diameter d1 ⁇ 1 mm, with six individual wires 10 bearing against a central individual wire 10 on the peripheral side.
  • the wire bundle 6 is indicated as a compressed wire bundle 6 and the individual wires 10 are pressed together accordingly.
  • the thickness of each wire bundle 6 or the diameter of each wire bundle 6 is reduced and the cross-sectional shape of each individual wire 10 deviates from a round shape due to the deformation that each individual wire 10 undergoes in the course of compression of the wire bundles 6.
  • the overall diameter d2 of the wire bundle 6 is in the range of 2 to 3 mm, for example.
  • the two wire bundles 6 are each held in their shape in part even without the insulating sheathing 8 .
  • the cohesion between the individual wires 10 is typically not as pronounced as in the case of a classic stranded conductor, in which the shape of the stranded wire is mainly due to the targeted twisting of the individual wires 10 .
  • Such a targeted twisting is not given in the wire bundles 6, as this from 2 emerges schematically.
  • the individual wires 10 therefore run at least essentially parallel to one another and to a central longitudinal axis. So they are untwisted.
  • a corresponding cable 2 is manufactured in a production plant 12, as shown in 3 is not drawn to scale.
  • the prefabricated individual wires 10 are unwound from a wire drum 14, for example as a loose wire bundle 6, and fed continuously to an extruder 16, in which they are provided with the insulating sheathing 8.
  • the individual wires 10 are connected by a Compression unit, namely a shaping sleeve 18, with the help of which the individual wires 10 are bundled and deformed into a compressed wire bundle 6.
  • An outlet of the shaping sleeve 18 is spaced from an inlet of the extruder by a distance a.
  • the distance a is preferably a maximum of a few meters, in particular less than 2 m, preferably around 0.5 m.
  • the processing speed ie the speed at which the wire bundle 6 is drawn through the shaping sleeve 18, is typically 1000-2000 m/min.
  • the shaping sleeve 18 rotates around the central longitudinal axis 20 of the wire bundle 6. It preferably rotates at a speed of more than 500 rpm, in particular around 1000 rpm. at least
  • the sheath 8 is then extruded onto the wire bundle in the extruder 16 .
  • the individual wires 10 of the bundle 6 are hard as drawn and should not be soft-annealed. Studies have shown that only hard-drawn wires can be compressed to the desired extent. Namely, annealed wire material preferably flows only in the axial direction, without that the desired compression, ie deformation in the radial direction of the individual wires 10 takes place.
  • the bundle 6 is not unwound from a rotating wire drum 14 during the manufacture of the cable 2, but rather from a stationary wire drum 14, this typically leads to a twisting of the individual wires 10 in the wire bundle 6, which is not intentionally caused, with a lay length s of, for example, 2 m, like this in 4 is sketched.
  • the lay length s denotes the length in which the wire bundle rotates once through 360° around its own central longitudinal axis.
  • the length of lay s of the twisting or twisting caused by the unwinding process essentially depends on the diameter of the wire drum 14 and is significantly greater than a length of lay that is produced in a targeted manner according to the prior art.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Processes Specially Adapted For Manufacturing Cables (AREA)
  • Non-Insulated Conductors (AREA)
  • Insulated Conductors (AREA)
EP15752932.2A 2014-07-23 2015-07-22 Verfahren zur herstellung einer elektrischen leitung, elektrische leitung sowie kraftfahrzeug-bordnetz mit einer entsprechenden elektrischen leitung Active EP3172742B1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102014214461.2A DE102014214461A1 (de) 2014-07-23 2014-07-23 Verfahren zur Herstellung einer elektrischen Leitung, elektrische Leitung sowie Kraftfahrzeug-Bordnetz mit einer entsprechenden elektrischen Leitung
PCT/EP2015/066800 WO2016012519A1 (de) 2014-07-23 2015-07-22 Verfahren zur herstellung einer elektrischen leitung, elektrische leitung sowie kraftfahrzeug-bordnetz mit einer entsprechenden elektrischen leitung

Publications (2)

Publication Number Publication Date
EP3172742A1 EP3172742A1 (de) 2017-05-31
EP3172742B1 true EP3172742B1 (de) 2023-01-11

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EP15752932.2A Active EP3172742B1 (de) 2014-07-23 2015-07-22 Verfahren zur herstellung einer elektrischen leitung, elektrische leitung sowie kraftfahrzeug-bordnetz mit einer entsprechenden elektrischen leitung

Country Status (6)

Country Link
US (1) US10566113B2 (ja)
EP (1) EP3172742B1 (ja)
JP (1) JP6738511B2 (ja)
CN (1) CN106471587B (ja)
DE (1) DE102014214461A1 (ja)
WO (1) WO2016012519A1 (ja)

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EP0802701A2 (en) * 1996-04-19 1997-10-22 Glenwood Franklin Heizer Variable power limiting heat tracing cable
US5831210A (en) * 1996-02-21 1998-11-03 Nugent; Steven Floyd Balanced audio interconnect cable with helical geometry
EP1191545A1 (de) * 2000-09-20 2002-03-27 Nexans Litzenleiter
US20020050395A1 (en) * 2000-07-10 2002-05-02 Katsuhiko Kusumoto Coil conductor for dynamoelectric machine
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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2262716A (en) * 1936-12-02 1941-11-11 Gen Cable Corp Method and apparatus for producing cable sheaths
JPS5622008A (en) * 1979-07-31 1981-03-02 Fujikura Ltd Method of manufacturing coated hard copper twisted wire
US4426837A (en) * 1982-08-30 1984-01-24 Northern Telecom Limited Apparatus for stranding wire
US5831210A (en) * 1996-02-21 1998-11-03 Nugent; Steven Floyd Balanced audio interconnect cable with helical geometry
EP0802701A2 (en) * 1996-04-19 1997-10-22 Glenwood Franklin Heizer Variable power limiting heat tracing cable
US20020050395A1 (en) * 2000-07-10 2002-05-02 Katsuhiko Kusumoto Coil conductor for dynamoelectric machine
EP1191545A1 (de) * 2000-09-20 2002-03-27 Nexans Litzenleiter
US20130161855A1 (en) * 2011-12-21 2013-06-27 Belden Inc. Systems and methods for producing cable

Also Published As

Publication number Publication date
DE102014214461A1 (de) 2016-01-28
JP6738511B2 (ja) 2020-08-12
US10566113B2 (en) 2020-02-18
US20170133128A1 (en) 2017-05-11
CN106471587B (zh) 2019-08-27
CN106471587A (zh) 2017-03-01
JP2017522701A (ja) 2017-08-10
EP3172742A1 (de) 2017-05-31
WO2016012519A1 (de) 2016-01-28

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