EP3454420B1 - Method for connecting an electrical aluminium conduit with an aluminium pipe - Google Patents

Method for connecting an electrical aluminium conduit with an aluminium pipe Download PDF

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Publication number
EP3454420B1
EP3454420B1 EP18192956.3A EP18192956A EP3454420B1 EP 3454420 B1 EP3454420 B1 EP 3454420B1 EP 18192956 A EP18192956 A EP 18192956A EP 3454420 B1 EP3454420 B1 EP 3454420B1
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EP
European Patent Office
Prior art keywords
crimping
tube
wire
welding
aluminium
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EP18192956.3A
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German (de)
French (fr)
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EP3454420A1 (en
Inventor
Olaf Strunk
Nico Langberg
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Strunk Connect Automated Solutions GmbH and Co KG
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Strunk Connect Automated Solutions GmbH and Co KG
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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
    • 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
    • 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
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
    • H01R43/0214—Resistance welding
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • 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
    • H01R4/187—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 combined with soldering or welding
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • 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
    • H01R4/625—Soldered or welded connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/28—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for wire processing before connecting to contact members, not provided for in groups H01R43/02 - H01R43/26
    • 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

Definitions

  • the invention relates to a method for connecting an electrical line having at least one wire made of aluminum to a connecting element made of aluminum and having a tube or a sleeve.
  • connection element z. B. is connected to a conductor by crimping and / or soldering.
  • This connection which has a certain resistance, is generally sufficient for many applications.
  • electrical connections are to be used for high currents or connections with large cross sections, e.g. B. in the automotive high-voltage sector, such as for electric vehicles, through which high currents flow continuously or during load changes, the aforementioned resistance already leads to unacceptable heating of the connection between the connection element and the line.
  • This breaking may still work with a few wires or strands made up of them, but with thicker electrical cables required for power supply in automobiles, this at least partial breaking of the oxide layers is no longer sufficient to be able to produce a halfway acceptable welded connection.
  • the invention is therefore based on the object of demonstrating a method by means of which as many areas of the electrical line as possible can be welded to the connection element.
  • an end piece of the electrical line is first stripped, that the stripped area of the electrical line is inserted into the tube of the connecting element, that the tube is placed in the area that is in the area of the stripped tip of the line in such a way is squeezed so that the at least one wire is held in the tube in such a way that a relative movement between the tube and the at least one wire is prevented, and then the tube is in a second region of the stripped electrical line, which is located further away from the end of the electrical line as the first crimping area, is crimped a second time and then resistance welding of the pipe with the at least one wire in the second crimping area takes place.
  • insulated wires e.g. varnished wires
  • stripping is not absolutely necessary as the insulation evaporates during the later welding process.
  • the first crimping process ensures that the at least one wire of any cross-section, but usually strands and then all of the stranded wires, are fixed in such a way that relative movements are not possible between the tube and the individual wires or between the individual wires themselves are. Since the stranded wire is still in the insulation at the other end of the electrical cable, no relative movement of the wires to one another is to be expected.
  • two squeezing processes can also preferably be carried out simultaneously and the second squeezing process can be placed between the two first squeezing positions. This means that the at least one wire, usually the wires of the strand for the second crimping process, is fixed from both sides in such a way that basically no movement of the wires against each other is possible.
  • the second crimping process is now carried out, the only thing left for the at least one wire of any cross-section or the individual wires of the strand of the electrical cable, in addition to being compressed, is an elongation of each of the individual wires. This elongation occurs for all stranded wires. This causes the oxide layer to burst from the wires, so that all of the stranded wires are freed from the oxide layer as a result of the lengthening.
  • the subsequent welding process can now take place at temperatures that are usual for aluminum. Since all aluminum wires and the pipe are free of the oxide layer, very good welding is achieved; any insulation is evaporated at these temperatures.
  • the second squeezing process z. B. could be carried out by a crimping tool and only then could the welding electrodes be attached to the location of the second crimping process, it has proven to be advantageous that the second crimping process is carried out by at least two welding electrodes. This means that an upsetting tool for the second squeezing process can be saved cost-effectively and the upsetting process can be carried out by the welding electrodes.
  • the first crushing process is expediently carried out by a compression tool, whereby this compression tool should be designed in at least two parts and this two-part or multi-part compression tool completely encloses the pipe after the crushing process.
  • the upsetting tool remains closed during the second crimping process, i.e. H. the cable is not moved and is squeezed at a second point, and the compression tool is only opened after the welding process has been completed.
  • the device for moving the electrical conductor is saved in the corresponding upsetting and welding device.
  • a second drive for the second crimping tool is necessary.
  • the two crimping processes can be carried out much more quickly one after the other if the crimping tools are arranged at two locations next to one another in the welding machine.
  • the Figure 1 shows an electrical line 1, consisting of an aluminum strand 2 which is surrounded by insulation 3. The individual wires of the aluminum strand 2 are indicated. Furthermore, a tube 4 is shown, into whose first open end 5 the aluminum strand 2 of the stripped end of the electrical line 1 is inserted, and at whose second end 6 the connecting element 7 is formed.
  • Figure 2 shows the electrical cable 1 with the connecting element 7 after the crimping and welding process.
  • a first pinch area 9 can be seen in the area of the end 8 of the aluminum strand 2.
  • the aluminum strand 2 is squeezed by the tube 4 in such a way that the individual wires of the aluminum strand 2 can no longer move against each other.
  • a second squeezing area 10 can be seen in the direction of the insulation 3.
  • the aluminum strand 2 was stretched and pressed due to the squeezing process and the fact that the aluminum strand 2 could not perform relative movement to one another either in the area of the squeezing area 9 or in the area of the insulation 3.
  • the oxide layer on almost all of the wires of the aluminum strand 2 has broken down.
  • its internal oxide layer is also broken.

Description

Die Erfindung betrifft ein Verfahren zum Verbinden einer, mindestens einen Draht aus Aluminium aufweisenden elektrischen Leitung mit einem aus Aluminium bestehenden, ein Rohr bzw. eine Hülse aufweisenden Anschlusselement.The invention relates to a method for connecting an electrical line having at least one wire made of aluminum to a connecting element made of aluminum and having a tube or a sleeve.

Für die Verwendung von elektrischen Leitungen insbesondere in Kraftfahrzeugen ist es bekannt, Kupfer bzw. Kupferlegierungen zu benutzen. Diese weisen jedoch ein hohes Gewicht auf. Um Gewicht und damit Spritkosten zu sparen ist es z. B. aus der EP 2 362 491 B1 bekannt, Aluminiumleitungen zu verwenden, welche mit Anschlusselementen aus anderen Materialien ausgestattet sind.For the use of electrical lines, particularly in motor vehicles, it is known to use copper or copper alloys. However, these are very heavy. In order to save weight and therefore fuel costs, it is e.g. B. from the EP 2 362 491 B1 known to use aluminum cables which are equipped with connection elements made of other materials.

Es sind Elektroanschlüsse in Kraftfahrzeugen bekannt, bei denen ein Anschlusselement z. B. durch Crimpen und / oder Löten mit einem Leiter verbunden ist. Diese, einen gewissen Widerstand aufweisende Verbindung reicht für viele Anwendungen grundsätzlich aus. Sollen jedoch elektrische Verbindungen für hohe Ströme oder Verbindungen mit großen Querschnitten, z. B. im automobilen Hochspannungsbereich, wie beispielsweise für Elektrofahrzeuge geschaffen werden, durch welche stetig oder im Lastwechsel hohe Ströme fließen, führt der zuvor erwähnte Widerstand bereits zu einer unzulässigen Erwärmung der Verbindung zwischen dem Anschlusselement und der Leitung.Electrical connections in motor vehicles are known in which a connection element z. B. is connected to a conductor by crimping and / or soldering. This connection, which has a certain resistance, is generally sufficient for many applications. However, if electrical connections are to be used for high currents or connections with large cross sections, e.g. B. in the automotive high-voltage sector, such as for electric vehicles, through which high currents flow continuously or during load changes, the aforementioned resistance already leads to unacceptable heating of the connection between the connection element and the line.

Daher schlägt die oben erwähnte EP 2 362 491 B1 neben einem Crimp-Schritt einen anschließenden Verschweiß-Schritt vor.Therefore suggests the above mentioned EP 2 362 491 B1 In addition to a crimping step, there is a subsequent welding step.

Beim Crimpen von Aluminiumleitern mit Anschlusselementen aus anderen Materialien ergeben sich jedoch Probleme mit den unterschiedlichen Wärmeausdehnungskoeffizienten der Materialien, welche nach der EP 2 362 491 B1 durch aufwendiges Einbringen von innenliegenden Vertiefungen in den Crimp-Abschnitt des Anschlusselements behoben werden sollen.However, when crimping aluminum conductors with connection elements made of other materials, problems arise with the different thermal expansion coefficients of the materials, which according to the EP 2 362 491 B1 should be remedied by laboriously introducing internal recesses into the crimp section of the connecting element.

Weitere Probleme ergeben sich bei der Verarbeitung von Aluminium, da Aluminium üblicherweise von einer Oxidschicht umgeben ist. Soll dieses Aluminium geschweißt werden, müssten Temperaturen von über 1500 °C aufgebracht werden, um die Oxidschicht zu schmelzen. Da Aluminium selbst jedoch schon bei ca. 660 °C schmilzt würden diese hohen Temperaturen zum Anschmelzen der Oxidschicht dazu führen, dass nach dem Schmelzen der Oxidschicht der Aluminiumkern verdampfen würde, so dass keine brauchbare Schweißverbindung entsteht.Further problems arise when processing aluminum, as aluminum is usually surrounded by an oxide layer. If this aluminum is to be welded, temperatures of over 1500 °C would have to be applied in order to melt the oxide layer. However, since aluminum itself melts at around 660 °C, these high temperatures for melting the oxide layer would mean that the aluminum core would evaporate after the oxide layer had melted, so that no usable weld connection would be created.

Aus diesem Grund schlägt die EP 2 362 491 B1 zunächst einen Crimp-Vorgang vor, bei dem durch Quetschen des Aluminiumdrahtes dessen Oxidschicht zumindest teilweise aufgebrochen wird.For this reason it beats EP 2 362 491 B1 First, a crimping process occurs, in which the oxide layer is at least partially broken by squeezing the aluminum wire.

Dieses Brechen mag noch bei wenigen Drähten bzw. aus diesen bestehenden Litzen funktionieren, bei in Automobilen für die Stromversorgung notwendigen dickeren elektrischen Leitungen reicht dieses zumindest teilweise Aufbrechen der Oxidschichten nicht mehr aus, um eine halbwegs annehmbare Schweißverbindung herstellen zu können.This breaking may still work with a few wires or strands made up of them, but with thicker electrical cables required for power supply in automobiles, this at least partial breaking of the oxide layers is no longer sufficient to be able to produce a halfway acceptable welded connection.

Aus der JP 2003 383 330 A ist bereits ein Verbinden eines Aluminiumdrahtes mit einer Aluminiumhülse eines Aluminiumanschlusses bekannt, wobei nach einem gleichzeitigen, in axialer Richtung auseinander gelegenem Quetschen der Hüles durch die Ultraschallenergie eines Ultraschallschweißverfahrens die Oxidschichten an der Verbindungsfläche zwischen Draht und Hülse zerstört werden und in diesem Bereich eine Verbindung hergestellt wird.From the JP 2003 383 330 A It is already known to connect an aluminum wire to an aluminum sleeve of an aluminum connection, after simultaneously squeezing the sleeve apart in the axial direction The ultrasonic energy of an ultrasonic welding process destroys the oxide layers on the connecting surface between the wire and the sleeve and creates a connection in this area.

Der Erfindung liegt daher die Aufgabe zugrunde, ein Verfahren aufzuzeigen, mittels dessen möglichst alle Bereiche der elektrischen Leitung mit dem Anschlusselement verschweißt werden können.The invention is therefore based on the object of demonstrating a method by means of which as many areas of the electrical line as possible can be welded to the connection element.

Diese Aufgabe wird erfindungsgemäß durch das Verfahren nach Anspruch 1 gelöst.This object is achieved according to the invention by the method according to claim 1.

Zur Lösung der Aufgabe wird vorgeschlagen, dass zunächst ein Endstück der elektrischen Leitung abisoliert wird, dass der abisolierte Bereich der elektrischen Leitung in das Rohr des Anschlusselements eingeführt wird, dass das Rohr in dem Bereich, der im Bereich der abisolierten Spitze der Leitung platziert ist derart gequetscht wird, dass der mindestens eine Draht in dem Rohr so gehalten ist, dass eine Relativbewegung zwischen Rohr und dem mindestens einen Draht verhindert ist, dass anschließend das Rohr in einem zweiten Bereich der abisolierten elektrischen Leitung, welche von dem Ende der elektrischen Leitung entfernter liegt als der erste Quetschbereich, ein zweites Mal gequetscht wird und anschließend ein Widerstandsschweißen des Rohrs mit dem mindestens einen Draht in dem zweiten Quetschbereich erfolgt.To solve the problem, it is proposed that an end piece of the electrical line is first stripped, that the stripped area of the electrical line is inserted into the tube of the connecting element, that the tube is placed in the area that is in the area of the stripped tip of the line in such a way is squeezed so that the at least one wire is held in the tube in such a way that a relative movement between the tube and the at least one wire is prevented, and then the tube is in a second region of the stripped electrical line, which is located further away from the end of the electrical line as the first crimping area, is crimped a second time and then resistance welding of the pipe with the at least one wire in the second crimping area takes place.

Es besteht aber auch die Möglichkeit isolierte Drähte z.B. lackisolierte Drähte zu verwenden, wobei ein Abisolieren nicht zwingend notwendig ist, da die Isolierung beim späteren Schweißvorgang verdampft.However, it is also possible to use insulated wires, e.g. varnished wires, although stripping is not absolutely necessary as the insulation evaporates during the later welding process.

Durch den ersten Quetschvorgang wird erreicht, dass der mindestens eine Draht beliebigen Querschnittes, in der Regel jedoch Litzen und dann sämtliche Drähte der Litze derart festgelegt werden, dass weder zwischen dem Rohr und den einzelnen Drähten noch zwischen den einzelnen Drähten selbst Relativbewegungen möglich sind. Da die Litze am anderen Ende der elektrischen Leitung noch in der Isolierung stecken, ist hier auch keine Relativbewegung der Drähte zueinander zu erwarten. Selbstverständlich können aber auch zwei Quetschvorgänge vorzugsweise gleichzeitig durchgeführt werden und der zweite Quetschvorgang zwischen den beiden ersten Quetschpositionen platziert werden. Damit ist der mindestens eine Draht, in der Regel sind es die Drähte der Litze für den zweiten Quetschvorgang von beiden Seiten so festgelegt, dass im Grunde keine Bewegung der Drähte mehr gegeneinander möglich ist.The first crimping process ensures that the at least one wire of any cross-section, but usually strands and then all of the stranded wires, are fixed in such a way that relative movements are not possible between the tube and the individual wires or between the individual wires themselves are. Since the stranded wire is still in the insulation at the other end of the electrical cable, no relative movement of the wires to one another is to be expected. Of course, two squeezing processes can also preferably be carried out simultaneously and the second squeezing process can be placed between the two first squeezing positions. This means that the at least one wire, usually the wires of the strand for the second crimping process, is fixed from both sides in such a way that basically no movement of the wires against each other is possible.

Wird nun der zweite Quetschvorgang durchgeführt, bleibt dem mindestens einen Draht beliebigen Querschnittes bzw. den einzelnen Drähten der Litze der elektrischen Leitung neben einem Komprimieren in sich nur eine Längung jeder der einzelnen Drähte übrig. Diese Längung erfolgt für alle Drähte der Litze. Dabei platzt die Oxidschicht von den Drähten an, so dass auch alle Drähte der Litze durch die Längung von der Oxidschicht befreit werden. Der dann folgende Schweißvorgang kann nunmehr bei Temperaturen, die für Aluminium üblich sind, erfolgen. Da alle Aluminiumdrähte und auch das Rohr von der Oxidschicht befreit sind, wird ein sehr gutes Durchschweißen bewirkt, eventuelle Isolierungen werden bei diesen Temperaturen verdampft.If the second crimping process is now carried out, the only thing left for the at least one wire of any cross-section or the individual wires of the strand of the electrical cable, in addition to being compressed, is an elongation of each of the individual wires. This elongation occurs for all stranded wires. This causes the oxide layer to burst from the wires, so that all of the stranded wires are freed from the oxide layer as a result of the lengthening. The subsequent welding process can now take place at temperatures that are usual for aluminum. Since all aluminum wires and the pipe are free of the oxide layer, very good welding is achieved; any insulation is evaporated at these temperatures.

Obwohl der zweite Quetschvorgang z. B. von einem Quetschwerkzeug durchgeführt werden könnte und anschließend erst die Schweißelektroden an die Stelle des zweiten Quetschvorgangs angebracht werden könnten, hat es sich als vorteilhaft erwiesen, dass der zweite Quetschvorgang von mindestens zwei Schweißelektroden durchgeführt wird. Dadurch kann kostengünstig ein Stauchwerkzeug für den zweiten Quetschvorgang eingespart werden und der Stauchvorgang von den Schweißelektroden durchgeführt werden.Although the second squeezing process z. B. could be carried out by a crimping tool and only then could the welding electrodes be attached to the location of the second crimping process, it has proven to be advantageous that the second crimping process is carried out by at least two welding electrodes. This means that an upsetting tool for the second squeezing process can be saved cost-effectively and the upsetting process can be carried out by the welding electrodes.

Soll nur ein Draht, z.B. ein dünner Anschlussdraht einer elektrischen Wicklung mit dem Rohr bzw. der Hülse verschweißt werden, ist auch hier eine optimale Längung, und damit eine optimale Entfernung der Oxidschicht möglich. Wenn das Ende des Drahtes im Bereich der ersten Quetschung fest gehalten ist.If only one wire, e.g. a thin connecting wire of an electrical winding, is to be welded to the tube or sleeve, this is also the optimal length. and thus optimal removal of the oxide layer is possible. When the end of the wire is held firmly in the area of the first pinch.

Vorteilhaft ist, wenn der zweite Quetschvorgang und das Verschweißen gleichzeitig erfolgen. Sicherlich ist es dabei sinnvoll, die Verschweißung erst am Ende des zweiten Quetschvorgangs durchzuführen.It is advantageous if the second squeezing process and the welding take place at the same time. It certainly makes sense to only carry out the welding at the end of the second crimping process.

Zweckmäßig wird der erste Quetschvorgang von einem Stauchwerkzeug bewirkt, wobei dieses Stauchwerkzeug mindestens zweiteilig ausgebildet sein sollte und dieses zwei- oder mehrteilige Stauchwerkzeug nach dem Quetschvorgang das Rohr komplett umschließt.The first crushing process is expediently carried out by a compression tool, whereby this compression tool should be designed in at least two parts and this two-part or multi-part compression tool completely encloses the pipe after the crushing process.

Obwohl selbstverständlich die Möglichkeit besteht, den ersten Quetschvorgang durchzuführen, anschließend die elektrische Leitung ein Stück weiterzubewegen und dann den zweiten Quetschvorgang auszuführen, hat es sich bewährt, dass das Stauchwerkzeug während des zweiten Quetschvorgangs geschlossen bleibt, d. h. die Leitung nicht bewegt wird, und an einer zweiten Stelle gequetscht wird, und erst nach Beendigung des Schweißvorgangs das Stauchwerkzeug geöffnet wird. Dadurch wird zwar bei der entsprechenden Stauch- und Schweißvorrichtung die Vorrichtung zum Bewegen des elektrischen Leiters eingespart. Es wird jedoch ein zweiter Antrieb für das zweite Quetschwerkzeug notwendig. Die beiden Quetschvorgänge lassen sich jedoch erheblich schneller hintereinander ausführen, wenn die Quetschwerkzeuge an zwei nebeneinander angeordneten Stellen in der Schweißmaschine angeordnet sind.Although it is of course possible to carry out the first crimping process, then move the electrical line a little further and then carry out the second crimping process, it has proven useful for the upsetting tool to remain closed during the second crimping process, i.e. H. the cable is not moved and is squeezed at a second point, and the compression tool is only opened after the welding process has been completed. This means that the device for moving the electrical conductor is saved in the corresponding upsetting and welding device. However, a second drive for the second crimping tool is necessary. However, the two crimping processes can be carried out much more quickly one after the other if the crimping tools are arranged at two locations next to one another in the welding machine.

Es hat sich bewährt, dass dem zweiten, im Wesentlichen in radialer Richtung wirkenden Quetschvorgang eine Komponente in axialer Richtung des mindestens einen Drahtes, weg vom ersten Quetschbereich überlagert wird.It has proven useful that the second squeezing process, which acts essentially in the radial direction, is superimposed on a component in the axial direction of the at least one wire, away from the first squeezing region.

Wenn es sich auch nur um sehr kleine Bewegungen in axialer Richtung handelt, ergibt sich eine noch besserte Längung des mindestens einen Drahtes, und damit ein noch besseres Entfernen der Oxidschicht.Even if there are only very small movements in the axial direction, this results in even better elongation of the at least one wire, and thus even better removal of the oxide layer.

Die Erfindung wird anhand einer Zeichnung näher erläutert. Dabei zeit

Fig. 1
einen erfindungsgemäßen elektrischen Leiter mit zugeordnetem Anschlusselement vor dem Quetsch- und Schweißschritt, und
Fig 2
einen erfindungsgemäßen elektrischen Leiter mit zugeordnetem Anschlusselement nach dem Quetsch- und Schweißschritt.
The invention is explained in more detail with reference to a drawing. This time
Fig. 1
an electrical conductor according to the invention with an associated connection element before the crimping and welding step, and
Fig 2
an electrical conductor according to the invention with an associated connection element after the crimping and welding step.

Die Figur 1 zeigt eine elektrische Leitung 1, bestehend aus einer Aluminiumlitze 2 die von einer Isolierung 3 umgeben ist. Die einzelnen Drähte der Aluminiumlitze 2 sind angedeutet. Weiterhin ist ein Rohr 4 gezeigt, in dessen erstes offene Ende 5 die Aluminiumlitze 2 des abisolierten Endes der elektrischen Leitung 1 eingeschoben ist, und an dessen zweitem Ende 6 das Anschlusselement 7 angeformt ist.The Figure 1 shows an electrical line 1, consisting of an aluminum strand 2 which is surrounded by insulation 3. The individual wires of the aluminum strand 2 are indicated. Furthermore, a tube 4 is shown, into whose first open end 5 the aluminum strand 2 of the stripped end of the electrical line 1 is inserted, and at whose second end 6 the connecting element 7 is formed.

Figur 2 zeigt die elektrische Leitung 1 mit dem Anschlusselement 7 nach dem Quetsch- und Schweißvorgang. Im Bereich des Endes 8 der Aluminiumlitze 2 ist ein erster Quetschbereich 9 zu erkennen. Hier ist die Aluminiumlitze 2 derart von dem Rohr 4 eingequetscht, dass sich die einzelnen Drähte der Aluminiumlitze 2 nicht mehr gegeneinander bewegen können. In Richtung zur Isolierung 3 hin ist neben dem ersten Quetschbereich 9 ein zweiter Quetschbereich 10 zu erkennen. Im zweiten Quetschbereich 10 wurde durch den Quetschvorgang und dadurch, dass die Aluminiumlitze 2 weder im Bereich des Quetschbereichs 9 noch im Bereich der Isolierung 3 Relativbewegung zueinander durchführen konnte, die Aluminiumlitze 2 gestreckt und gepresst. Dadurch ist die Oxidschicht auf nahezu allen Drähten der Aluminiumlitze 2 aufgebrochen. Durch das Quetschen des Rohr 4 ist auch dessen innen liegende Oxidschicht aufgebrochen. Figure 2 shows the electrical cable 1 with the connecting element 7 after the crimping and welding process. In the area of the end 8 of the aluminum strand 2, a first pinch area 9 can be seen. Here the aluminum strand 2 is squeezed by the tube 4 in such a way that the individual wires of the aluminum strand 2 can no longer move against each other. In the direction of the insulation 3, next to the first squeezing area 9, a second squeezing area 10 can be seen. In the second squeezing area 10, the aluminum strand 2 was stretched and pressed due to the squeezing process and the fact that the aluminum strand 2 could not perform relative movement to one another either in the area of the squeezing area 9 or in the area of the insulation 3. As a result, the oxide layer on almost all of the wires of the aluminum strand 2 has broken down. By squeezing the tube 4, its internal oxide layer is also broken.

Durch den anschließenden Schweißvorgang ist die Aluminiumlitze 2 großflächig mit dem Rohr 4 verschweißt worden, was durch die angedeutete Schweißlinse 11 erkennbar ist.As a result of the subsequent welding process, the aluminum strand 2 has been welded to the tube 4 over a large area, which can be seen by the indicated welding lens 11.

BezugszeichenlisteReference symbol list

11
elektrische Leitungelectrical line
22
AluminiumlitzeAluminum strand
33
Isolierunginsulation
44
RohrPipe
55
erstes offenes Endefirst open ending
66
zweites Endesecond ending
77
AnschlusselementConnection element
88th
Ende der AluminiumlitzeEnd of the aluminum strand
99
erster Quetschbereichfirst crush area
1010
zweiter Quetschbereichsecond crush area
1111
SchweißlinseWelding nugget

Claims (7)

  1. A method for connecting an electrical cable (1), having at least one wire which is made of aluminium, to a connector element (7) consisting of aluminium and having a tube (4), wherein after inserting a stripped end (8) or - when using insulated wires - an unstripped end of the electrical cable (1) into the tube (4), the method is characterised by the following method steps,
    a) in a first crimping process, crimping the tube (4) in a first crimping region (9) in which the end (8) of the electrical cable (1) is placed, such that the at least one wire is held in the tube (4) so that a relative movement between the tube (4) and the at least one wire is prevented,
    b) in a second crimping process, crimping the tube (4) in a second crimping region (10) of the electrical cable (1) which is located further removed from the end (8) of the electrical cable than the first crimping region (9), wherein an elongation of the at least one wire is brought about in addition to a change in cross section, and
    c) in a welding process, resistance welding the tube (4) to the at least one wire in the second crimping region (10).
  2. The method according to Claim 1,
    characterised in that
    the second crimping process is carried out by at least two welding electrodes.
  3. The method according to Claim 1 or 2,
    characterised in that
    the second crimping process and the welding at the end of the second crimping process take place at the same time.
  4. The method according to one of Claims 1 to 3,
    characterised in that
    the first crimping process is brought about by a compression tool.
  5. The method according to Claim 4,
    characterised in that
    the at least two-part compression tool encloses the crimped tube (4).
  6. The method according to Claim 4 or 5,
    characterised in that
    the compression tool remains closed during the second crimping process and is opened only after the welding process is completed.
  7. The method according to Claim 6,
    characterised in that
    a component in the axial direction of the at least one wire and remote from the first crimping region (9) is superimposed on the second crimping process acting in the radial direction.
EP18192956.3A 2017-09-11 2018-09-06 Method for connecting an electrical aluminium conduit with an aluminium pipe Active EP3454420B1 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
DE102017215970.7A DE102017215970B3 (en) 2017-09-11 2017-09-11 Method for connecting an aluminum electrical line to an aluminum tube

Publications (2)

Publication Number Publication Date
EP3454420A1 EP3454420A1 (en) 2019-03-13
EP3454420B1 true EP3454420B1 (en) 2023-11-01

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Country Status (6)

Country Link
US (1) US11038312B2 (en)
EP (1) EP3454420B1 (en)
JP (1) JP6720258B2 (en)
CN (1) CN109494542B (en)
DE (1) DE102017215970B3 (en)
MX (1) MX2018010945A (en)

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DE102017215970B3 (en) * 2017-09-11 2018-07-26 Strunk Connect automated solutions GmbH & Co. KG Method for connecting an aluminum electrical line to an aluminum tube
CN114220311B (en) * 2022-01-11 2024-01-26 重庆煌能科技有限公司 Be used for real examination platform of operating of special type operation low-voltage electric safety technique

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Also Published As

Publication number Publication date
US11038312B2 (en) 2021-06-15
CN109494542A (en) 2019-03-19
EP3454420A1 (en) 2019-03-13
DE102017215970B3 (en) 2018-07-26
JP6720258B2 (en) 2020-07-08
MX2018010945A (en) 2019-03-12
US20190081446A1 (en) 2019-03-14
JP2019050202A (en) 2019-03-28
CN109494542B (en) 2020-10-23

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