EP3454420B1 - Procédé de raccordement d'une conduite d'aluminium électrique à un tube d'aluminium - Google Patents
Procédé de raccordement d'une conduite d'aluminium électrique à un tube d'aluminium Download PDFInfo
- 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
- Authority
- EP
- European Patent Office
- Prior art keywords
- crimping
- tube
- wire
- welding
- aluminium
- 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
Links
- 238000000034 method Methods 0.000 title claims description 50
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 title claims description 30
- 229910052782 aluminium Inorganic materials 0.000 title claims description 30
- 239000004411 aluminium Substances 0.000 title claims 4
- 238000002788 crimping Methods 0.000 claims description 37
- 238000003466 welding Methods 0.000 claims description 25
- 230000006835 compression Effects 0.000 claims description 7
- 238000007906 compression Methods 0.000 claims description 7
- 238000009413 insulation Methods 0.000 description 7
- 239000004020 conductor Substances 0.000 description 5
- 239000000463 material Substances 0.000 description 3
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 229910000881 Cu alloy Inorganic materials 0.000 description 1
- AZDRQVAHHNSJOQ-UHFFFAOYSA-N alumane Chemical group [AlH3] AZDRQVAHHNSJOQ-UHFFFAOYSA-N 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 238000005476 soldering Methods 0.000 description 1
- 238000004804 winding Methods 0.000 description 1
Images
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.
Landscapes
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
- Manufacturing Of Electrical Connectors (AREA)
- Wire Processing (AREA)
Claims (7)
- Procédé de connexion d'une ligne électrique (1) comportant au moins un fil en aluminium à un élément de connexion (7) en aluminium et présentant un tube (4), dans lequel après insertion d'une extrémité dénudée (8) ou - lors de l'utilisation de fils isolés- une extrémité non dénudée de la ligne électrique (1) dans le tube (4), le procédé est caractérisé par les étapes de procédé suivantes,a) dans un premier processus de pressage, presser le tube (4) dans une première zone de pressage (9), dans laquelle l'extrémité (8) de la ligne électrique (1) est placée de telle sorte que le au moins un fil dans le tube (4) soit maintenu de telle sorte qu'un mouvement relatif entre le tube (4) et le au moins un fil soit empêché,b) dans un deuxième processus de pressage, presser le tube (4) dans une deuxième zone de pressage (10) de la ligne électrique (1) qui est plus éloignée de l'extrémité (8) de la ligne électrique que la première zone de pressage (9), dans lequel, à côté d'un changement de section transversale, le au moins un fil s'allonge, etc) dans un processus de soudage, soudage par résistance du tube (4) avec au moins un fil dans la deuxième zone de pressage (10).
- Procédé selon la revendication 1, caractérisé en ce que
le deuxième processus de pressage est effectué par au moins deux électrodes de soudage. - Procédé selon la revendication 1 ou 2, caractérisé en ce que
que le deuxième processus de pressage et le processus de soudage ont lieu simultanément à la fin du deuxième processus de pressage. - Procédé selon une quelconque des revendications 1 à 3, caractérisé en ce que le premier processus de pressage est effectué par un outil de refoulement.
- Procédé selon la revendication 4, caractérisé en ce que l'outil de refoulement enserre le tube pressé (4) en au moins deux parties.
- Procédé selon la revendication 4 ou 5, caractérisé en ce que l'outil de refoulement reste fermé pendant le deuxième processus de pressage et n'est ouvert qu'après la fin du processus de soudage.
- Procédé selon la revendication 6, caractérisé en ce que une composante dans la direction axiale du au moins un fil, à l'opposé de la première zone de pressage (9), est superposée au deuxième processus de pressage agissant dans la direction radiale.
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE102017215970.7A DE102017215970B3 (de) | 2017-09-11 | 2017-09-11 | Verfahren zum Verbinden einer elektrischen Aluminiumleitung mit einem Aluminiumrohr |
Publications (2)
Publication Number | Publication Date |
---|---|
EP3454420A1 EP3454420A1 (fr) | 2019-03-13 |
EP3454420B1 true EP3454420B1 (fr) | 2023-11-01 |
Family
ID=62813188
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP18192956.3A Active EP3454420B1 (fr) | 2017-09-11 | 2018-09-06 | Procédé de raccordement d'une conduite d'aluminium électrique à un tube d'aluminium |
Country Status (6)
Country | Link |
---|---|
US (1) | US11038312B2 (fr) |
EP (1) | EP3454420B1 (fr) |
JP (1) | JP6720258B2 (fr) |
CN (1) | CN109494542B (fr) |
DE (1) | DE102017215970B3 (fr) |
MX (1) | MX2018010945A (fr) |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE102017215970B3 (de) * | 2017-09-11 | 2018-07-26 | Strunk Connect automated solutions GmbH & Co. KG | Verfahren zum Verbinden einer elektrischen Aluminiumleitung mit einem Aluminiumrohr |
CN114220311B (zh) * | 2022-01-11 | 2024-01-26 | 重庆煌能科技有限公司 | 一种用于特种作业低压电工安全技术实操考核平台 |
Citations (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2003338330A (ja) * | 2002-05-20 | 2003-11-28 | Mitsubishi Cable Ind Ltd | 端子接続方法及び端子接続構造 |
Family Cites Families (27)
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US2815497A (en) * | 1953-04-23 | 1957-12-03 | Amp Inc | Connector for aluminum wire |
US3626363A (en) * | 1969-07-29 | 1971-12-07 | Itt | Roll-formed contact and crimping device therefor |
US3717842A (en) * | 1971-02-26 | 1973-02-20 | Perfection Electrical Prod Inc | Method of connecting aluminum wire to electrical terminals |
US3842487A (en) * | 1971-10-18 | 1974-10-22 | Essex International Inc | Terminating of electrical conductors |
US4208788A (en) * | 1976-01-28 | 1980-06-24 | Raychem Corporation | Splicing electrical wires |
FR2501923A1 (fr) * | 1981-03-13 | 1982-09-17 | Pechiney Aluminium | Procede de raccordement d'un cable electrique sous une cosse ou analogue par sertissage mecanique assiste par des vibrations ultrasonores |
GB8319264D0 (en) * | 1983-07-15 | 1983-08-17 | Omniglass Ltd | Corner for spacer strip of sealed window units |
GB9002629D0 (en) * | 1990-02-06 | 1990-04-04 | Raychem Pontoise Sa | Electrical connection |
DE19908031B4 (de) * | 1999-02-24 | 2009-08-13 | Auto-Kabel Management Gmbh | Verbindung eines elektrischen Aluminiumkabels mit einem aus Kupfer oder dergleichen Metall bestehenden Anschlußteil |
JP2001357903A (ja) * | 2000-06-13 | 2001-12-26 | Sumitomo Wiring Syst Ltd | 電線間接続用の圧着端子 |
JP2003338349A (ja) * | 2002-05-20 | 2003-11-28 | Mitsubishi Cable Ind Ltd | 端子接続方法及び端子接続構造 |
JP4422391B2 (ja) | 2002-08-07 | 2010-02-24 | 矢崎総業株式会社 | 電線と端子の接続方法 |
JP2006190662A (ja) | 2004-12-10 | 2006-07-20 | Hitachi Cable Ltd | 配線材およびその製造方法、並びにその製造に用いる抵抗溶接機 |
DE102004063056A1 (de) * | 2004-12-22 | 2006-07-13 | Fröhlich, Bernhard | Vorrichtung und Verfahren zur Verbindung einer Anschlusshülse mit einem Kabel |
DE102007020210A1 (de) * | 2006-06-03 | 2007-12-06 | Hirschmann Automotive Gmbh | Schweißen einer Umformverbindung |
JP2010146739A (ja) * | 2008-12-16 | 2010-07-01 | Sumitomo Wiring Syst Ltd | 電線接続スリーブ、電線接続スリーブの製造方法、電線接続スリーブが予め圧着されたリペア電線、および電線の接続方法 |
EP2362491B1 (fr) | 2010-02-26 | 2017-10-04 | Delphi Technologies, Inc. | Procédé de connexion d'une conduite électrique avec un élément de raccordement électrique |
DE102010038465A1 (de) * | 2010-07-27 | 2012-02-02 | Robert Bosch Gmbh | Elektrische Verbindung |
US8826533B2 (en) | 2011-06-24 | 2014-09-09 | Delphi Technologies, Inc. | Crimp connection to aluminum cable |
JP2013020761A (ja) * | 2011-07-08 | 2013-01-31 | Swcc Showa Cable Systems Co Ltd | アルミリッツ線の端子接続方法及び端子接続部 |
JP5884986B2 (ja) | 2012-07-31 | 2016-03-15 | 矢崎総業株式会社 | 圧着端子付きアルミ電線 |
FR2995459B1 (fr) * | 2012-09-07 | 2014-10-10 | Mecatraction | Procede d'assemblage d'un dispositif de connexion sur un troncon terminal denude d'un cable electrique et ensemble comportant un tel dispositif assemble solidairement sur un tel troncon de cable |
KR101505793B1 (ko) | 2013-02-24 | 2015-03-24 | 후루카와 덴키 고교 가부시키가이샤 | 전선 접속 구조체의 제조방법 및 전선 접속 구조체 |
DE102015012906A1 (de) * | 2015-02-27 | 2016-09-01 | Gentherm Gmbh | Hülse, Kontaktier-Einrichtung und Verfahren zum Schweißen von dünnen strangförmigen Leitern mittels Ultraschall |
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DE102017215970B3 (de) * | 2017-09-11 | 2018-07-26 | Strunk Connect automated solutions GmbH & Co. KG | Verfahren zum Verbinden einer elektrischen Aluminiumleitung mit einem Aluminiumrohr |
-
2017
- 2017-09-11 DE DE102017215970.7A patent/DE102017215970B3/de active Active
-
2018
- 2018-09-06 EP EP18192956.3A patent/EP3454420B1/fr active Active
- 2018-09-10 MX MX2018010945A patent/MX2018010945A/es unknown
- 2018-09-10 US US16/125,836 patent/US11038312B2/en active Active
- 2018-09-10 JP JP2018168515A patent/JP6720258B2/ja active Active
- 2018-09-11 CN CN201811056020.5A patent/CN109494542B/zh active Active
Patent Citations (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2003338330A (ja) * | 2002-05-20 | 2003-11-28 | Mitsubishi Cable Ind Ltd | 端子接続方法及び端子接続構造 |
Also Published As
Publication number | Publication date |
---|---|
JP2019050202A (ja) | 2019-03-28 |
US20190081446A1 (en) | 2019-03-14 |
CN109494542A (zh) | 2019-03-19 |
JP6720258B2 (ja) | 2020-07-08 |
US11038312B2 (en) | 2021-06-15 |
DE102017215970B3 (de) | 2018-07-26 |
EP3454420A1 (fr) | 2019-03-13 |
CN109494542B (zh) | 2020-10-23 |
MX2018010945A (es) | 2019-03-12 |
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