EP3579343B1 - High current cable, in particular for induction applications - Google Patents

High current cable, in particular for induction applications Download PDF

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Publication number
EP3579343B1
EP3579343B1 EP19171174.6A EP19171174A EP3579343B1 EP 3579343 B1 EP3579343 B1 EP 3579343B1 EP 19171174 A EP19171174 A EP 19171174A EP 3579343 B1 EP3579343 B1 EP 3579343B1
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EP
European Patent Office
Prior art keywords
aluminum
section
coupling sleeve
current
current cable
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EP19171174.6A
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German (de)
French (fr)
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EP3579343A1 (en
Inventor
Andreas Nebelung
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Weldotherm Gesellschaft Fuer Waermetechnik Mbh
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Weldotherm Gesellschaft Fuer Waermetechnik Mbh
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R11/00—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
    • H01R11/11—End pieces or tapping pieces for wires, supported by the wire and for facilitating electrical connection to some other wire, terminal or conductive member
    • H01R11/16—End pieces terminating in a soldering tip or socket
    • 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
    • H01R4/02—Soldered or welded connections
    • H01R4/023—Soldered or welded connections between cables or wires and terminals
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/58—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation characterised by the form or material of the contacting members
    • H01R4/62—Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • 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
    • H01R43/02—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
    • H01R43/0207—Ultrasonic-, H.F.-, cold- or impact 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
    • H01R4/20—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping using a crimping sleeve

Definitions

  • the invention relates to a high-current cable for induction applications such as the inductive heating of metallic components during welding.
  • the invention also relates to a method for attaching an electrical connection to such a high-current cable.
  • the components In certain welding processes, it is necessary to preheat the components to be joined or to keep them at a certain temperature after a welding process. By preheating the components (depending on the material), a so-called hardening (formation of very hard structural zones when certain carbon values are exceeded in the zone affected by heat during welding) can be prevented. In the case of multi-layer welding, the so-called interpass temperature is important, which should not fall below a certain value in order to avoid so-called cold cracks. In certain processes, the components should be kept (annealed) at a certain temperature for a certain time after the actual welding process. In all of these cases, the components must be heated by suitable means in addition to the actual welding process.
  • one or more gas burners are connected upstream of a welding device, past which the components are then passed in order to preheat the weld seam area of the components to be welded.
  • the heating of the components is very uneven, which can have negative effects on the material of the components.
  • the steel 15 NiCuMoNb 5 - WB 36 material number 1.6368
  • preheating by means of infrared radiation is known, with which temperature peaks in the components are to be avoided.
  • this process is very energy-intensive and involves energy losses in the region of 70%.
  • only superficial heating of the components is often possible by means of infrared radiation, while heating of the entire weld seam area is desirable, especially in the case of components with a large thickness.
  • inductor In recent years, components have therefore increasingly been heated using induction. In this case, eddy currents are induced in the components in the weld seam area in front of an actual welding device by means of a device called an inductor, which lead to resistance heating. Depending on the inductor geometry, weld seam geometry and inductor power, the entire weld seam area can be preheated.
  • inductor namely rigid and slack, each of which has proven its worth for certain types of application.
  • inductors that are actively cooled by fluid coolants and have corresponding coolant lines and those that do not have coolant lines.
  • the inductors are specifically manufactured for certain weld seam shapes (e.g. fillet weld, butt weld), welding processes and components and are used to drastically increase the welding speed by inductively heating the components very quickly (typically around 100 mm) in front of the welding torch.
  • the inductors are placed very close to the components.
  • a working height i.e. a distance between inductor and component, of 1 to 2 mm, for aluminum alloys, even preferably less than 1 mm.
  • Corresponding inductors work with an inductor power of around 15 to 30 kW, and alternating current fields are induced in the frequency range of around 9 to 23 kHz. This means that welding speeds of 400 to 1,200 mm / minute can be achieved.
  • Inductors of the other type so-called slack, band or hose-shaped inductors are, for example, from the US 2007/0215606 A1 famous. They consist of a high-current cable in the form of preferably stranded stranded wire or a wire, the cable either, as in the above US 2007/0215606 A1 described, surrounded directly with a watertight hose or else encased by a generally metallic braided hose, which, if cooling is required, can be surrounded by a watertight hose for guiding a coolant.
  • metal hoses sheathed with one to three layers of copper braided hose are known, in which a connector is soldered to the end, by means of which the electrical connection can then be made by screwing with a union nut.
  • a connector is soldered to the end, by means of which the electrical connection can then be made by screwing with a union nut.
  • such cables are still in a protective tube made of glass fiber fabric. The problem with this type of cable is that it is only moderately robust mechanically and also requires water cooling at application temperatures above 200 ° C.
  • connection elements on the cable side are soldered or pressed onto the copper braid as appropriately shaped sleeves.
  • high-current cables when very high temperatures are to be generated inductively using high-current cables, e.g. temperatures up to 800 ° C, aluminum high-current cables have proven particularly useful, in which an aluminum braid is usually guided in a stainless steel braided hose. Despite the high temperatures, such cables do not require water cooling and are very robust.
  • the DE 10 2010 114 994 B3 a method in which a sleeve is attached to an aluminum cable by means of friction welding, to which a specially designed contact element is then welded.
  • a method for contacting an aluminum cable is known in which a first sleeve made of aluminum is connected to the cable by tinning and a second sleeve, which surrounds the first sleeve and the cable, is also connected to the first sleeve by tinning.
  • the design requires separate sleeves to be attached to the cable one after the other.
  • the proposed tin-plating limits the application temperatures of the cable, since tin has a melting temperature of 232 ° C, while high-current cables of the type in question here can reach cable temperatures of up to around 280 ° C.
  • JP 2018 073688 A suggests the use of multi-part, nested sleeves made of different materials.
  • the invention is based on the object of improving the known solutions and of specifying a sheathed aluminum high-current cable which can be connected in a simple and safe manner to typical electrical devices, such as, for example, generators of an induction current.
  • the invention is also based on the object to specify a simplified method for attaching an electrical connection sleeve to a sheathed aluminum high-current cable.
  • the object is achieved by a high-current cable with the features of claim 1 or a method with the features of claim 7.
  • the invention has the advantage that it enables aluminum high-current cables, which have a number of advantages over other high-current cables, especially in so-called medium-frequency applications (i.e. applications in which alternating currents with a frequency of typically a few hundred Hz up to a few kHz are used).
  • medium-frequency applications i.e. applications in which alternating currents with a frequency of typically a few hundred Hz up to a few kHz are used.
  • inductive heating of metallic components in the context of workpiece preparation or post-processing during welding processes have to be provided in a simple and, above all, safe manner with a quasi-standardized high-current plug for making plug connections.
  • connection sleeve provided according to the invention with a first essentially cylindrical section made of a first metal and a substantially cylindrical section made of a second metal welded to it, the first section being made of aluminum, advantageously enables the connection sleeve to be welded to the aluminum braid.
  • the second essentially cylindrical section it can advantageously be connected to a high-current plug, in particular soldered.
  • the second section is made of copper. However, it can also consist of other suitable materials, e.g. silver. Since high-current plugs of the type in question here typically consist of brass, the second section can then be soldered to the high-current plug.
  • the inside diameter of at least the second section is dimensioned to accommodate the sheathing with the aluminum braid. This also makes it possible to enclose the sheathing and thus to form a "clean" termination of the cable.
  • the sheathing is a stainless steel braided sheathing. This advantageously enables a particularly robust, but at the same time flexible design of the high-current cable that can be adapted to different geometries of an area to be heated inductively, for example.
  • first essentially cylindrical section and the second essentially cylindrical section are friction-welded to one another. This enables a particularly stable configuration of the connecting sleeve while at the same time maintaining very good electrical conductivity.
  • a connecting sleeve with two essentially cylindrical sections welded together, one of which is made of aluminum and the other of another metal, preferably copper or silver, is provided and a part of the aluminum braid is exposed at at least one end of the high-current cable, whereby these two steps can of course take place in any order or also in parallel.
  • the connecting sleeve is then pushed onto the high-current cable in such a way that the aluminum braid is located in the section of the connecting sleeve made of aluminum, whereupon the section of the connecting sleeve made of aluminum is welded to the aluminum braid.
  • the connection sleeve can then be introduced into a receptacle of a high-current plug that is at least partially complementary to the connection sleeve and fastened there.
  • the provision of the connecting sleeve comprises the friction welding of the two essentially cylindrical sections to one another.
  • connection sleeve can be fastened in the receptacle, provided that suitable materials are used for the receptacle, for example brass, and the second essentially cylindrical section of the connection sleeve, for example copper, is used by soldering.
  • Fig. 1 shows a high-current cable designated in its entirety by 10, which consists of a stranded aluminum braid 14 sheathed in this exemplary embodiment by a stainless steel braid 12.
  • a relatively long section of the aluminum braid 14 is exposed, that is to say significantly more than would actually have to be exposed for the welding of the aluminum braid to a section of a connecting sleeve, which is described below.
  • the Fig. 2 shows a connecting sleeve according to the invention, denoted in its entirety by 20, with two essentially cylindrical sections 22 and 24, the section 22 being made of aluminum and the section 24 being made of copper in this exemplary embodiment.
  • the two sections 22 and 24 are friction welded together.
  • the connecting sleeve 20 also has two grub screws 26 in the end region of the section 24 made of copper, which serve to clamp a high-current cable inserted into the connecting sleeve 20, but which are optional and do not have to be provided.
  • the two cylindrical sections 22 and 24 have the same outside diameter, but the inside diameter of section 24 can be larger than that of section 22 made of aluminum, so that part of the sheathing of the cable, as in FIG Fig. 3 shown can be inserted into the sleeve.
  • the inner diameter of the section made of aluminum can be smaller, since it only has to accommodate the aluminum braid.
  • Fig. 3 the state after sliding and the connecting sleeve on the cable, welding the aluminum braid to the aluminum section 22 of the sleeve and soldering the section 24, which is made of copper in this embodiment, to the sheathing 12, which is made of stainless steel braiding, so that a high-current cable according to the invention 30 is formed.
  • the high-current plug 40 has a cylindrical contact section 42, a cylindrical receiving sleeve 44 and a closing flange 46 Fig. 2 forms.
  • the connecting sleeve can be secured by grub screws which are screwed into the receptacle sleeve through one or more bores 50.
  • connection sleeve is preferably soldered to the plug 40 after it has been introduced into the receptacle 48, which is advantageously possible in that the portion of the connection sleeve located on the cable-facing part of the connection sleeve is made of a metal, such as copper or silver in particular, that interacts well the metal, from which a high-current plug of the type in question here, in particular brass, is typically made, can be soldered.
  • a metal such as copper or silver in particular
  • these materials are also significantly harder than aluminum, so that the receiving section of the plug not only ensures a good electrical connection between the high-current cable and the plug, but at the same time also protects the aluminum section of the connecting sleeve that is on the inside after the corresponding connection has been made.
  • the contact section 42 of the plug 40 is provided in a manner known per se for insertion into a corresponding receptacle on an electrical device.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)

Description

TECHNISCHES GEBIET DER ERFINDUNGTECHNICAL FIELD OF THE INVENTION

Die Erfindung betrifft ein Hochstromkabel für Induktionsanwendungen wie z.B. das induktive Erwärmen metallischer Bauteile beim Schweißen. Die Erfindung betrifft auch ein Verfahren zum Anbringen eines elektrischen Anschlusses an ein solches Hochstromkabel.The invention relates to a high-current cable for induction applications such as the inductive heating of metallic components during welding. The invention also relates to a method for attaching an electrical connection to such a high-current cable.

HINTERGRUND DER ERFINDUNGBACKGROUND OF THE INVENTION

Bei bestimmten Schweißvorgängen ist es notwendig, die miteinander zu verbindenden Bauteile vorzuwärmen bzw. nach einem Schweißgang auf einer bestimmten Temperatur zu halten. Durch Vorwärmen der Bauteile kann (materialabhängig) eine sog. Aufhärtung (Bildung sehr harter Gefügezonen durch Überschreitung bestimmter Kohlenstoffwerte in der beim Schweißen wärmebeeinflussten Zone) verhindert werden. Bei mehrlagigem Schweißen ist die sog. Zwischenlagentemperatur von Bedeutung, die nicht unter einen bestimmten Wert fallen sollte, um sog. Kaltrisse zu vermeiden. Bei bestimmten Prozessen sollen die Bauteile nach dem eigentlichen Schweißvorgang für eine bestimmte Zeit auf einer bestimmten Temperatur gehalten (geglüht) werden. In allen diesen Fällen müssen die Bauteile durch geeignete Mittel zusätzlich zum eigentlichen Schweißvorgang erwärmt werden.In certain welding processes, it is necessary to preheat the components to be joined or to keep them at a certain temperature after a welding process. By preheating the components (depending on the material), a so-called hardening (formation of very hard structural zones when certain carbon values are exceeded in the zone affected by heat during welding) can be prevented. In the case of multi-layer welding, the so-called interpass temperature is important, which should not fall below a certain value in order to avoid so-called cold cracks. In certain processes, the components should be kept (annealed) at a certain temperature for a certain time after the actual welding process. In all of these cases, the components must be heated by suitable means in addition to the actual welding process.

Bei einem bekannten und häufig verwendeten Verfahren werden ein oder mehrere Gasbrenner einer Schweißvorrichtung vorgeschaltet, an denen die Bauteile dann vorbeigeführt werden, um den Schweißnahtbereich der zu schweißenden Bauteile vorzuwärmen. Je nach Anordnung und Ausrichtung der Brenner, Material und Form der Bauteile und Geschwindigkeit, mit der sich Bauteile und Brenner relativ zueinander bewegen, ist die Erwärmung der Bauteile sehr ungleichmäßig, was negative Auswirkungen auf den Werkstoff der Bauteile haben kann. Beispielsweise toleriert der Stahl 15 NiCuMoNb 5 - WB 36 (Werkstoffnummer 1.6368), der in der Kesselindustrie sehr oft eingesetzt wird, nur sehr niedrige Auf- und Abkühlraten und sollte daher nicht mit einer Flamme vorgewärmt werden.In a known and frequently used method, one or more gas burners are connected upstream of a welding device, past which the components are then passed in order to preheat the weld seam area of the components to be welded. Depending on the arrangement and orientation of the burners, the material and shape of the components and the speed at which the components and burners move relative to one another, the heating of the components is very uneven, which can have negative effects on the material of the components. For example, the steel 15 NiCuMoNb 5 - WB 36 (material number 1.6368), which is very often used in the boiler industry, only tolerates very low heating and cooling rates and should therefore not be preheated with a flame.

Neben der sog. Flammenvorwärmung ist die Vorwärmung mittels Infrarotstrahlung bekannt, womit Temperaturspitzen in den Bauteilen vermieden werden sollen. Dieses Verfahren ist allerdings ebenso wie die Erwärmung mit Flammen sehr energieintensiv und mit Energieverlusten im Bereich von 70 % verbunden. Zudem ist mittels Infrarotstrahlung oft nur eine oberflächliche Erwärmung der Bauteile möglich, während gerade bei Bauteilen mit einer großen Dicke eine Erwärmung des gesamten Schweißnahtbereichs wünschenswert ist.In addition to the so-called flame preheating, preheating by means of infrared radiation is known, with which temperature peaks in the components are to be avoided. However, like heating with flames, this process is very energy-intensive and involves energy losses in the region of 70%. In addition, only superficial heating of the components is often possible by means of infrared radiation, while heating of the entire weld seam area is desirable, especially in the case of components with a large thickness.

In den letzten Jahren werden Bauteile deshalb verstärkt mittels Induktion erwärmt. Dabei werden im Schweißnahtbereich vor einer eigentlichen Schweißvorrichtung mittels einer als Induktor bezeichneten Vorrichtung Wirbelströme in den Bauteilen induziert, die zur Widerstandserwärmung führen. Je nach Induktorgeometrie, Schweißnahtgeometrie und Induktorleistung kann der gesamte Schweißnahtbereich vorgewärmt werden. Dabei kann zwischen zwei grundsätzlich verschiedenen Induktorbauarten, nämlichen starren und schlaffen, unterschieden werden, die sich jeweils für bestimmte Anwendungsarten durchaus bewährt haben. Daneben kann zwischen Induktoren, die aktiv über fluide Kühlmittel gekühlt werden und über entsprechende Kühlmittelleitungen verfügen, und solchen, die nicht über Kühlmittelleitungen verfügen, unterschieden werden.In recent years, components have therefore increasingly been heated using induction. In this case, eddy currents are induced in the components in the weld seam area in front of an actual welding device by means of a device called an inductor, which lead to resistance heating. Depending on the inductor geometry, weld seam geometry and inductor power, the entire weld seam area can be preheated. A distinction can be made between two fundamentally different types of inductor, namely rigid and slack, each of which has proven its worth for certain types of application. In addition, a distinction can be made between inductors that are actively cooled by fluid coolants and have corresponding coolant lines and those that do not have coolant lines.

Aus der DE 100 47 492 A1 sind verschiedene starre Induktoren bekannt, die nicht über Kühlmittelleitungen verfügen und zur schnellen lokalen Aufheizung bestimmt sind. Die Induktoren sind spezifisch für bestimmte Schweißnahtformen (z.B. Kehlnaht, Stumpfnaht), Schweißverfahren und Bauteile gefertigt und dienen dazu, die Schweißgeschwindigkeit dadurch drastisch zu erhöhen, dass die Bauteile kurz (typischerweise etwa 100 mm) vor dem Schweißbrenner sehr schnell induktiv erwärmt werden. Dazu werden die Induktoren sehr dicht über den Bauteilen platziert. Für Stähle wird eine Arbeitshöhe, also ein Abstand zwischen Induktor und Bauteil, von 1 bis 2 mm, für Aluminium-Legierungen sogar von vorzugsweise weniger als 1 mm genannt. Entsprechende Induktoren arbeiten mit einer Induktorleistung von etwa 15 bis 30 kW, und es werden Wechselstromfelder im Frequenzbereich von ca. 9 bis 23 kHz induziert. Damit sind dann Schweißgeschwindigkeiten von 400 bis 1.200 mm/Minute erreichbar.From the DE 100 47 492 A1 various rigid inductors are known that do not have coolant lines and are intended for rapid local heating. The inductors are specifically manufactured for certain weld seam shapes (e.g. fillet weld, butt weld), welding processes and components and are used to drastically increase the welding speed by inductively heating the components very quickly (typically around 100 mm) in front of the welding torch. For this purpose, the inductors are placed very close to the components. For steels, a working height, i.e. a distance between inductor and component, of 1 to 2 mm, for aluminum alloys, even preferably less than 1 mm. Corresponding inductors work with an inductor power of around 15 to 30 kW, and alternating current fields are induced in the frequency range of around 9 to 23 kHz. This means that welding speeds of 400 to 1,200 mm / minute can be achieved.

Induktoren der anderen Bauart, sogenannte schlaffe, band- oder schlauchförmige Induktoren sind z.B. aus der US 2007/0215606 A1 bekannt. Sie bestehen aus einem Hochstromkabel in Form vorzugsweise verseilten Litze oder eines Drahtes, wobei das Kabel entweder, wie in der genannten US 2007/0215606 A1 beschrieben, direkt mit einem wasserdichten Schlauch umgeben oder aber von aber von einem i.d.R. metallischen Geflechtschlauch ummantelt ist, der dann, falls eine Kühlung benötigt wird, von einem wasserdichten Schlauch zur Führung eines Kühlmittels umgeben sein kann.Inductors of the other type, so-called slack, band or hose-shaped inductors are, for example, from the US 2007/0215606 A1 famous. They consist of a high-current cable in the form of preferably stranded stranded wire or a wire, the cable either, as in the above US 2007/0215606 A1 described, surrounded directly with a watertight hose or else encased by a generally metallic braided hose, which, if cooling is required, can be surrounded by a watertight hose for guiding a coolant.

So sind z.B. mit ein bis drei Lagen Kupfergeflechtschlauch ummantelte Metallschläuche bekannt, bei denen an das Ende ein Anschlussstück gelötet ist, mittels welchem dann der elektrische Anschluss durch Verschraubung mit Überwurfmutter erfolgen kann. Typischerweise befinden sich solche Kabel noch in einem Schutzschlauch aus Glasfasergewebe. Problematisch bei dieser Art von Kabeln ist, dass sie mechanisch nur mittelmäßig robust sind und zudem bereits bei Anwendungstemperaturen über 200 °C eine Wasserkühlung benötigen.For example, metal hoses sheathed with one to three layers of copper braided hose are known, in which a connector is soldered to the end, by means of which the electrical connection can then be made by screwing with a union nut. Typically, such cables are still in a protective tube made of glass fiber fabric. The problem with this type of cable is that it is only moderately robust mechanically and also requires water cooling at application temperatures above 200 ° C.

Ferner sind in Silikonschläuchen geführte Kupferlitzen bekannt, bei denen der elektrische Anschluss über eine sogenannte Hochstrom-Steckverbindung meist mittels Lamellen-Kontaktelementen mit äußerer Wasserführung oder als Bajonett-Stecker mit innerer Wasserführung erfolgt. Solche Kabel sind mechanisch wenig robust, besitzen aber eine Strombelastbarkeit von etwa 40 A/mm2. Die kabelseitigen Anschlusselemente werden dabei als entsprechend geformte Hülsen an die Kupferlitze gelötet oder gepresst.Furthermore, copper strands guided in silicone hoses are known in which the electrical connection is made via what is known as a high-current plug connection, usually by means of lamellar contact elements with external water supply or as a bayonet connector with internal water supply. Such cables are not mechanically robust, but have a current carrying capacity of around 40 A / mm 2 . The connection elements on the cable side are soldered or pressed onto the copper braid as appropriately shaped sleeves.

Insbesondere wenn sehr hohe Temperaturen unter Verwendung von Hochstromkabeln induktiv erzeugt werden sollen, z.B. Temperaturen bis zu 800 °C, haben sich Aluminium-Hochstromkabel besonders bewährt, bei denen i.d.R. in einem Edelstahlgeflechtschlauch eine Aluminiumlitze geführt ist. Trotz der hohen Temperaturen benötigen solche Kabel keine Wasserkühlung und sind sehr robust.In particular, when very high temperatures are to be generated inductively using high-current cables, e.g. temperatures up to 800 ° C, aluminum high-current cables have proven particularly useful, in which an aluminum braid is usually guided in a stainless steel braided hose. Despite the high temperatures, such cables do not require water cooling and are very robust.

Es hat sich allerdings gezeigt, dass es problematisch ist, solche Aluminium-Hochstromkabel in leichter und zuverlässiger Weise mit Anschlussstücken zum Anschließen der Kabel an elektrische Geräte zu versehen. Bislang werden dazu an das jeweilige Aluminiumkabel Kabelschuhe ebenfalls aus Aluminium angeschweißt. Allerdings werden entsprechende Induktionswärmeanlagen häufig durch fachfremdes Personal verwendet, so dass es nicht selten zu Fehlern bei der Verschraubung der Kabelschuhe mit Anschlüssen an einem elektrischen Gerät kommt, die sogar zur Zerstörung der Kabelschuhe führen können. Zudem ist die Isolation der Kabelschuhe problematisch.However, it has been shown that it is problematic to provide such aluminum high-current cables in a simple and reliable manner with connecting pieces for connecting the cables to electrical devices. So far, aluminum cable lugs have also been welded to the respective aluminum cable. However, corresponding induction heating systems are often used by non-skilled personnel, so that it is not uncommon for errors to occur when screwing the cable lugs to connections on an electrical device, which can even lead to the destruction of the cable lugs. In addition, the insulation of the cable lugs is problematic.

Zur zumindest partiellen Lösung des Problems schlägt die DE 10 2010 114 994 B3 ein Verfahren vor, bei dem mittels Reibschweißen eine Hülse an einem Aluminiumkabel befestigt wird, an welcher dann ein speziell ausgestaltetes Kontaktelement angeschweißt wird.For at least a partial solution to the problem, the DE 10 2010 114 994 B3 a method in which a sleeve is attached to an aluminum cable by means of friction welding, to which a specially designed contact element is then welded.

Aus der DE 103 46 160 B3 ist ein Verfahren zur Kontaktierung eines Aluminiumkabels bekannt, bei dem eine erste Hülse aus Aluminium durch Verzinnung mit dem Kabel verbunden und eine zweite Hülse, die die erste Hülse und das Kabel umgibt, ebenfalls durch Verzinnung mit der ersten Hülse verbunden wird. Die Ausgestaltung erfordert allerdings das nacheinander erfolgende Anbringen separater Hülsen an dem Kabel. Zudem begrenzt die vorgeschlagene Verzinnung die Anwendungstemperaturen des Kabels, da Zinn eine Schmelztemperatur von 232 °C besitzt, während bei Hochstromkabeln der hier in Frage stehenden Art Kabeltemperaturen bis zu etwa 280 °C auftreten können.From the DE 103 46 160 B3 a method for contacting an aluminum cable is known in which a first sleeve made of aluminum is connected to the cable by tinning and a second sleeve, which surrounds the first sleeve and the cable, is also connected to the first sleeve by tinning. The design, however, requires separate sleeves to be attached to the cable one after the other. In addition, the proposed tin-plating limits the application temperatures of the cable, since tin has a melting temperature of 232 ° C, while high-current cables of the type in question here can reach cable temperatures of up to around 280 ° C.

Aus der GB 1 213 922 A ist ein Verfahren bekannt, bei dem ebenfalls zwei konzentrisch ineinander angeordnete Hülsen aus unterschiedlichen Materialien an einem Kabel befestigt werden.From the GB 1 213 922 A a method is known in which two concentrically arranged sleeves made of different materials are also attached to a cable.

Auch die JP 2018 073688 A schlägt die Verwendung mehrteiliger, ineinander gesteckter Hülsen aus unterschiedlichen Materialien vor.Also the JP 2018 073688 A suggests the use of multi-part, nested sleeves made of different materials.

OFFENBARUNG DER ERFINDUNGDISCLOSURE OF THE INVENTION

Der Erfindung liegt die Aufgabe zugrunde, die bekannten Lösungen zu verbessern und ein ummanteltes Aluminium-Hochstromkabel anzugeben, das in einfacher und sicherer Weise an typische elektrische Geräte, wie z.B. Erzeuger eines Induktionsstroms, anschließbar ist. Der Erfindung liegt auch die Aufgabe zugrunde, ein vereinfachtes Verfahren zum Anbringen einer elektrischen Anschlusshülse an einem ummantelten Aluminium-Hochstromkabel anzugeben.The invention is based on the object of improving the known solutions and of specifying a sheathed aluminum high-current cable which can be connected in a simple and safe manner to typical electrical devices, such as, for example, generators of an induction current. The invention is also based on the object to specify a simplified method for attaching an electrical connection sleeve to a sheathed aluminum high-current cable.

Die Aufgabe wird gelöst von einem Hochstromkabel mit den Merkmalen des Anspruchs 1 bzw. einem Verfahren mit den Merkmalen des Anspruchs 7.The object is achieved by a high-current cable with the features of claim 1 or a method with the features of claim 7.

Die Erfindung hat den Vorteil, dass sie es ermöglicht, Aluminium-Hochstromkabel, die eine Reihe von Vorteilen gegenüber anderen Hochstromkabeln gerade bei sogenannten Mittelfrequenzanwendungen (d.h. Anwendungen, bei denen Wechselströme mit einer Frequenz von typischerweise einigen hundert Hz bis hin zu einigen kHz angewandt werden) wie z.B. der induktiven Erwärmung von metallischen Bauteilen im Rahmen der Werkstückvor- oder -nachbereitung bei Schweißvorgängen besitzen, in einfacher und vor allem sicherer Weise mit einem quasi standardisierten Hochstromstecker zur Herstellung von Steckverbindungen zu versehen.The invention has the advantage that it enables aluminum high-current cables, which have a number of advantages over other high-current cables, especially in so-called medium-frequency applications (i.e. applications in which alternating currents with a frequency of typically a few hundred Hz up to a few kHz are used). such as the inductive heating of metallic components in the context of workpiece preparation or post-processing during welding processes, have to be provided in a simple and, above all, safe manner with a quasi-standardized high-current plug for making plug connections.

Die erfindungsgemäß vorgesehene Anschlusshülse mit einem ersten im Wesentlichen zylindrischen Abschnitt aus einem ersten Metall und einem daran angeschweißten im Wesentlichen zylindrischen Abschnitt aus einem zweiten Metall, wobei der erste Abschnitt aus Aluminium besteht, ermöglicht es vorteilhaft, die Anschlusshülse mit der Aluminiumlitze zu verschweißen. Je nach Material des zweiten im Wesentlichen zylindrischen Abschnitts kann dieser vorteilhaft mit einem Hochstromstecker verbunden, insbesondere verlötet werden.The connection sleeve provided according to the invention with a first essentially cylindrical section made of a first metal and a substantially cylindrical section made of a second metal welded to it, the first section being made of aluminum, advantageously enables the connection sleeve to be welded to the aluminum braid. Depending on the material of the second essentially cylindrical section, it can advantageously be connected to a high-current plug, in particular soldered.

Bei einer bevorzugten Ausführungsform besteht der zweite Abschnitt aus Kupfer. Er kann aber auch aus anderen geeigneten Materialien, z.B. Silber, bestehen. Da Hochstromstecker der hier in Frage stehenden Art typischerweise aus Messing bestehen, kann dann der zweite Abschnitt mit dem Hochstromstecker verlötet werden.In a preferred embodiment, the second section is made of copper. However, it can also consist of other suitable materials, e.g. silver. Since high-current plugs of the type in question here typically consist of brass, the second section can then be soldered to the high-current plug.

Bei einer weiteren bevorzugten Ausführungsform ist der Innendurchmesser zumindest des zweiten Abschnitts dazu bemessen, die Ummantelung mit der Aluminiumlitze aufzunehmen. Dies ermöglicht es, auch die Ummantelung einzufassen und somit einen "sauberen" Abschluss des Kabels zu bilden.In a further preferred embodiment, the inside diameter of at least the second section is dimensioned to accommodate the sheathing with the aluminum braid. This also makes it possible to enclose the sheathing and thus to form a "clean" termination of the cable.

Bei einer weiteren bevorzugten Ausführungsform handelt es sich bei der Ummantelung um eine Edelstahl-Geflechtummantelung. Dies ermöglicht vorteilhaft eine besonders robuste, gleichzeitig aber auch flexible und mithin an unterschiedliche Geometrien eines z.B. induktiv zu erwärmenden Bereichs anpassbare Ausgestaltung des Hochstromkabels.In a further preferred embodiment, the sheathing is a stainless steel braided sheathing. This advantageously enables a particularly robust, but at the same time flexible design of the high-current cable that can be adapted to different geometries of an area to be heated inductively, for example.

Bei einer weiteren bevorzugten Ausführungsform sind der erste im Wesentlichen zylindrische Abschnitt und der zweite im Wesentlichen zylindrische Abschnitt miteinander reibverschweißt. Dies ermöglicht eine besonders stabile Ausgestaltung der Anschlusshülse bei gleichzeitiger Beibehaltung einer sehr guten elektrischen Leitfähigkeit.In a further preferred embodiment, the first essentially cylindrical section and the second essentially cylindrical section are friction-welded to one another. This enables a particularly stable configuration of the connecting sleeve while at the same time maintaining very good electrical conductivity.

Gemäß dem erfindungsgemäßen Verfahren zum Anbringen eines Hochstromsteckers an einem Hochstromkabel mit einer ummantelten Aluminiumlitze wird zunächst eine Anschlusshülse mit zwei miteinander verschweißten, im Wesentlichen zylindrischen Abschnitten, von denen einer aus Aluminium und der andere aus einem anderen Metall, vorzugsweise Kupfer oder Silber, besteht, bereitgestellt und es wird an wenigstens einem Ende des Hochstromkabels ein Teil der Aluminiumlitze freigelegt, wobei diese beiden Schritte natürlich in beliebiger Reihenfolge oder auch parallel erfolgen können. Dann wird die Anschlusshülse auf das Hochstromkabel so aufgeschoben, dass sich die Aluminiumlitze in dem aus Aluminium bestehenden Abschnitt der Anschlusshülse befindet, worauf der aus Aluminium bestehende Abschnitt der Anschlusshülse mit der Aluminiumlitze verschweißt wird. Anschließend kann die Anschlusshülse in eine zu der Anschlusshülse zumindest partiell komplementäre Aufnahme eines Hochstromsteckers eingebracht und dort befestigt werden.According to the inventive method for attaching a high-current plug to a high-current cable with a sheathed aluminum braid, a connecting sleeve with two essentially cylindrical sections welded together, one of which is made of aluminum and the other of another metal, preferably copper or silver, is provided and a part of the aluminum braid is exposed at at least one end of the high-current cable, whereby these two steps can of course take place in any order or also in parallel. The connecting sleeve is then pushed onto the high-current cable in such a way that the aluminum braid is located in the section of the connecting sleeve made of aluminum, whereupon the section of the connecting sleeve made of aluminum is welded to the aluminum braid. The connection sleeve can then be introduced into a receptacle of a high-current plug that is at least partially complementary to the connection sleeve and fastened there.

Bei einer bevorzugten Ausführungsform des Verfahrens umfasst das Bereitstellen der Anschlusshülse das Reibverschweißen der beiden im Wesentlichen zylindrischen Abschnitte miteinander.In a preferred embodiment of the method, the provision of the connecting sleeve comprises the friction welding of the two essentially cylindrical sections to one another.

Das Befestigen der Anschlusshülse in der Aufnahme kann, sofern geeignete Materialien für die Aufnahme, z.B. Messing, und den zweiten im Wesentlichen zylindrischen Abschnitt der Anschlusshülse, z.B. Kuper, verwendet werden, durch Anlöten erfolgen.The connection sleeve can be fastened in the receptacle, provided that suitable materials are used for the receptacle, for example brass, and the second essentially cylindrical section of the connection sleeve, for example copper, is used by soldering.

Weitere Einzelheiten und Vorteile der Erfindung ergeben sich aus der nachfolgenden rein beispielhaften und nicht beschränkenden Beschreibung eines Ausführungsbeispiels in Verbindung mit der vier Zeichnungsfiguren umfassenden Zeichnung.Further details and advantages of the invention emerge from the following, purely exemplary and non-limiting description of an exemplary embodiment in conjunction with the drawing comprising four drawing figures.

KURZE BESCHREIBUNG DER ZEICHNUNGBRIEF DESCRIPTION OF THE DRAWING

Fig. 1Fig. 1
zeigt ein geflechtummanteltes Aluminium-Hochstromkabel mit teilweise entfernter Ummantelung.shows a braided aluminum high-current cable with the sheathing partially removed.
Fig. 2Fig. 2
zeigt eine Anschlusshülse zum Anschweißen an das Kabel gemäß Fig. 1.shows a connection sleeve for welding to the cable according to FIG Fig. 1 .
Fig. 3Fig. 3
zeigt das Kabel mit angeschweißter Hülse.shows the cable with a welded sleeve.
Fig. 4Fig. 4
zeigt einen Stecker zur Aufnahme der Anschlusshülse.shows a plug for receiving the connecting sleeve.
BESCHREIBUNG BEVORZUGTER AUSFÜHRUNGSFORMENDESCRIPTION OF PREFERRED EMBODIMENTS

In der Fig. 1 ist ein in seiner Gesamtheit mit 10 bezeichnetes Hochstromkabel gezeigt, das aus einer bei diesem Ausführungsbeispiel von einem Edelstahlgeflecht 12 ummantelten verseilten Aluminiumlitze 14 besteht. Zum besseren Verständnis des Aufbaus des Kabels ist ein relativ langer Abschnitt der Aluminiumlitze 14 freigelegt, also deutlich mehr, als eigentlich zum nachfolgend noch beschriebenen Verschweißen der Aluminiumlitze mit einem Abschnitt einer Anschlusshülse freigelegt werden müsste.In the Fig. 1 shows a high-current cable designated in its entirety by 10, which consists of a stranded aluminum braid 14 sheathed in this exemplary embodiment by a stainless steel braid 12. For a better understanding of the structure of the cable, a relatively long section of the aluminum braid 14 is exposed, that is to say significantly more than would actually have to be exposed for the welding of the aluminum braid to a section of a connecting sleeve, which is described below.

Damit sich die einzelnen Stränge der Aluminiumlitze nicht vollständig auffasern, wurde im gezeigten Zustand das Ende der Aluminiumlitze mit Isolierband 16 umwickelt.So that the individual strands of the aluminum braid do not fray completely, the end of the aluminum braid was wrapped with insulating tape 16 in the state shown.

Die Fig. 2 zeigt eine in ihrer Gesamtheit mit 20 bezeichnete erfindungsgemäße Anschlusshülse mit zwei im Wesentlichen zylindrischen Abschnitten 22 und 24, wobei der Abschnitt 22 aus Aluminium und der Abschnitt 24 bei diesem Ausführungsbeispiel aus Kupfer bestehen. Die beiden Abschnitte 22 und 24 sind miteinander reibverschweißt.the Fig. 2 shows a connecting sleeve according to the invention, denoted in its entirety by 20, with two essentially cylindrical sections 22 and 24, the section 22 being made of aluminum and the section 24 being made of copper in this exemplary embodiment. The two sections 22 and 24 are friction welded together.

Bei diesem Ausführungsbeispiel besitzt die Anschlusshülse 20 ferner zwei Madenschrauben 26 im Endbereich des aus Kupfer bestehenden Abschnitts 24, die zum Festklemmen eines in die Anschlusshülse 20 eingeführten Hochstromkabels dienen, die aber optional sind und nicht vorgesehen sein müssen.In this exemplary embodiment, the connecting sleeve 20 also has two grub screws 26 in the end region of the section 24 made of copper, which serve to clamp a high-current cable inserted into the connecting sleeve 20, but which are optional and do not have to be provided.

Die beiden zylindrischen Abschnitte 22 und 24 besitzen denselben Außendurchmesser, der Innendurchmesser des Abschnitts 24 kann aber größer bemessen sein als der des aus Aluminium bestehenden Abschnitts 22, so dass auch ein Teil der Ummantelung des Kabels, wie in Fig. 3 gezeigt, in die Hülse eingeführt werden kann. Der Innendurchmesser des aus Aluminium bestehenden Abschnitts kann dagegen kleiner sein, da er nur die Aluminiumlitze aufnehmen muss.The two cylindrical sections 22 and 24 have the same outside diameter, but the inside diameter of section 24 can be larger than that of section 22 made of aluminum, so that part of the sheathing of the cable, as in FIG Fig. 3 shown can be inserted into the sleeve. The inner diameter of the section made of aluminum, however, can be smaller, since it only has to accommodate the aluminum braid.

In Fig. 3 ist der Zustand nach Aufschieben und der Anschlusshülse auf das Kabel, Verschweißen der Aluminiumlitze mit dem aus Aluminium bestehenden Abschnitt 22 der Hülse und Anlöten des bei diesem Ausführungsbeispiel aus Kupfer bestehenden Abschnitts 24 an die hier aus Edelstahlgeflecht bestehende Ummantelung 12 gezeigt, so dass ein erfindungsgemäßes Hochstromkabel 30 gebildet ist. Für den Fachmann erschließt sich sofort, dass auf diese Weise ein nicht nur optisch ansprechender und eleganter Abschluss des Hochstromkabels gebildet werden kann, sondern dass sich dieser Abschluss hervorragend zum Anschließen an elektrische Geräte wie z.B. Erzeuger von Induktionswechselströmen eignet, denn der aus Aluminium bestehende Abschnitt kann leicht und dauerhaft mit der aus Aluminium bestehenden Litze verschweißt werden, während der aus Kupfer oder einem entsprechenden anderen geeigneten Metall bestehende Abschnitt eine hervorragende Leitfähigkeit und Robustheit aufweist, insbesondere aber leicht mit einem Stecker aus einem entsprechenden Material, typischerweise aus Messing, verbunden werden kann. Fig. 4 zeigt einen in seiner Gesamtheit mit 40 bezeichneten entsprechenden Hochstromstecker.In Fig. 3 the state after sliding and the connecting sleeve on the cable, welding the aluminum braid to the aluminum section 22 of the sleeve and soldering the section 24, which is made of copper in this embodiment, to the sheathing 12, which is made of stainless steel braiding, so that a high-current cable according to the invention 30 is formed. For those skilled in the art it is immediately apparent that in this way not only a visually appealing and elegant termination of the high-current cable can be formed, but that this termination is ideally suited for connection to electrical devices such as generators of induction alternating currents, because the section made of aluminum can can be easily and permanently welded to the strand made of aluminum, while the section made of copper or another suitable metal has excellent conductivity and robustness, but in particular can easily be connected to a plug made of a suitable material, typically brass. Fig. 4 shows a corresponding high-current plug, designated in its entirety by 40.

Der Hochstromstecker 40 besitzt bei diesem Ausführungsbeispiel einen zylindrischen Kontaktabschnitt 42, eine zylindrische Aufnahmehülse 44 und einen Abschlussflansch 46. Der Innendurchmesser der Aufnahmehülse 44 ist so bemessen, dass die Aufnahmehülse 44 eine Aufnahme 48 für die Anschlusshülse 20 gemäß Fig. 2 bildet. Die Anschlusshülse kann nach Einführen in die Aufnahme 48 durch Madenschrauben gesichert werden, die durch eine oder mehrere Bohrungen 50 in die Aufnahmehülse eingedreht werden. Vorzugsweise wird die Anschlusshülse jedoch nach dem Einbringen selbiger in die Aufnahme 48 mit dem Stecker 40 verlötet, was vorteilhaft dadurch möglich ist, dass der am kabelzugewandten Teil der Anschlusshülse befindliche Abschnitt der Anschlusshülse aus einem Metall wie insbesondere Kupfer oder Silber besteht, das sich gut mit dem Metall, aus dem typischerweise ein Hochstromstecker der hier in Frage stehenden Art, insbesondere Messing, besteht, verlöten lässt. Diese Materialien sind auch deutlich härter als Aluminium, so dass der Aufnahmeabschnitt des Steckers nicht nur für eine gute elektrische Verbindung zwischen dem Hochstromkabel und dem Stecker sorgt, sondern gleichzeitig auch den nach Herstellen der entsprechenden Verbindung innenliegenden Aluminiumabschnitt der Anschlusshülse schützt. Der Kontaktabschnitt 42 des Steckers 40 ist in an sich bekannter Weise zum Einbringen in eine entsprechende Aufnahme an einem elektrischen Gerät vorgesehen.In this exemplary embodiment, the high-current plug 40 has a cylindrical contact section 42, a cylindrical receiving sleeve 44 and a closing flange 46 Fig. 2 forms. After being inserted into the receptacle 48, the connecting sleeve can be secured by grub screws which are screwed into the receptacle sleeve through one or more bores 50. However, the connection sleeve is preferably soldered to the plug 40 after it has been introduced into the receptacle 48, which is advantageously possible in that the portion of the connection sleeve located on the cable-facing part of the connection sleeve is made of a metal, such as copper or silver in particular, that interacts well the metal, from which a high-current plug of the type in question here, in particular brass, is typically made, can be soldered. These materials are also significantly harder than aluminum, so that the receiving section of the plug not only ensures a good electrical connection between the high-current cable and the plug, but at the same time also protects the aluminum section of the connecting sleeve that is on the inside after the corresponding connection has been made. The contact section 42 of the plug 40 is provided in a manner known per se for insertion into a corresponding receptacle on an electrical device.

Wichtig ist, dass die Ausgestaltung der Hülse aus zwei unterschiedlichen Materialien, von denen eines Aluminium ist, gewährleistet, dass die Anschlusshülse sicher und dauerhaft mit der Aluminiumlitze verschweißt werden kann.It is important that the design of the sleeve from two different materials, one of which is aluminum, ensures that the connecting sleeve can be welded safely and permanently to the aluminum braid.

BEZUGSZEICHENLISTEREFERENCE LIST

1010
HochstromkabelHigh current cable
1212th
EdelstahlgeflechtStainless steel mesh
1414th
AluminiumlitzAluminum strand
1616
Isolierbandelectrical tape
2020th
AnschlusshülseConnecting sleeve
2222nd
zylindrischer Abschnittcylindrical section
2424
zylindrischer Abschnittcylindrical section
2626th
MadenschraubeGrub screw
3030th
HochstromkabelHigh current cable
4040
HochstromsteckerHigh current plug
4242
zylindrischer Kontaktabschnittcylindrical contact section
4444
zylindrische Aufnahmehülsecylindrical receiving sleeve
4646
AbschlussflanschEnd flange
4848
Aufnahmerecording
5050
Bohrungdrilling

Claims (9)

  1. A high-current cable (10), in particular for induction applications with a preferably stranded aluminum litz wire running in a sheathing (12), wherein the high-current cable (10) comprises a coupling sleeve (20) pushed onto the litz wire at at least one end of the aluminum litz wire,
    - wherein the coupling sleeve (20) consists of a first substantially cylindrical section (22) near the cable end made of a first metal and, welded thereto, a second substantially cylindrical section (24) remote from the cable end made of a second metal,
    - wherein the first section (22) is made of aluminum and welded to the aluminum litz wire (14),
    characterized in that the two substantially cylindrical sections (22, 24) have the same outer diameter.
  2. The high-current cable according to claim 1, characterized in that the second section (24) consists of copper or silver.
  3. The high-current cable according to any one of claims 1 or 2, characterized in that the inner diameter of at least the second section (24) is dimensioned to receive the sheathing (12) with the aluminum litz wire (14).
  4. The high-current cable according to any one of claims 1 to 3, characterized in that the sheathing (12) is a stainless steel braid sheathing.
  5. The high-current cable according to any one of claims 1 to 4, characterized in that the first substantially cylindrical section (22) and the second substantially cylindrical section (24) are friction welded together.
  6. The high-current cable according to any one of claims 1 to 5, characterized in that the coupling sleeve (20) can be fastened in a high-current plug (40).
  7. A method for attaching a high-current plug (40) to a high-current cable (10) with a sheathed aluminum litz wire (14),
    characterized by
    - providing a coupling sleeve (20) with two substantially cylindrical sections (22, 24) welded together and having the same outer diameter, one (22) of which consisting of aluminum and the second (24) consisting of a different metal, preferably copper or silver,
    - exposing part of the aluminum litz wire (14),
    - pushing the coupling sleeve (20) on the high-current cable (10) with the second section (24) first, so that the aluminum litz wire (14) is in the section (22) of the coupling sleeve (20) consisting of aluminum,
    - welding the section (22) of the coupling sleeve (20) consisting of aluminum to the aluminum litz wire (14),
    - introducing the coupling sleeve (20) into a receptacle (48) of a high-current plug (40) that is at least partially complementary to the coupling sleeve, and
    - fastening the coupling sleeve (20) in the receptacle (48).
  8. The method according to claim 7, characterized in that said providing the coupling sleeve (20) comprises friction welding together the two substantially cylindrical sections (22, 24).
  9. The method according to claim 7 or 8, characterized in that said fastening the coupling sleeve (20) in the receptacle (48) takes place by soldering.
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IL31854A (en) * 1968-04-12 1972-07-26 Amp Inc Terminals for weld connection to electrical conductor wires
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DE10346160B3 (en) * 2002-05-25 2005-07-14 Feindrahtwerk Adolf Edelhoff Gmbh & Co. Contacting cable with wires or braids of aluminum or aluminum alloy involves tinning metal terminal on end with individual conductors at end of cable by ultrasonic tinning with metal via opening
US20070215606A1 (en) 2006-03-20 2007-09-20 Albaugh Timothy O Wonder-flex induction coil
JP6623142B2 (en) * 2016-11-01 2019-12-18 古河電気工業株式会社 Connection structure between aluminum cable and joint member
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