EP3878053A1

EP3878053A1 - Method for producing a connector part for electrical installations, connector part, and connection of a connector part to a cable

Info

Publication number: EP3878053A1
Application number: EP19789891.9A
Authority: EP
Inventors: Matthias RUDA
Original assignee: Auto Kabel Management GmbH
Current assignee: Auto Kabel Management GmbH
Priority date: 2018-11-07
Filing date: 2019-10-10
Publication date: 2021-09-15
Also published as: US20210408701A1; CN113228420A; US11916321B2; WO2020094327A1; MX2021005324A; DE102018127729A1

Abstract

The invention relates to a method for producing a connector part (22) for electrical installations, in particular for an on-board electrical system of a motor vehicle, comprising the steps of: deep-drawing a sheet blank in order to produce a sleeve (2) having a first end region (6) and a second end region (10), the first end region (6) having a base (8), and the second end region (10) being open; deforming, in particular compressing, the second end region (10) in order to create a tab (14) and introducing a through-hole (20) in the tab (14). The invention also relates to a connector part (22) for electrical installations, in particular for an on-board electrical system of a motor vehicle, and to a connection of between a connector part (22) according to one of the preceding claims and a cable (24) formed from a plurality of wires (26) or litz wires.

Description

Process for producing a connector for electrical systems, connector and connection of a connector with a cable

The subject matter relates to a method for producing a connection part for electrical systems, in particular for an on-board network of a motor vehicle. The

The subject also relates to a connector for electrical systems and the connection of a connector with a cable formed from a plurality of wires or strands.

Nowadays motor vehicles have an increasing number of electrical consumers in the course of electrification. For the electrical connection of

electrical systems with the current-carrying lines or cables of one

Motor vehicle connecting parts are usually used. Due to the increasing use of connecting parts and enormous cost pressure, ever increasing demands are being made on connecting parts.

Thus, the connection parts not only have to be able to be connected particularly easily to the current-carrying lines or cables of a motor vehicle, but should also have good electrical conductivity and the lowest possible weight. In addition, the manufacturing process of the connection parts should be inexpensive and reliable.

Due to the increasing number of electrical consumers and a consequent increase in current-carrying lines or cables, small cable cross-sections are preferably used and therefore also connecting parts with a small cross-section and a resulting small size are required.

It is known from the prior art to stretch sheet metal and

then bend to make a connector. Such a thing However, the manufacturing process is disadvantageous in that the stretching - in particular in the case of small connecting parts - does not provide a sufficiently thick wall of the connecting part, as a result of which a welded connection with an electrical conductor or cable cannot be reliably established.

It is also known to design a connecting part in several parts. However, this is disadvantageous with regard to the mechanical strength of the connecting part and leads to a resource-intensive assembly process.

Based on this, the object of the object was to specify a method for producing a connection part, a connection part and a connection of a connection part with a cable formed from a plurality of wires or strands, with which small geometries can be produced reliably and inexpensively, and a reliable connection with a Cable is made possible.

This task is solved objectively by an aforementioned method for producing a connecting part, which comprises the following steps:

- deep drawing of a sheet metal blank for producing a sleeve having a first end region and a second end region, the first

End region has a floor and the second end region is open,

- Forming, in particular pressing, the second end region to create a tab and

- Making a through hole in the tab.

The deep-drawing process enables a sleeve to be process-reliable with only a small amount

To produce tolerances. This is particularly advantageous for the production of connecting parts with small dimensions. Furthermore, the bottom of the first one

End area of the sleeve due to the deep-drawing process on small outer radii.

As a result, the bottom of the first end region can advantageously be provided by means of a The weld seam can be connected both mechanically and electrically using an electrical cable. It is particularly advantageous if the weld seam is a friction weld seam, that is to say a weld seam that was created by means of a friction weld.

It is also possible to carry out a previously mentioned deep-drawing process with large quantities and low cycle times, which results in the connecting parts

Have it produced inexpensively. The shaping, in particular pressing, of the second end region to create a tab and the introduction of one

Through holes in the tab are inexpensively possible with high process reliability.

Furthermore, the connecting part is preferably configured in one piece. This leads to an increased stability of the connection part and also to a low level

Production costs, since there is no need for complex assembly work.

According to one embodiment, the second end region of the sleeve is reshaped, preferably pressed, in such a way that the inner wall sides of the tab at least partially abut one another and the cross section of the tab is essentially elliptical, a wide plane defining the maximum cross-sectional width of the tab. The wide plane is preferably formed by the at least partially abutting inner wall sides of the tab. By pressing the second end region of the sleeve, a uniformly stable electrical contact can be ensured, for example in the case of a clamp contact on an electrically conductive component. The size of the second end region of the connecting part can also be reduced by the pressing, which is advantageous in terms of the installation space required.

Another embodiment is characterized in that the

Through hole is introduced into the tab substantially orthogonal to the wide plane. The axis of the through hole is thus orthogonal to the broad plane of the tab. With such a through hole, the Connection part, for example with an electrical cable or with a

electrical consumers, in particular by means of a screw, can be connected in a favorable manner. It is preferred that the through hole is made substantially centrally in the broad plane of the tab and that the through hole is preferably essentially circular.

According to a further exemplary embodiment, the tab, in particular after the through-hole has been made, is deformed one or more times, preferably bent.

It is also preferable that the through hole and the

Deformation of the tab can be carried out simultaneously in a combined bending / punching process. By deforming, in particular by bending, the tab, the connector can be used in various installation scenarios or

Available space can be adjusted.

According to a further exemplary embodiment, it is preferred that the tab is deformed, in particular bent, about an axis lying in the broad plane and essentially running in the transverse direction of the connecting part. In this way it can be achieved that the through hole is provided in the position planned in terms of construction.

It is also preferred that the tab is bent several times, the respective bending axes, that is to say those axes about which the tab is bent, essentially parallel or transverse to the one lying in the broad plane

Axis extending essentially in the transverse direction of the connecting part are formed. Such bending processes make it possible to provide variable fastening options for the connecting part, since the position of the through hole can be adapted to different installation scenarios.

According to a further exemplary embodiment, it is preferred that the sleeve has a wall thickness of at least 1 mm after the deep-drawing. This can ensure that the wall thickness of the floor after further processing of the sleeve has a sufficient thickness so that it can be reliably connected to a cable by means of a welded connection, in particular with a friction welded connection.

Another aspect relates to a connection part for electrical systems, in particular for an electrical system of a motor vehicle, with a first end region and with a second end region, the connection part being formed in one piece, the first end region being formed as a closed, U-shaped tube section, the second end region is formed as a tab with an essentially elliptical cross-section and wherein the tab has a through hole.

It is preferred that the closed, U-shaped pipe section is preferably composed of a substantially circular wall and a bottom, which is also essentially circular, delimiting the wall on the underside. Advantages of a connection part designed in this way have already been explained in connection with the method for producing the connection part.

In terms of saving space, it is advantageous that the

Outer diameter of the first end region is larger than the outer diameter of the second end region. This is because the outer diameter of the first end region generally corresponds to the outer diameter of a cable to be connected. Thus, a smaller outer diameter of the second

Both end space can be saved as well as the

Connection options of the connector are increased.

According to one exemplary embodiment, it is proposed that a transition region is arranged between the first end region and the second end region and that the transition region tapers substantially starting from the first end region in the direction of the second end region. It is preferred that the

Transition area starting from the first end area in the direction of the second Tapered end area. However, other types of tapering are also conceivable, for example a curved taper.

With regard to a simple and process-reliable production of the connection part, it is preferred that the first end region, the transition region and at least part of the second end region along the longitudinal axis of the connection part are designed to be essentially mirror-symmetrical. It is preferred that the entire second end region, with the exception of the deformed part of the tab, also

is designed mirror-symmetrical.

According to a further embodiment, it is preferred that the first end region has an outer diameter of at most 25 mm, in particular of at most 8 mm. Such outer diameters can be realized in particular by deep drawing a sheet metal blank with only small tolerances, so that small ones

Connection parts can be manufactured that are too small

Cable diameters correspond. Small connecting parts are also advantageous in terms of material costs and the consumption of installation space.

With regard to the welding properties and the forming properties of the

It is advantageous if the connecting part is made of aluminum, copper, an aluminum alloy or a copper alloy.

The connecting part can be manufactured particularly cost-effectively if it is a

Tubular cable lug is. Tubular cable lugs are particularly in demand as mass-produced goods.

Another aspect relates to a connection of the aforementioned connection part to a cable formed from a plurality of wires or strands, the cable being enclosed by a support sleeve for receiving an end face of the cable in such a way that the wires or strands of the cable are held in the support sleeve and wherein the end face of the first end region of the connecting part is welded to the end face of the cable and / or the end face of the support sleeve by means of a weld seam. By deep-drawing the aforementioned connection part, a sufficient one can be

Soil thickness can be provided for a reliable white bond. Due to the closed design of the bottom of the connecting part, that is

Connecting part connected to the cable in a longitudinally sealed manner, thereby preventing entry of

Liquid, for example due to capillary forces, can be reliably prevented in the cable.

With regard to technical aspects of production, it is also advantageous if the weld seam is a friction weld seam, that is to say by means of a

Friction welding connection between the end face of the first end region of the

Connection part and the end face of the cable and / or the end face of the support sleeve is formed. The connecting part is preferably rotated during the welding process.

In particular, it is preferred that the friction welding connection of the end face of the first end region exists both with the end face of the cable and with the end face of the support sleeve. The friction weld can be a rotary friction weld.

A further embodiment is characterized in that the end face of the cable is essentially flush with the end face of the support sleeve. The end face of the cable is preferably formed by the ends of the wires or strands. This enables a friction weld connection to be reliably established both with the cable and with the support sleeve.

According to a further embodiment, it is advantageous that the cable is stripped in the area of the support sleeve. This enables a reliable electrical connection between the cable and the support sleeve.

The subject is explained in more detail below with reference to a drawing showing exemplary embodiments. The drawing shows:

La is a side view of an embodiment of a sleeve during an objective process after deep drawing in section, Fig. Lb the embodiment of the sleeve shown in Fig. La after deep drawing in a front view,

Fig. 2a is a side view of that shown in Figs. La and lb

Embodiment of the sleeve after pressing in section,

Fig. 2b the embodiment of the sleeve shown in Fig. 2a after

Pressing in a front view,

A top view of the embodiment of the sleeve shown above after the insertion of a through hole,

Fig. 3b, the embodiment of the sleeve shown in Fig. 3a after

Making the through hole in a rotated front view,

4a shows a first process step of joining an exemplary embodiment of the connection part in question to a cable by means of a rotary friction welding method in a side view,

4b shows a second process step of the joining shown in FIG. 4a, FIG. 4c shows a third process step of the joining shown in FIGS. 4a and 4b

Joining,

Fig. 5a shows an embodiment of the connector in a

Side view,

5b shows the embodiment of the connecting part shown in FIG. 5a in a plan view, 6a shows a further embodiment of the connection part in question in a side view,

6b shows the exemplary embodiment of the connecting part shown in FIG. 6a

a top view,

7a shows a further embodiment of the connection part in question in a side view,

7b shows a top view of the exemplary embodiment of the connecting part shown in FIG. 7a,

Fig. 8a shows another embodiment of the connector in a side view

Fig. 8b the embodiment of the connector shown in Fig. 8a in a plan view.

In the following description of the different exemplary embodiments, components and elements with the same function and the same mode of operation are provided with the same reference numerals, even if the components and elements in the different exemplary embodiments can have differences in their dimensions or shape.

Fig. La shows a side view of an embodiment of a sleeve 2 during a subject process after deep drawing. The sleeve 2 is tubular and has an essentially circular wall 4. This can be seen in the front view of the sleeve 2 shown in FIG. 1b. Furthermore, the sleeve comprises a first end region 6, which has a bottom 8 and a second end region 10, which is open. The sleeve 2 has an essentially U-shaped cross-sectional profile and is preferably made of copper, Aluminum or alloys thereof. The wall thickness of the sleeve 2 is preferably at least 1 mm.

In Fig. 2a is a side view of that shown in Figs. La and Ib

Embodiment of the sleeve 2 shown after pressing. It can be seen that the inner walls 12 or the inner lateral surface of the wall 4 essentially abut one another in the second end region 10. As a result of the pressing, a tab 14 with an essentially has in the second end region 10

elliptical cross section formed (see. Fig. 2b). The first end region 6 tapers essentially conically by means of a transition region 16 and then merges into the second end region 10 or the tab 14. The

Transition area 16 and first end area 6 enclose an internal cavity 18. 2b that the outer diameter di of the first end region 6 is larger than the outer diameter d2 of the second

End region 10 or the tab 14. The outer diameter di is preferably at most 10 mm, in particular at most 8 mm.

FIG. 3a shows a top view of the previously illustrated embodiment of the sleeve 2 after the insertion of a through hole 20. After the

Through hole 20 all process steps have been completed, so that a connector 22 has now been produced. The through hole 20 is made centrally in a wide plane E of the tab 14. The broad plane E of the tab 14 is shown in FIG. 3b and runs along the maximum cross-sectional width of the tab 14. The longitudinal axis X of the connecting part 22 preferably runs centrally through the through hole 20.

4a to 4c show the connection of an objective connector 22 to a cable 24 by means of a rotary friction welding process. The cable 24 is preferably a battery cable of a motor vehicle, in particular for connecting a battery to a starter, a generator or else to another electrical line of a motor vehicle. The cable 24 is composed of several strands or wires 26, which are sheathed by an insulation 28 are. In the end region of the cable 24, the insulation 26 is removed, so that the wires 26 are exposed and are surrounded by a support sleeve 30. The support sleeve 30 is preferably round and made of aluminum, copper or alloys thereof. It can be seen that the end face 30a of the support sleeve 30 is flush with the end face 24a of the cable 24

The support sleeve 30 is preferably pressed so that the wires 26 lie closely together within the support sleeve 30. In a first process step of the rotary friction welding process, the connecting part 22 is set in rotation, whereas the cable 24 is arranged in a holder (not shown) in a rotationally fixed manner

In the process step shown in FIG. 4b, the connection part 22 is brought into contact with the cable 24 in such a way that the end face 22a of the connection part 22 comes into contact with the end face 30a of the support sleeve 30 and the end face 24a of the cable 24 moved in the direction of arrow Y towards the connector 22.

Due to the rotation of the connection part 22, friction occurs between the connection part 22 and the cable 24 or the support sleeve 30, whereby the materials in contact with one another are heated and plasticized.This causes the connection part 22 to be integrally connected by means of a friction weld 32 with the cable 24 and welded to the support sleeve 30 In Fig. 4c a friction weld 32 is shown

5a to 8b show various exemplary embodiments of a connecting part 22 in question. The connecting parts 22 differ only in the bending processes to which they have been subjected. It is possible to provide the bending processes simultaneously with the introduction of the through hole 20 or after the introduction of the through hole 20. The connection part 22 shown in FIGS. 5a and 5b has not been subjected to any bending process. It essentially corresponds to that in FIGS. 3a _; 3b and FIGS. 4a to 4c, the connection part 22 shown.

The connecting part 22 or the tab 14 of the connecting part 22 shown in FIGS. 6a and 6b has been bent around two bending axes Bi and B ₂ . It can be seen that the bending axes Bi and B _{2 run} in the transverse direction of the connecting part 22, the bending axis Bi lying in the plane E shown in FIG. 3b and the bending axis B ₂ extending parallel to the bending axis Bi. The double bending of the tab 14 enables an offset screwing surface for the through hole 20, the axis running through the through hole 20 continuing to run in the transverse direction of the connecting part 22.

7a and 7b, the exemplary embodiment of the connecting part 22 has been bent essentially by 90 ° about a bending axis B ₃ , so that the axis running through the through hole 20 extends essentially parallel to the longitudinal axis X of the connecting part 22.

8a and 8b show a connecting part 22, the tab 14 of which has been bent around a total of three bending axes B ₄ , Bs and B ₆ . As a result, the tab 14 can be adapted to special structural conditions. It can be seen that the axis running through the through hole 20 runs obliquely to the longitudinal and transverse axes of the connection part 22.

Claims

Patent claims

1. Process for producing a connection part for electrical systems,

in particular for an electrical system of a motor vehicle, comprising:

Deep drawing a sheet metal blank for producing a sleeve having a first end region and a second end region, the first end region having a bottom and the second end region being open,

Forming, in particular pressing, the second end area to create a tab and

Make a through hole in the tab.

2. The method according to the preceding claim,

characterized,

that the second end region of the sleeve is shaped in such a way that

The inside of the wall of the bracket at least partially abuts one another and the cross section of the bracket is essentially elliptical, with a broad plane defining the maximum cross-sectional width of the bracket.

3. The method according to any one of the preceding claims,

characterized,

that the through hole is made substantially orthogonal to the wide plane in the tab.

4. The method according to any one of the preceding claims,

characterized,

that the tab is deformed, preferably bent, one or more times, in particular after the through hole has been made.

5. The method according to any one of the preceding claims,

characterized,

that the tab is deformed, in particular bent, about an axis lying in the broad plane and essentially running in the transverse direction of the connecting part.

6. The method according to any one of the preceding claims,

characterized,

that the sleeve has a wall thickness of at least 1 mm after deep drawing.

7. Connection part for electrical systems, in particular for an on-board electrical system

Motor vehicle,

with a first end region (6) and

with a second end region (10),

the connecting part (22) being formed in one piece,

characterized,

that the first end region (6) is formed as a closed, U-shaped tube section,

that the second end region (10) is formed as a tab (14) with an essentially elliptical cross section and

that the tab (14) has a through hole (20).

8. connecting part according to the preceding claim,

characterized,

that the outer diameter (di) of the first end region (6) is larger than the outer diameter (d ₂ ) of the second end region (10).

9. Connection part according to one of the preceding claims,

characterized, that a transition region (16) is arranged between the first end region (6) and the second end region (10) and

that the transition region (16) tapers substantially from the first end region (6) in the direction of the second end region (10).

10. Connection part according to one of the preceding claims,

characterized,

that the first end region (6), the transition region (16) and at least a part of the second end region (10) along the longitudinal axis (X) of the connection part (22) are designed to be essentially mirror-symmetrical.

11. Connection part according to one of the preceding claims,

characterized,

that the first end region (6) has an outer diameter (di) of at most 25 mm, in particular of at most 8 mm.

12. Connection part according to one of the preceding claims,

characterized,

that the connector (22) made of aluminum, copper, from a

Aluminum alloy or is formed from a copper alloy.

13. Connection part according to one of the preceding claims,

characterized,

that the connecting part (22) is formed as a preferably closed tubular cable lug.

14. Connection of a connecting part (22) according to one of the preceding claims with a cable (24) formed from a plurality of wires (26) or strands, the cable (24) from a support sleeve (30) for receiving an end face (24a) of the Cable (24) is enclosed in such a way that the wires (26) or strands of the cable (24) are held in the support sleeve (30), characterized,

that the end face (22a) of the first end region (10) of the connecting part (22) is welded to the end face (24a) of the cable (24) and / or the end face (30a) of the support sleeve (30) by means of a weld seam (32)

15. A compound according to the preceding claim,

characterized,

that the weld is a friction weld (32).

16. Connection according to one of the preceding claims,

characterized,

that the end face (24a) of the cable (24) is essentially flush with the end face (30a) of the support sleeve (30).

17. Connection according to one of the preceding claims,

characterized,

that the cable (24) is stripped in the area of the support sleeve (30).