EP3883064B1 - Connector and socket for aluminium power cable and aluminium power cable with a connector or a socket - Google Patents

Description

AREA

The present invention relates to electrical plug connections, in particular for aluminum power cables, more particularly for aluminum power cables with stranded conductors.

BACKGROUND

There are a large number of different electrical lines for transporting electrical energy to the place of consumption, for example solid conductors of different cross sections, multi-wire conductors and stranded conductors, which consist of a large number of individual conductors of smaller cross sections, which are usually twisted, and whose entirety has the desired cross section of the leader. Stranded conductors are more flexible than solid and stranded conductors, making handling and installation easier. Some applications or devices require electrical conductors, which must also be able to move flexibly during operation, for example for electrically connecting wagons of trains or trams, which are usually mechanically connected to one another via movable couplings. The IEC standard 60228 defines, among other things, different classes for the flexibility of electrical connections. For example, class 5 includes flexible cables with fine-wire construction, while class 6 includes highly flexible cables with fine-wire construction.

In applications or devices in which electrical connections conduct high currents, large conductor cross-sections are usually required for the conductors and the conductor connectors; the diameters of such electrical conductors can be 20 mm or more.

If the cross sections or diameters of the electrical conductors are large, the weight of the electrical connection also increases, especially at longer cable lengths. For this reason, aluminum is often used for the electrical conductor, as it has high electrical conductivity and is low in weight. In addition, aluminum is comparatively soft and easily deformable, which has advantages in the production of flexible stranded conductors. Aluminum is also inexpensive compared to copper.

Unfortunately, aluminum tends to oxidize very quickly on the surface when it comes into contact with atmospheric oxygen. The oxide layer has a significantly lower electrical conductivity than pure aluminum and it is therefore essential to remove or break up the oxide layer when making electrical contact with an aluminum conductor.

Some electrical connections must be designed to be separable, for example when wagons of trains or trams are decoupled from one another. For this purpose, plugs and sockets can be provided on conductor segments to be connected to one another.

The plugs and sockets are usually designed in such a way that they can be brought together in a form-fitting manner in order to produce the largest possible electrical contact. The plug or socket must be connected to the electrical conductor with the lowest possible electrical contact resistance. To connect plugs or sockets to electrical stranded conductors, press connections are often used, in which a tubular section is mechanically placed around the strands of the electrical conductor and pressed firmly with them. In order to achieve a connection between the stranded conductor and the plug or socket with the lowest possible electrical resistance, it must be ensured that each individual strand of the stranded conductor has good electrical contact with the plug or socket and that there are no oxide layers that may be on the surface the conductors have formed must be removed or broken open. Due to the deformation of the strands and the press sleeve during pressing, the oxide layers are usually broken up, so that high-purity aluminum lies freely on the surface. The oxide layers can be broken up by adding abrasives, for example in one Lubricant-bound corundum grains can be further improved. In order to prevent the entry of atmospheric oxygen into the press connection, aluminum press connections can be additionally sealed in some embodiments. From the disclosure document DE 23 54 356 A1 a connecting device for connecting axially movable electrical conductors made of aluminum is known, in which Al / Cu adapters are used. The aluminum conductor is connected to an aluminum sleeve, for example by pressing, and the copper parts of two AI/Cu adapters create the plug-in connection that can move towards one another. The plug pin and/or the socket can be provided with contact elements, for example contact lamellae made of beryllium bronze.

It is an object of the present invention to propose a plug or socket for connecting aluminum stranded conductors, which has good electrical contact between the individual strands with the plug or socket and between the plug and socket. A further object of the present invention is to propose a power line arrangement with an aluminum stranded conductor according to the invention and a plug or a socket.

DESCRIPTION OF THE INVENTION

The object is achieved by a plug or a socket of an electrical connection arrangement for aluminum stranded conductors according to claim 1 or claim 2, and by an electrical connection arrangement according to claim 10 with a plug according to the invention and / or a socket according to the invention. Advantageous refinements or further developments are specified in the dependent claims.

The plug or socket has a press area made of aluminum. For electrically conductive connections, high-purity aluminum known as Al 99.5 is usually used. The pressing area is designed to accommodate strands of the aluminum stranded conductor and to be crimped with them. The pressing area of the plug is electrically conductive with an in a corresponding hole in the socket is connected to the insertable contact pin, and the pressing area of the socket is electrically conductively connected to a receiving area in which the hole receiving the contact pin is arranged. An electrically conductive ring is arranged on the contact pin of the plug and has elastically deformable or resilient structures projecting outwards over the diameter of the contact pin. Alternatively or additionally, an electrically conductive ring can be arranged in the bore of the socket, which extends inwards Diameter of the bore has elastically deformable or resilient protruding structures.

In one or more embodiments of the plug or socket of the electrical connection arrangement, the electrically conductive ring is arranged in a groove of the contact pin or the bore. As a result, the ring can be fixed in the axial direction of the contact pin or the bore.

In one or more configurations of the plug or socket of the electrical connection arrangement, the electrically conductive ring is axially slotted. This can make it easier to attach the ring to the contact pin or in the hole, especially if the ring is attached in a groove.

In one or more configurations of the plug or socket of the electrical connection arrangement, the structures of the electrically conductive ring include lamellas, knives or fins.

In one or more embodiments of the plug or socket of the electrical connection arrangement, the structures of the electrically conductive ring run at least in sections axially parallel to the contact pin or the bore.

According to the invention, the structures of the electrically conductive ring run at least in sections obliquely or helically to a longitudinal axis of the contact pin or the bore. The helical or oblique structures can also be designed in opposite directions.

According to the invention, at least the structures of the electrically conductive ring consist of a material whose hardness is sufficient, an aluminum oxide layer or a corrosion protection layer on the surface of the The contact pin or the hole has to be broken open or at least scraped off in areas, or are coated with such a material.

In one or more embodiments of the plug or socket of the electrical connection arrangement, the contact pin and/or the bore is made of an electrically conductive material at least in an area in which the electrically conductive ring or its structures make electrical contact in the assembled end position coated, which has a higher corrosion resistance than aluminum, at least in the normal earth's atmosphere and in a temperature range at which production usually takes place, for example between minus 40 ° and plus 120 ° Celsius. The material can include, for example, gold, silver, nickel or tin, with silver being used in particular when the number of times the plug and socket are plugged in is large and the currents carried through the connection arrangement are high. In this embodiment, an electrically conductive contact can be produced in an area that is not covered with an oxide layer during a plug-in process, without an oxide layer having to be broken up or removed beforehand.

In one or more configurations of the plug or socket of the electrical connection arrangement, the contact pin of the plug and/or the receiving area of the socket consists of a material or is coated with a material that prevents an oxide layer or whose oxide layer can be easily removed.

In one or more configurations of the plug or socket of the electrical connection arrangement, the contact pin of the plug and/or the receiving area of the socket consists of copper, hard copper alloys, aluminum alloy or brass, and are electrically conductively connected to one another in a material or material bond with the respective pressing area. The connection can be made, for example, by means of cold pressure welding, friction stir welding, resistance welding and the like.

In one or more configurations of the plug or socket of the electrical connection arrangement, the contact pin of the plug tapers conically towards its tip to a small extent. Accordingly, the bore of the socket tapers slightly conically towards its end. The taper of the contact pin and bore is preferably such that the surfaces lie completely inside one another when the plug and socket are completely plugged together.

According to a further aspect of the invention, an electrical power cable with an aluminum stranded conductor and a plug and/or a socket of one of the embodiments of the electrical connection arrangement described above is proposed, in which the aluminum conductor is connected to one another in a pressing area of the plug and/or the socket are pressed.

The plug according to the invention and/or the socket according to the invention can advantageously be used in electrical connections through which high currents flow, for example currents of several 100 amperes, as can be found in electrically driven vehicles, in particular rail vehicles.

The invention is explained in more detail below with reference to the figures in the drawing.

BRIEF DESCRIPTION OF THE DRAWING

Fig. 1

eine schematische Schnittdarstellung einer ersten Ausführung einer elektrischen Verbindungsanordnung,

Fig. 2

eine schematische Schnittdarstellung einer zweiten Ausführung einer elektrischen Verbindungsanordnung,

Fig. 3

eine schematische Schnittdarstellung einer dritten Ausführung einer elektrischen Verbindungsanordnung,

Fig. 4

eine schematische Schnittdarstellung einer vierten Ausführung einer elektrischen Verbindungsanordnung,

Fig. 5

eine Schrägansicht der ersten Ausführung einer elektrischen Verbindungsanordnung in teiltransparenter Darstellung,

Fig. 6

eine Schrägansicht der zweiten Ausführung einer elektrischen Verbindungsanordnung in teiltransparenter Darstellung,

Fig. 7

eine Schrägansicht der dritten Ausführung einer elektrischen Verbindungsanordnung in teiltransparenter Darstellung,

Fig. 8

eine Schrägansicht der vierten Ausführung einer elektrischen Verbindungsanordnung in teiltransparenter Darstellung, und

Fig. 9

eine beispielhafte Darstellung einer Pressverbindung der Verbindungsanordnung.

Shown in the drawing

Fig. 1

a schematic sectional view of a first embodiment of an electrical connection arrangement,

Fig. 2

a schematic sectional view of a second embodiment of an electrical connection arrangement,

Fig. 3

a schematic sectional view of a third embodiment of an electrical connection arrangement,

Fig. 4

a schematic sectional view of a fourth embodiment of an electrical connection arrangement,

Fig. 5

an oblique view of the first embodiment of an electrical connection arrangement in a partially transparent representation,

Fig. 6

an oblique view of the second embodiment of an electrical connection arrangement in a partially transparent representation,

Fig. 7

an oblique view of the third embodiment of an electrical connection arrangement in a partially transparent representation,

Fig. 8

an oblique view of the fourth embodiment of an electrical connection arrangement in a partially transparent representation, and

Fig. 9

an exemplary representation of a press connection of the connection arrangement.

DESCRIPTION OF EMBODIMENTS

In the figures, the same or similar elements are designated with the same reference symbols.
Figure 1 shows a schematic sectional view of a first embodiment of an electrical connection arrangement 10 according to the invention, which includes a plug 100 and a socket 200. The plug 100 and the socket 200 are made of aluminum, in particular AI 99.5, which contains an aluminum content of 99.5%. The plug 100 has a pressing area 102 made of aluminum, which is electrically conductively connected to a contact pin 104. The socket 200 has a pressing area 202, which is electrically conductively connected to a receiving area 208, in which a bore 204 receiving the contact pin 104 is arranged. An electrically conductive ring 206 is arranged in the bore 204 of the socket 200, which has structures which project inwards into the diameter of the bore 206 in an elastically deformable manner. In the figure, the electrically conductive ring 206 is arranged in a groove. The contact pin 104 has only a slightly smaller diameter than the bore 204. The structures of the electrically conductive ring 206 are pressed outwards into the groove by the contact pin 104. Pressing areas 102 and 202 of plug 100 and socket 200 have holes (not shown in the figure) for receiving stranded aluminum conductors.

Figure 2 shows a schematic representation of a second embodiment of an electrical connection arrangement 10 according to the invention, which includes a plug 100 and a socket 200. The connection arrangement 10 corresponds in most parts to that with reference Figure 1 described connection arrangement. Deviating from the previously described connection arrangement 10, an electrically conductive ring 106 is arranged on the contact pin 104 instead of in the bore 204. To accommodate the electrically conductive ring 106, contact pin 104 has a groove.

Figure 3 shows a schematic representation of a third embodiment of an electrical connection arrangement 10 according to the invention, which includes a plug 100 and a socket 200. The connection arrangement 10 corresponds in most parts to that with reference Figure 1 described connection arrangement. Deviating from the previously described connection arrangement 10, only the pressing areas 102 and 202 of the plug 100 and the socket 200 are made of aluminum, in particular AI 99.5, while at least the contact pin 104 of the plug 100 and the receiving area 208 of the socket 200 are made of a different material consist. The pressing area 102 of the plug 100 is connected to the contact pin 104 in an electrically conductive manner, for example by pressure welding or friction stir welding. The connection is indicated by line 110. Accordingly, the pressing area 202 of the socket 200 is connected to the receiving area 208 in an electrically conductive manner. The connection is indicated by line 210.

Figure 4 shows a schematic representation of a fourth embodiment of an electrical connection arrangement 10 according to the invention, which includes a plug 100 and a socket 200. The connection arrangement 10 corresponds in most parts to the reference Figure 2 described connection arrangement, in which the electrically conductive ring 106 is arranged on the contact pin 104. Different from that with reference to the Figure 2 The connection arrangement described exists, as in the one with reference to Figure 3 described connection arrangement, only the pressing areas 102 and 202 of the plug 100 and the socket 200 made of aluminum, while at least the contact pin 104 of the plug 100 and the receiving area 208 of the socket 200 consist of a different material. As with the one related to the Figure 3 The connection arrangement described is the pressing area 102 of the plug 100 with the contact pin 104 and the pressing area 202 of the socket 200 with the receiving area 208 electrically connected, for example by pressure welding or friction stir welding. Like in the Figure 3 the connections are indicated by lines 110 and 210.

Figure 5 shows an oblique view of the first embodiment of an electrical connection arrangement 10 Figure 1 in a partially transparent representation. In the Figure 5 the plug 100 is shown non-transparent, and the socket 200 is shown transparent. It can be clearly seen how the contact pin 104 of the plug 100 is received in the bore 204 of the socket 200, and how the contact pin 104 is enclosed by the electrically conductive ring 206, which is mounted in a groove in the bore 204 (not specified).

Figure 6 shows an oblique view of the second embodiment of an electrical connection arrangement 10 Figure 2 in a partially transparent representation. As before in the Figure 5 is in the Figure 6 the plug 100 is shown non-transparent, and the socket 200 is shown transparent. In this figure it can be clearly seen how the contact pin 104 is received in the bore 204 of the socket 200 with the electrically conductive ring 106 mounted in a groove (not specified).

Figure 7 shows an oblique view of the third embodiment of an electrical connection arrangement 10 Figure 3 in a partially transparent representation. As before in the Figures 5 and 6 are in the Figure 7 the components of the plug 100 are shown non-transparently, and the components of the socket 200 are shown transparently. In the Figure 7 the connecting seam 110 or the connecting surface 210 can be clearly seen, on which the respective pressing area 102 or 202 of the plug 100 or the socket 200 are electrically conductively connected to the contact pin 104 or the receiving area 208. The remaining elements of the Figure 7 correspond to those of the Figure 3 and are not explained in more detail.

Figure 8 shows an oblique view of the fourth embodiment of an electrical connection arrangement 10 Figure 4 in a partially transparent representation. As before in the Figures 7 are in the Figure 8 the components of the plug 100 are shown non-transparently, and the components of the socket 200 are shown transparently. In this figure, too, the connecting seam 110 or the connecting surface 210 can be clearly seen, where the respective pressing area 102 or 202 of the plug 100 or the socket 200 are electrically conductively connected to the contact pin 104 or the receiving area 208. The remaining elements of the Figure 8 correspond to those of the Figure 4 and are not explained in more detail.

Figure 9 shows an exemplary representation of a press connection of the connection arrangement 10. In the figure, a section of the connection arrangement 10 is shown Figure 1 a press connection 300 created at three points using press molds is shown. A sectional view of the press connection 300 is shown in the middle on the right edge of the figure. Halves 302a and 302b of a pressing tool 302 are shown above and below. The shape of the stamp of half 320a of the pressing tool 302 ensures complete compression of the aluminum strands, which also breaks up any oxide layers that may be present.

REFERENCE SYMBOL LIST

10

Connection arrangement

100

Plug

102

Press area

104

Contact pin

106

electrically conductive ring

110

Connecting seam or surface of the contact pin and pressing area

200

Rifle

202

Press area

204

drilling

206

electrically conductive ring

208

Recording area

210

Connecting seam or surface between the receiving area and the pressing area

Claims (11)

1. A connector (100) of an electrical connection arrangement (10) for aluminum stranded conductors, having a pressing area (102) made of aluminum, which is configured to accommodate strands of the stranded conductor, wherein the pressing area (102) of the connector (100) is connected electrically conductively to a contact pin (104) which can be inserted into a corresponding borehole of a socket, wherein an electrically conductive ring (106) is arranged on the contact pin (104) of the connector (100) with elastically deformable structures projecting outwards beyond the diameter of the contact pin (104), which structures consist of a material or are coated with a material, the hardness of which suffices to break up or at least partially scrape off an aluminum oxide layer or a corrosion protection layer on the surface of the borehole (204), characterized in that the structures of the electrically conductive ring (106, 206) run obliquely or helically to a longitudinal axis of the contact pin (104) or the borehole (204) at least in sections.
2. A socket (200) of an electrical connection arrangement (10) for aluminum stranded conductors, having a socket (200), wherein the pressing area (202) of the socket (200) is connected electrically conductively to the reception area (208), in which a borehole (204) receiving a contact pin of a connector is arranged, wherein in the borehole (204) of the socket (200) an electrically conductive ring (206) is arranged with elastically deformable structures projecting inwards into the diameter of the borehole (204), which structures consist of a material or are coated with a material, the hardness of which suffices to break up or at least partially scrape off an aluminum oxide layer or a corrosion protection layer on the surface of the contact pin (104), characterized in that the structures of the electrically conductive ring (206) run obliquely or helically to a longitudinal axis of the contact pin (104) or the borehole (204) at least in sections.
3. The connector (100) or socket (200) according to claim 1 or 2, wherein the electrically conductive ring (106, 206) is arranged in a groove (110, 210) of the contact pin (104) or of the borehole (204).
4. The connector (100) or socket (200) according to claim 1 or 3, wherein the electrically conductive ring (106, 206) is axially slotted.
5. The connector (100) or socket (200) according to any one of the preceding claims, wherein the structures of the electrically conductive ring (106, 206) run axially parallel to the contact pin (104) or the borehole (204) at least in sections.
6. The connector (100) or socket (200) according to any one of the preceding claims, wherein the structures of the electrically conductive ring (106, 206) comprise lamellas, blades or fins.
7. The connector (100) or socket (200) according to any one of the preceding claims 1 to 6, wherein the contact pin (104) and/or the borehole (204) are coated with an electrically conductive material, which has a higher corrosion resistance than aluminum, in particular gold, silver, nickel or tin, at least in a region, in which the electrically conductive ring or its structures are electrically contacted in a plugged-together end position.
8. The connector (100) or socket (200) according to any one of the preceding claims, wherein the contact pin (104) of the connector and/or the reception area (208) of the socket consists of a material or is coated with a material, that prevents an oxide layer or whose oxide layer can be easily removed.
9. The connector (100) or socket (200) according to any one of the preceding claims, wherein the contact pin (104) of the connector and/or the reception area (208) of the socket consists of copper, aluminum alloy or brass and are electrically conductively connected to each other with the respective pressing area (102, 202) in a bonded or material manner.
10. An electrical connection arrangement (10) comprising at least one connector (100) or one socket (200) according to any one of the preceding claims.
11. An electrical power cable having an aluminum stranded conductor and a connector (100) and/or a socket (200) of an electrical connection arrangement (10) according to any one of the preceding claims, which are crimped with each other in a pressing area (1 02, 202) of the connector (100) and/or the socket (200).

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