EP4005037B1 - Method, device and system for manufacturing an electric cable - Google Patents

Description

The invention relates to a method for assembling an electrical cable, according to the preamble of claim 1.

The invention also relates to a device and a system for assembling an electrical cable.

When assembling cables, their conductors are typically connected to a plug connector in order to then be able to establish electrical connections with other cables or conductors that have corresponding plug connectors or mating plug connectors. A connector or mating connector can be a plug, a built-in plug, a socket, a coupling or an adapter. The term “connector” or “mating connector” used in the context of the invention represents all variants.

Plug connectors for the automotive industry and vehicles in particular are subject to high demands on their robustness and the safety of the plug connections. Electromobility in particular poses major challenges for the automotive industry and its suppliers, as high currents with voltages of up to 1,500 V are sometimes transmitted in vehicles via cables or lines. Given the risk that component failure in an electric vehicle would result in, particularly high demands must be placed on the quality of the cables or lines and plug connections.

A plug connection must sometimes withstand high loads, for example mechanical loads, and remain closed in a defined manner so that the electrical connection is not unintentionally disconnected, for example during operation of a vehicle.

For reasons of quality monitoring and in order to make the cable assembly as transparent and comprehensible as possible for the end customer, it can be advantageous to document the assembly of the individual cables.

Documenting cable processing that can be traced back to individual cables is particularly complex in the context of fully or partially automated cable assembly.

Another requirement for connectors, especially for the automotive industry, is that they must be able to be produced economically in large quantities. For this reason, cable assembly that is as fully automated as possible is preferable, particularly for the assembly of cables for the automotive industry. Appropriate production lines must be established in order to achieve the required quantities while maintaining high quality.

For further technological background, please refer to the following publications. The US 5,208,977 A and the EP 3 093 933 A1 Each relates to assembly processes for electrical cables, whereby the individual cables should be identifiable during processing. Cable clamps are used to identify individual cables. Also the US 2007/178742 A1 relates to a method for identifying an electrical cable using an RFID system.

In view of the known prior art, the object of the present invention is to provide an advantageous method for assembling an electrical cable that is particularly suitable for automated cable processing.

Finally, it is also an object of the invention to provide an advantageous device and an advantageous system for assembling an electrical cable, which can be particularly suitable for automated cable processing.

The task is solved for the method with the features listed in claims 1 and 16. With regard to the device, the task is solved by the features of claim 14. Regarding the system, the task is solved by claim 15.

The dependent claims and the features described below relate to advantageous embodiments and variants of the invention.

A method is provided for assembling an electrical cable, according to which the cable is processed one after the other in independent processing modules. In particular, the invention can be intended for automated or fully automated assembly of an electrical cable.

The electrical cable is preferably designed as a high-voltage line.

The method can be provided for assembling a single-core cable that has a single inner conductor and/or for assembling a multi-core cable that has several inner conductors.

The area of the electrical cable in which the processing or assembly primarily takes place is sometimes referred to below as the “cable section to be processed”. The cable section to be processed can be a cable end piece. Preferably, two cable sections of the cable, in particular both cable end pieces, are processed or assembled with a respective plug connector.

In principle, within the scope of the invention, any electrical cable can be assembled with any connectors. The electrical cable preferably has an outer conductor or is designed as a shielded electrical cable. The invention is particularly advantageously suitable for assembling electrical cables with a large cross-section for high power transmission, for example in the vehicle sector, particularly preferably in the field of electromobility. An electrical cable for the high-voltage range can therefore be provided, in particular a high-voltage line.

The multi-core electrical cable can have any number of inner conductors, for example two inner conductors or more inner conductors, three inner conductors or more inner conductors, four inner conductors or even more inner conductors. The inner conductors can run twisted through the cable, in the manner of a twisted pair cable known from telecommunications or communications technology. However, the inner conductors can also be routed parallel in the cable.

The multi-core electrical cable is particularly preferably designed as a cable shielded with exactly one outer conductor and with exactly two inner conductors.

The single-core electrical cable is preferably designed as a coaxial cable with exactly one inner conductor and exactly one outer conductor.

Preferably, it can also be provided that the electrical cable is assembled with a plug connector in which more than one cable can be accommodated, in particular two cables, particularly preferably two single-core coaxial cables. Within the scope of the invention, an electrical connector can therefore be mounted on, for example, two electrical cables. For this purpose, the method according to the invention can be carried out several times sequentially or in parallel.

In the context of the invention, an inner conductor is understood to mean, in particular, a line running through the cable, which consists of insulation and an electrical conductor (wire) running within the insulation. The electrical conductor or core can be designed as a single wire or as a combination of several wires (also referred to as stranded wire). In principle, however, the inner conductor mentioned in the context of the invention can also consist exclusively of the electrical conductor or the wire or can also have other components in addition to the insulator.

Because, according to the invention, the cable assembly is distributed across independent processing modules or processing processes, the method or the system described below can be operated as an “assembly line process” or as an “automatic cycle” with successive individual steps in order to reduce the processing time in mass production.

Furthermore, the individual processing modules can have a modular structure, whereby individual processing modules of the system can be replaced, modified or removed without much effort. This means that the method can be configured using simple means, particularly for processing different types of cables.

According to the invention, according to a first variant of the invention, it is provided that at least one sheath clamp is fastened in a force-fitting manner on a cable sheath of the cable at a defined axial position along the longitudinal axis of the cable. Alternatively or additionally, according to a second variant of the invention, it is provided that the cable is fastened on a cable carrier, the cable carrier having at least one stop element arranged at a defined axial position along the longitudinal axis of the cable.

The sheath clamp is independent of the connector to be mounted on the cable during assembly. In particular, the jacket clamp is therefore not a connector component that later becomes part of the connector.

The sheath clamp can preferably be a clamp for holding objects together in a force-fitting manner.

The sheath clamp can have a clamping area for attachment to the cable sheath. The clamping area can, for example, have two or more clamping jaws, for example clamping jaws made of a plastic, for example rubber. The clamping area can optionally also have one or more claws for fastening to the cable jacket to be further strengthened. However, the use of claws is not preferred due to the associated damage to the cable jacket.

The sheath clamp can also have an actuation area. The actuation area can in particular be actuated by a user or a device for handling and/or fastening the casing clamp. In particular, the actuation area can serve to at least partially open the sheath clamp for attachment to the cable sheath of the cable - preferably against a spring force to close the sheath clamp.

The jacket clamp can preferably have two clamping legs connected to one another in a central section, the first ends of the clamping legs forming the actuation area and the second ends of the clamping legs forming the clamping area. A spring can be arranged at the connecting area of the two clamping legs, which presses the two clamping legs together with their respective second ends.

In principle, the sheath clamp can have any structure. The jacket clamp can, for example, also have one or more elastic fastening rings or consist of one or more elastic fastening rings. For example, an elastic fastening ring can be made of a plastic, preferably rubber, (in the manner of a rubber seal) in order to be clamped non-positively on the cable jacket. Springy, part-ring-shaped fastening rings, for example made of metal, can also be provided.

Furthermore, the jacket clamp can also be designed magnetically, for example. For this purpose, the sheath clamp can, for example, have two half-shells that can be magnetically connected to one another.

The fact that, according to the invention, at least one sheath clamp is attached to the cable sheath of the cable results in various advantages when assembling the cable, in particular when handling and identifying the cable during processing by processing modules that are independent of one another.

The cable carrier can be part of a workpiece carrier system. For example, the cable carrier can be movable between the processing modules by means of a transport device in order to deliver the cable to the processing modules for its processing.

The stop elements can in particular be designed as pins or webs on the cable carrier.

Preferably, two stop elements arranged at the same axial position, between which the cable fastened in the cable carrier runs, form a pair of stop elements. Preferably, at least one pair of stop elements is provided, preferably several pairs of stop elements, for example two, three, four, five, six, seven, eight, nine, ten or even more pairs of stop elements.

The stop elements can be flexibly mounted or positioned on the cable carrier manually or mechanically/automatically in order to assume different axial positions as required. The stop elements can be positioned freely or in a predetermined grid on the cable carrier.

The stop elements can be positioned equidistantly on the cable carrier along the longitudinal axis.

The stop elements can be adjusted manually or mechanically/automatically in the direction of the longitudinal axis of the cable. The stop elements can, for example, be displaceable along a respective guide rail in the direction of the longitudinal axis of the cable.

The stop elements can optionally be designed to be elastic or resilient in order to rest non-positively on the cable jacket when the cable is inserted.

In an advantageous development of the invention, it can be provided that the sheath clamp is pushed onto the cable sheath of the cable starting from a front, free end of the cable until the defined axial position is reached.

To push the at least one sheath clamp onto the cable sheath of the cable, the cable can be delivered to the sheath clamp and/or the sheath clamp to the cable.

In order to be able to advantageously push the sheath clamp onto the cable sheath, the clamping area of the sheath clamp, for example two or more clamping jaws of the sheath clamp or an elastic fastening ring of the sheath clamp, can be at least partially spread beforehand.

In order to support the sliding, the use of a lubricant can also be provided, which is applied to the sheath clamp and/or to the cable jacket of the cable becomes. The lubricant can be, for example, an alcohol or, particularly preferably, an oil, for example a silicone oil.

For example, 2-propanol (also known as isopropyl alcohol or isopropanol) can be used as a lubricant.

However, a silicone oil, i.e. a synthetic, silicon-based oil, can particularly preferably be used as a lubricant. For example, a polydimethylsiloxane with a high content of phenyl groups can be used, in particular a silicone oil known under the trade name ^WACKER® AP 150 from Wacker Chemie AG.

It can be provided to use a lubricant for pushing on a connector component and/or a sheath terminal, which is already contained in the cable. For example, self-lubricating silicones are sometimes used to train e.g. B. the cable jacket is used, which sweats out the oil on the surface after vulcanization. The use of the lubricants already used for self-exudation in the cable, in particular silicone oils, is generally safe from a safety perspective.

It can also be provided to create a film of compressed air between the cable jacket and the connector component and/or the jacket clamp in order to improve the sliding behavior when pushing on the connector component or the jacket clamp.

This means, for example, that there is no need for additional lubricant.

In order to generate the compressed air film, provision can be made to partially encase the connector component or the sheath terminal with a molded part and, if necessary, to support it on the cable sheath. The compressed air can therefore preferably flow exclusively (or at least essentially) through the gap between the plug connector component or the jacket clamp and the cable jacket and thereby widen the gap or even create it in the first place. The compressed air can thus advantageously and extremely gently expand a through hole in the connector component or the sheath terminal. At the same time, an axial displacement of the connector component or the sheath clamp on the cable jacket of the cable can be further improved by the air film.

According to a further development of the invention, it can be provided that the sheath clamp is applied to the cable sheath of the cable radially in the direction of the central axis of the cable at the defined axial position.

It can therefore also be provided to first spread the sheath clamp in such a way that it can be applied radially to the cable sheath. In particular, axial sliding over a longer section of the cable jacket and the associated effort can thereby be avoided.

A radial sliding of the sheath clamp can be particularly suitable for sheath clamps that are partially ring-shaped or designed in the manner of a clamp.

According to a further development of the invention, it can be provided that the at least one sheath clamp is removed again from the cable jacket of the cable after processing by at least one of the processing modules, preferably after processing by all processing modules.

In principle, however, provision can also be made for at least one of the sheath terminals not to be removed and, for example, to be delivered together with the assembled electrical cable.

Preferably, the at least one sheath clamp is assigned to the cable throughout the entire assembly process.

If the sheath clamp has one or more fastening rings or irreversibly closed lashing elements, these can be cut open if necessary. However, the sheath clamp is preferably removed from the cable in a non-destructive manner.

In a further development of the invention it can be provided that the sheath clamp is made identifiable with an information carrier in order to be able to clearly identify the cable during its processing.

Because the cable is made identifiable by the information carrier of the sheath clamp, the method according to the invention is particularly advantageous for use in the context of automated or fully automated assembly of the electrical cable.

In a further development of the invention, it can be provided that documentation of the processing of the cable is created for at least one processing process of one of the processing modules and assigned to the sheath clamp attached to the cable.

The assignment of the documentation of the processing of the cable is preferably carried out taking into account information impressed or impressed on the information carrier.

In an advantageous development of the invention it can be provided that the documentation is at least partially embossed into the information carrier of the jacket clamp.

If the information carrier is suitable for storing data, the documentation can advantageously already be embossed or imprinted on the information carrier (completely or partially).

In a further development of the invention, provision can be made for a unique identifier for the cable to be embossed into the information carrier or for a unique identifier already present on the information carrier to be assigned to the cable.

The cable can therefore be clearly identified using the identifier during cable assembly - and preferably later.

The cable can be made identifiable by applying and/or modifying the information carrier of the sheath clamp. It can therefore be provided that the information carrier (and possibly the identifier) is applied to the sheath clamp for the first time as part of the process, for example at the beginning of the assembly of the electrical cable. The information carrier can, for example, be printed or glued on, for example in the manner of a label as part of labeling.

An existing information carrier of the sheath clamp can, if necessary, also be modified in order to make the cable identifiable. For example, information can be added to the information carrier or information on the information carrier can be revised.

In particular, if the information carrier already has an identifier, the need to emboss an identifier may possibly be eliminated. The existing identifier, for example a sequential master number of sheath terminals, can thus be used to uniquely identify the cable (at least as part of cable assembly).

In an advantageous development of the invention it can be provided that the information carrier is designed optically and/or electronically.

An optical or electronic information carrier has proven to be particularly suitable. In principle, however, a magnetic, haptic and/or other information carrier can also be provided within the scope of the invention.

Provision can be made to use a global database in which documentation created as part of cable assembly is assigned to individual cables, preferably based on the unique identifier.

By using a global database, flexibility in storing and assigning the documentation is particularly advantageous. The information carrier, in particular an identifier contained in the information carrier, can be used in the database as an identification of the data record that contains the documentation of a specific cable.

In an advantageous development of the invention, it can be provided that the optical information carrier is designed as a bar code, numeric code and/or 2D code, for example data matrix code or QR code.

The codes mentioned have proven to be particularly suitable for forming an optical information carrier.

It can be advantageous to equip the information carrier with an error correction method, for example to provide redundant information. In particular, an optical information carrier can sometimes be prone to errors when reading out the information.

The same identifier can, if necessary, be assigned to the same cable several times by using several sheath terminals. In particular, provision can be made to attach a corresponding sheath clamp to both cable ends.

In an advantageous development of the invention, it can be provided that the electronic information carrier comprises at least one programmable memory module, for example an RFID transponder, which is modified to identify the cable and/or to document the processing of the cable.

An electronic information carrier, for example an RFID transponder, can be used particularly advantageously within the scope of the invention, for example to store the documentation or at least parts of the documentation electronically and to link it directly to the sheath clamp or to the cable.

In an advantageous embodiment of the invention it can be provided that the documentation is used as part of quality management. Particularly when assembling an electrical cable for the automotive industry, quality assurance or quality control is particularly relevant to ensure the defined quality requirements. The documentation according to the invention can be particularly advantageous for this.

In an advantageous embodiment of the invention it can also be provided that the cable is sorted or post-processed depending on the information contained in the documentation. For example, it can be provided that the cable is sorted into different quality classes depending on the information contained in the documentation. It can also be planned to sort out the cable and remove it from the production chain depending on the information contained in the documentation.

In one embodiment of the invention, it can be provided that the documentation includes information regarding a successful machining process, a faulty machining process, a failed machining process and/or at least one process parameter of the machining process. For example, successful processing, incorrect processing, failed processing and/or at least one process parameter can be included in the documentation for each of the independent processing processes or for each of the independent processing modules. The process parameter can be, for example, a parameter that particularly characterizes the machining process. The process parameter can be, for example, a force, a moment and/or a pressure. For example, the intended and/or measured actual pressing force of a crimping process can be included in the documentation. If failed and/or incorrect processing has been documented, the cable assembly of the corresponding cable can be terminated. A subsequent processing module can, for example, read out the documentation of the cable to be processed before starting cable processing and check whether the cable is released for processing. If necessary, the cable can be passed on unprocessed by the individual processing modules until it has left the production line.

In an advantageous embodiment of the invention, it can be provided that the information for the documentation is recorded by a control unit using a communication interface and/or a sensor device. The information relevant to the documentation of the individual processing processes can, for example, be read out by a controller of a respective processing module (for example specified ones Process parameters and/or process parameters actually recorded during processing). The respective processing modules can have their own sensors to record the relevant information. In particular, for checking the processing processes carried out on the cable as part of quality management, a separately designed sensor device can also be provided, which is communicatively connected to the control unit and transmits the results of the test, for example the tests listed above, to the control unit for the creation of the documentation.

In particular, a check for the presence of certain connector components of a connector to be mounted on the cable end (assembly test) can be provided.

According to the invention, it is provided that the cable jacket of the cable, preferably starting from the front, free end of the cable, is equipped with one or more connector components for later connector assembly.

The connector components can be any components of the electrical connector to be mounted on the corresponding cable end, which preferably have a respective through hole for receiving the cable. The connector components can therefore be pushed onto the electrical cable, in particular onto the cable jacket of the cable. The diameter of the through holes can essentially correspond to the diameter of the electrical cable or its cable jacket. However, the diameter of the through hole can also be larger or slightly smaller than the diameter of the electrical cable or its cable jacket in order to be able to influence the mechanical play of a connector component pushed onto the cable.

In principle, within the scope of the invention, the electrical cable can be equipped with any connector components, some of which are described below as examples.

The cable can be fitted with the connector components manually, for example by a production employee, or mechanically/automatically. This also applies to the assembly of the sheath clamp(s).

According to the invention, with regard to the first variant of the invention, it is provided that the at least one sheath clamp of the at least one connector component is on the cable sheath is arranged axially adjacent in order to positively block the displacement path of the connector component on the cable jacket.

According to the invention, with regard to the second variant of the invention, it is provided that the at least one stop element of the cable carrier is arranged axially adjacent to the at least one connector component along the longitudinal axis of the cable in order to positively block the displacement path of the connector component on the cable jacket.

Sometimes connector components are loose or axially displaceable on the cable jacket until they are assembled with other connector components during the connector assembly and fastened to the cable jacket or to another component of the cable. In order to avoid that connector components move uncontrollably on the cable jacket after the cable jacket has been fitted as part of further processing and/or during the transport of the cable between individual processing modules (e.g. move too close to one another for subsequent processing or even slide into one another) or even fall away from the cable sheath, the sheath clamps and/or the stop elements can be advantageously suitable for securing the axial positions of the connector components.

The invention is therefore particularly suitable for processing the cable in processing modules that are independent of one another, after which the cable must be moved between the individual processing modules. Cable transport in particular can be problematic and cause previously pushed-on connector components to be displaced or even lost. This can be avoided by the sheath clamps and/or stop elements according to the invention.

In an advantageous development of the invention, an assembly module with individual chambers for receiving plug connector components and sheath terminals can be provided, which are arranged in such a way that the plug connector components and sheath terminals accommodated in the chambers form a common channel with a common central axis. An actuator device can be provided and designed to guide the cable with its front end along the central axis through the connector components and the jacket clamps in order to push the connector components and the jacket clamps axially onto the cable jacket of the cable. Alternatively or in addition to an actuator device, the cable can also be guided manually, for example by a production employee, through the connector components and the sheath terminals.

The chambers of the assembly module are preferably designed to accommodate only a single connector component or a single sheath terminal. The chambers are particularly preferably structurally separated from one another, for example by respective walls, which, however, have recesses for the passage of the electrical cable and, if necessary, additionally shape the channel for the passage of the electrical cable or are able to guide the electrical cable while it is being passed through. However, the chambers can also simply be “imaginary” areas within the assembly module that are not structurally separated from one another.

The channel preferably runs linearly or the chambers are arranged linearly one behind the other. However, the arrangement of the chambers relative to one another or the channel can also have a curved course.

The actuator device can be designed to move the cable and/or the assembly module. In particular, a relative movement between the cable and the assembly module can be provided in order to push the connector components or the at least one jacket clamp onto the cable jacket of the cable. The electrical cable is preferably inserted into the assembly module. For this purpose, the actuator device can z. B. have a roller conveyor with one, two or more rollers to linearly guide the electrical cable between the rollers.

Because the plug connector components and at least one of the sheath terminals are arranged in the chambers of the assembly module, the plug connector components and the at least one sheath terminal can subsequently be pushed onto the cable sheath by the actuator device in a coherent processing operation. A sequential assembly of the cable with the connector components and the sheath terminal(s), for example by gripping and pushing on each individual connector component or sheath terminal, is therefore not absolutely necessary.

The connector components and sheath terminals can advantageously be arranged in the desired order in the chambers of the assembly module.

An assembly module with individual chambers is particularly suitable for fully automated cable assembly. The throughput of assembled electrical cables of an appropriately equipped device can thus be increased.

Furthermore, assembly errors or assembly errors can be avoided according to the invention, especially if the chambers of the assembly module are designed to only accommodate specific ones To accommodate connector components or sheath terminals. Mixed-up loading or loading in the wrong order or in the wrong orientation can thus be avoided.

In an advantageous development of the invention, it can be provided that the assembly module has a magazine in order to provide further connector components or further sheath terminals for equipping further cables.

Storage of the connector components and sheath terminals can therefore advantageously be provided.

For example, a funnel magazine can be provided, the individual funnels of which open into the chambers of the assembly module, whereby the connector components or sheath terminals can be inserted from above in an orderly or disorderly manner. A shaft magazine can preferably also be provided, after which the individual connector components or sheath terminals lie one above the other and ultimately open into the chambers.

In principle, any type of magazine can be provided, for example a roller track magazine, a step magazine, a conveyor belt magazine, a slideway magazine, a chain magazine, a lifting magazine or another magazine, but in particular a magazine using gravity to insert the individual connector components or sheath terminals as easily as possible to move the chambers.

In an advantageous embodiment of the invention, it can be provided that the chambers of the assembly module are arranged in such a way that the connector components and sheath terminals accommodated in the chambers are spaced apart from one another at defined distances along the central axis.

However, the connector components and sheath terminals can also be arranged directly adjacent to one another. It can also be provided that individual connector components are already partially pushed one on top of the other or are arranged pre-assembled together in the chambers.

The individual connector components and sheath terminals can, if necessary, be kept at the defined distances from one another that will later be provided on the electrical cable. For example, a distance can be provided between the connector components to make them easier to grip in the subsequent assembly steps or to be able to assemble. In order to fix the connector components at these defined positions on the cable jacket, the jacket clamps can be attached to the cable jacket adjacent to the connector components. In particular, a defined distance from the front, free end of the cable can also be provided in order to be able to process the front, free end as part of the cable assembly (for example, to be able to strip the insulation) without damaging or having to move the front connector component.

In an advantageous embodiment of the invention, it can be provided that the chambers of the assembly module are designed in such a way that through holes running through the plug connector components and the sheath terminals for receiving the cable are aligned coaxially with one another when the plug connector components and sheath terminals are accommodated in the chambers.

A coaxial alignment of the through holes of the connector components and sheath terminals can be particularly advantageous if the diameters of the through holes correspond to, approximately correspond to, or are smaller than the diameter of the cable jacket of the cable. Particularly if the through holes are comparatively large with regard to the cable diameter, a coaxial alignment may also be unnecessary.

In particular, it can also be advantageous if the connector components and/or the sheath terminals are positively blocked in the insertion direction of the electrical cable so that they are not displaced by the cable while the electrical cable is being passed through.

In principle, it can be provided that chambers of the assembly module are designed to fix the connector components and/or sheath terminals in one, two, three, four, five or in all degrees of freedom in a form-fitting and/or force-fitting manner.

In an advantageous embodiment of the invention, a sensor device can be provided which is set up to monitor the position of the cable along the central axis. For example, provision may be made to monitor the position of the electrical cable as the electrical cable passes through the connector components and sheath terminals. Monitoring can be carried out completely or only in sections.

In an advantageous embodiment of the invention, it can be provided that at least one of the connector components is a shield sleeve, a connector housing, a line seal, a cable retainer, a retaining cap or an angle cap.

As already mentioned at the beginning, within the scope of the invention, any connector components can be pushed onto the cable jacket of the electrical cable and preferably held in position by means of the jacket clamps. The above-mentioned connector components are only to be understood as examples and can be provided particularly advantageously for assembly within the scope of the invention.

The shielding sleeve can also be referred to as a “ferrule” (or outer ferrule) and is generally provided to electromagnetically shield a contact part carrier, particularly in the area of the contact elements of the electrical connector.

The contact part carrier can in particular be a housing component of the later electrical plug connector. The contact parts carrier can also be referred to as an inner housing or inner housing shell. As a rule, the contact parts carrier has corresponding receptacles for receiving the contact element or contact elements, which extend axially through the contact parts carrier. The inner conductors can thereby be accommodated in the contact parts carrier so that they do not rotate. The contact part carrier is preferably made of a plastic.

For rotation-proof fastening on the contact parts carrier, the contact parts carrier and shielding sleeve can have a corresponding mechanical coding, for example a locking lug on the one hand and a corresponding locking groove on the other. For example, the shielding sleeve can only be pushed onto the contact part carrier in a predetermined orientation or in two orientations.

Preferably, within the scope of the invention, the shielding sleeve is pushed onto the electrical cable or onto its cable jacket from the front and can be mounted from behind, i.e. after the contact parts carrier has been installed. H. starting from the cable jacket, pushed over the contact parts carrier or attached to it in some other way.

In particular, if the assembly between the shielding sleeve and the contact part carrier has to be carried out in one or more defined orientations, it can be advantageous if at least the chamber of the assembly module that accommodates the shielding sleeve is designed to accommodate the shielding sleeve in a rotation-proof and pre-aligned manner.

The connector housing can in particular be a socket housing/plug housing (also referred to as an outer housing, outer housing or outer housing shell), which is pushed over the mounted shielding sleeve and fastened to the shielding sleeve as part of the assembly of the electrical connector, for example from behind. For this purpose, in particular, a correct positional locking with the shield sleeve and/or the contact parts carrier can be provided, which is why a rotation-proof storage within the corresponding chamber can also be advantageous with regard to the connector housing.

The line seal can in particular be a mechanical seal, for example a sealing ring for sealing against dirt, dust, liquids or gases, which can be inserted, for example, from behind into a mounted connector housing. The diameter of the through hole of the cable seal can preferably be made slightly smaller than the diameter of the cable jacket in order to improve the seal. The line seal can have any cross-sectional geometry. Circular line seals are often used. However, oval or polygonal, in particular rectangular, for example square line seals can also be provided. A specific orientation is generally not important when installing the cable seal, especially for cable seals with a circular cross-sectional geometry. If an oval or polygonal (for example rectangular) cable seal is provided, the cable seal can also depend on a predetermined orientation relative to other connector components.

A cable holder can, in particular, be a connector component that enables or supports tension retention of the cable.

A final retaining cap - or in the case of an angled connector, an angle cap - can be a connector component that closes the connector on the cable side and, for example, fixes a cable retainer and/or a line seal in the connector, for example the connector housing. It can be provided that the retaining cap or angle cap has locking means in order to lock with the cable holder and/or the connector housing. The retaining cap or angle cap can also be referred to as an end cap assembly.

The sheath clamp can be independent of the connector to be mounted on the cable during assembly. Preferably, the sheath terminal is therefore not a connector component that later forms part of the connector.

According to the invention, plug connector components can advantageously be held in position on the cable jacket of the cable by means of the at least one sheath clamp.

Furthermore, the sheath clamp can be well suited for identifying the cable when assembling the electrical cable.

The invention also relates to a device for assembling an electrical cable with the features described in claim 14.

The device can be additionally designed to remove the sheath clamp(s) from the cable again after processing by at least one of the processing modules.

The electrical cable can be designed, for example, as a high-voltage line.

It can be provided that the method described above is carried out using the device mentioned.

The invention also relates to a system for assembling an electrical cable, in particular a high-voltage cable. The system includes a device for assembling an electrical cable, preferably in accordance with the information above and below. The system further includes at least two independent processing modules for assembling the electrical cable.

The distribution of the processing steps according to the invention across several independent modules makes it possible to operate the system as an “assembly line process” or as an “automatic cycle” with successive individual steps in order to reduce the processing time in mass processing.

Furthermore, the device or the individual processing modules can have a modular structure, whereby individual processing modules of the assembly can be replaced, modified or removed without much effort. This means that the system can be configured using simple means, particularly for processing different types of cables.

The independent processing modules can preferably be arranged upstream or downstream of the device.

According to a further development of the invention, it can be provided that at least one of the processing modules acts as a processing module for stripping a section of a cable component of the cable and/or is designed as a processing module for equipping the electrical cable with a connector component of a connector to be applied to the electrical cable and/or is designed as a processing module for ensuring that the cable jacket is correctly equipped with the connector components and/or as a Processing module is designed for assembling a connector component of an electrical connector.

Further processing modules that are independent of one another and of the device can also be provided, which are arranged upstream or downstream of the device.

Features that have been described in connection with the method according to the invention can of course also be implemented advantageously for the device and the system - and vice versa. Furthermore, advantages that have already been mentioned in connection with the method according to the invention can also be understood in relation to the device or the system - and vice versa.

In addition, it should be noted that terms such as “comprising”, “having” or “with” do not exclude other features or steps. Furthermore, terms such as "a" or "the", which indicate a singular number of steps or features, do not exclude a plurality of features or steps - and vice versa.

In a puristic embodiment of the invention, however, it can also be provided that the features introduced in the invention with the terms “comprising”, “having” or “with” are listed exhaustively. Accordingly, one or more lists can be considered complete within the scope of the invention, for example considered for each patent claim. The invention can, for example, consist exclusively of the features mentioned in claim 1.

Furthermore, it should be emphasized that the values and parameters described here represent deviations or fluctuations of ±10% or less, preferably ±5% or less, more preferably ±1% or less, and most preferably ±0.1% or less of the respectively named Value or parameter included, provided that these deviations are not excluded when implementing the invention in practice. The specification of ranges through initial and final values also includes all those values and fractions that are included in the respectively named range, in particular the initial and final values and a respective mean value.

Exemplary embodiments of the invention are described in more detail below with reference to the drawing.

The figures each show preferred exemplary embodiments in which individual features of the present invention are shown in combination with one another. Features of one exemplary embodiment can also be implemented separately from the other features of the same exemplary embodiment and can accordingly be easily combined by a person skilled in the art to form further sensible combinations and sub-combinations with features of other exemplary embodiments.

In the figures, functionally identical elements are provided with the same reference numbers.

Figur 1

ein auf einem Kabelträger befestigtes elektrisches Kabel mit zwei auf dem Kabelmantel befestigten Mantelklemmen;

Figur 2

ein mit vier Steckverbinderkomponenten und mehreren Mantelklemmen bestücktes, beispielhaftes zweiadriges elektrisches Kabel in einer Seitenansicht;

Figur 3

ein mit drei Steckverbinderkomponenten und mehreren Mantelklemmen bestücktes, beispielhaftes einadriges elektrisches Kabel in einer Seitenansicht;

Figur 4

ein Bestückungsmodul mit einer Aktuatoreinrichtung in einer seitlichen Schnittdarstellung;

Figur 5

einen Ausschnitt des Bestückungsmodul gemäß Figur 4 nach dem Durchführen des elektrischen Kabels durch die Steckverbinderkomponenten;

Figur 6

einen Ausschnitt des Bestückungsmodul gemäß Figur 4 während des Entnehmens des elektrischen Kabels;

Figur 7

zwei Kammern des Bestückungsmoduls der Figur 4 in einer perspektivischen Schnittdarstellung;

Figur 8

ein System zur Konfektionierung eines elektrischen Kabels mit einer Vorrichtung zur Konfektionierung des elektrischen Kabels und mit zumindest zwei voneinander unabhängigen Bearbeitungsmodulen; und

Figur 9

einen Kabelträger mit verschiedenen Anschlagelementen, um den Verschiebeweg von Steckverbinderkomponenten auf dem Kabelmantel zu blockieren.

It shows schematically:

Figure 1

an electrical cable attached to a cable carrier with two sheath clamps attached to the cable jacket;

Figure 2

an exemplary two-wire electrical cable equipped with four connector components and several sheath terminals in a side view;

Figure 3

an exemplary single-core electrical cable equipped with three connector components and several sheath terminals in a side view;

Figure 4

an assembly module with an actuator device in a side sectional view;

Figure 5

a section of the assembly module according to Figure 4 after passing the electrical cable through the connector components;

Figure 6

a section of the assembly module according to Figure 4 while removing the electrical cable;

Figure 7

two chambers of the assembly module Figure 4 in a perspective sectional view;

Figure 8

a system for assembling an electrical cable with a device for assembling the electrical cable and with at least two independent processing modules; and

Figure 9

a cable carrier with various stop elements to block the displacement of connector components on the cable jacket.

Figure 1 shows a device 1 for assembling an electrical cable 2 as part of the processing of the cable 2 in independent processing modules 41, 43 (cf. Figure 8 ).

A workpiece carrier system 3 is provided which has a cable carrier 4 on which the electrical cable 2 is attached. The electrical cable 2 can thus be attached to the cable carrier 4 during its processing as part of the entire assembly or during a section of the assembly, e.g. B. be assigned during processing by one of the independent processing modules 41, 43. It should be mentioned that, in principle, several cable carriers 4 can also be provided, each of which is assigned to different processing modules 41, 43 (however, for the sake of simplicity, this variant is not shown in the exemplary embodiments). For example, a first cable carrier can transport the cable 2 between processing modules of a first group of processing modules and a second cable carrier can transport the cable 2 between processing modules of a second group of processing modules. Even more cable carriers 4 and associated processing modules can be provided, with even a single cable carrier 4 per processing module 41, 43 being possible. In principle, the cable 2 can also be attached to an immovable cable carrier 4, for example if a tool carrier system delivers one or more tools of the processing modules 41, 43 or the processing modules 41, 43 to the cable 2. The cable 2 can be transferred between individual cable carriers 4, for example by means of a gripping device or other transport device, preferably in a known or unchanged alignment or orientation.

The cable carrier 4 has clamping jaws 5 in order to fix the first cable end 6 and/or the second cable end 7 of the cable 2, in the exemplary embodiment both cable ends 6, 7. In the exemplary embodiment, the cable 2 is clamped into the cable carrier 4 in such a way that a U-shaped course is formed between the two cable ends 6, 7. In principle, a different course can also be provided, for example a helical winding with a comparatively long cable 2. It can also be provided that only one of the two cable ends 6, 7 is accommodated in the cable carrier 4. The actual design of the cable carrier 4 and the type of fastening of the cable 2 on the cable carrier 4 are not important within the scope of the invention.

In order to transport the cable 2 between the independent processing modules 41, 43 for its processing, the cable carrier 4 is, for example, mounted on a transport device 8 in the manner of a conveyor belt. In principle, the cable 2 can be moved between the processing modules 41, 43 in any way, for example by a production employee using a roller conveyor.

Within the scope of the invention it is provided that at least one sheath clamp 10.1, 10.2, 10.3, 10.4 is fastened in a force-fitting manner on a cable sheath 9 of the cable 2 at a defined axial position along the longitudinal axis L of the cable 2. Examples are in Figure 1 two sheath clamps 10.1 shown (one sheath clamp 10.1 at each cable end 6, 7). The sheath terminal 10.1, 10.2, 10.3, 10.4 is not part of the later connector.

It can be provided that the sheath clamp(s) 10.1, 10.2, 10.3, 10.4 can be identified with an information carrier 11.1, 11.2 in order to be able to clearly identify the cable 2 during its processing. By way of example, an optical information carrier 11.1 is shown on the sheath clamp 10.1 assigned to the first cable end 6 and an electronic information carrier 11.2 on the sheath clamp 10.1 assigned to the second cable end 7.

The optical information carrier 11.1 is shown as an example as a bar code. The optical information carrier 11.1 can, for example, also be a numeric code and/or a 2D code, for example a data matrix code or a QR code.

Within the scope of the invention, the information carrier 11.1, 11.2 can be applied to the jacket clamp 10.1, 10.2, 10.3, 10.4, for example by means of a laser, not shown. It can also be provided to modify an already existing information carrier 11.1, 11.2, for example a serial number already printed on the sheath clamp 10.1, 10.2, 10.3, 10.4 or an already existing bar code. Instead of a laser, any device for applying and/or modifying an optical information carrier 11.1 can in principle be provided, for example an inkjet printer.

The electronic information carrier 11.2 can, for example, be at least one programmable memory module, in particular an RFID transponder, which can be modified to identify the cable 2 and/or to document the processing of the cable 2. An example is a reading/writing device 12 for communication with the RFID transponder 11.2 in Figure 1 shown.

It can be provided to create documentation 13 of the processing of the cable 2 for at least one processing process of one of the processing modules 41, 43 and to assign it to the cable 2.

For this purpose, for example, a unique identifier 14 for the cable 2 can be embossed into the information carrier 11.1, 11.2 and/or a unique identifier 14 already embossed on the information carrier 11.1, 11.2 can be temporarily assigned to the cable 2 for its assembly.

The identifier 14 can be, for example, a binary, decimal or hexadecimal numerical value or a sequence of digits. The identifier 14 can, for example, be coded or embossed in the bar code or another code. The identifier 14 can also be in an electronic component, for example a memory chip, e.g. B. be embossed or stored in the RFID transponder 11.2.

For example, it can also be provided that different jacket clamps 10.1, 10.2, 10.3, 10.4 already have a respective information carrier 11.1, 11.2 with a unique identifier 14. By attaching the sheath clamps 10.1, 10.2, 10.3, 10.4 to the cable 2 during assembly or at least during a sub-process of assembly, the documentation 13 can finally be assigned. For example, it can also be provided that the information carrier 11.1, 11.2 is specifically provided with an identifier 14 for identifying the cable 2 for the assembly process to be documented.

It can be provided that the documentation 13 is at least partially embossed into the information carrier 11.1, 11.2. This can be particularly advantageous if the information carrier 11.1, 11.2 is an electronic information carrier 11.2 on which sufficient storage space is available (in Figure 1 indicated). However, for example, a continuous sequence of numbers or a similar code can also be provided in order to continuously record the documentation 13 as part of the cable assembly, for example in optical form on the sheath clamp 10.1, 10.2, 10.3, 10.4.

For example, one, some or all of the processing modules 41, 43 may have a reader/writer 12 and/or a scanner for reading a bar code (or other code) and/or a laser or printer in order to expand the documentation 13 or for the Evaluate cable processing.

However, a global database 15 can preferably be used, in which documentation 13 created as part of the assembly production line can be assigned to individual cables 2, preferably based on the respective unique identifier 14. The addressing in the database 15 can therefore be dependent on the identifier 14 of the respective cable 2.

A control unit 16 can be provided as part of the device 1 according to the invention for assembly in order to carry out the method described. The control unit 16 can, for example, be communicatively connected to the devices for imprinting and/or reading out and/or modifying the information carrier 11.1, 11.2 (indicated with respect to the reading/writing device 12) and can also be communicatively connected to the database 15.

For example, information regarding a successful machining process, a faulty machining process, a failed machining process and/or at least one process parameter of the machining process can be included in the documentation 13. The documentation 13 can be used as part of quality management. As part of quality management, for example, provision can be made to sort the cable 2 depending on the information contained in the documentation 13 or to release it for post-processing. In particular, removal of an incorrectly processed cable 2 can be provided as part of quality management.

The information for the documentation 13 can be recorded by the control unit 16, for example using a communication interface. For example, the control unit 16 can be communicatively connected to the individual processing modules 41, 43 via a respective communication interface in order to obtain information about the processing processes from the respective processing modules 41, 43 and to include it in the documentation 13.

In Figure 2 an exemplary multi-core electrical cable 2 is shown enlarged in a side view.

The inner conductors 17 of the cable 2 extend from the first cable end 6 to the second cable end 7 (in Figure 2 not shown). The first cable end 6 is also referred to here as the front, free end of the cable 2.

The multi-core electrical cable 2 is already partially processed at its front end 6. As a rule, however, the connector components 24, 25, 26, 27, 28 described below are pushed onto an unprocessed cable end 6, 7. In particular, for a better representation of possible components of the electrical cable 2, the front, free end 6 of the cable is in Figure 2 In this case, however, the insulation has already been stripped in some areas. This also applies to the single-core cable 2 Figure 3 .

The two-core cable 2 has a cable shield braid 18 running under the cable jacket 9. A shielding film can optionally run above the cable shield braid 18 (not shown). Below the cable shield braid 18, the two inner conductors 17 run within a filling layer 19. The electrical conductors 20 or cores of the inner conductors 17 are each covered by insulation 21. As part of cable assembly, the electrical conductors 20 of the inner conductors 17 can be exposed in the area of the inner conductor ends, as shown. At the respective inner conductor ends, inner conductor contact elements (not shown) of an electrical plug connector 22 (cf. Figure 8 ) attached, especially crimped. As part of the cable assembly, the cable shield braid 18 can be folded backwards over the cable jacket 9, preferably over a metal sleeve or support sleeve, not shown, and optionally with a fabric tape 23 (cf. Figure 8 ) can be fixed.

This in Figure 2 The two-wire cable 2 shown is only to be understood as an example for use with the invention. In principle, the invention is suitable for use with any type of cable, for example also for use with an electrical cable 2 with only one inner conductor 17, for example in a coaxial design, as in Figure 3 shown.

Figure 3 shows the front, free end 6 of a single-core electrical cable 2, which has already been partially stripped. The single-core cable 2 also has a cable jacket 9 and a cable shield braid 18 running under the cable jacket 9. The cable shield braid 18 can also be folded over onto a support sleeve, not shown. The insulation 21 or the primary insulation of the inner conductor 17 runs under the cable shield braid 18. The electrical conductor 20 of the inner conductor 17 can, for example, be designed as a strand made up of several individual wires, as in Figure 3 indicated. In principle, however, the exact structure of the single-core cable 2 is not important.

As part of the assembly of the electrical cable 2, provision can be made to equip the cable jacket 9 of the cable 2 with two or more connector components 24, 25, 26, 27, 28 for a connector assembly starting from one of the cable ends 6, 7 of the cable 2. The connector components can be, for example, one Shield sleeve 24 (cf. Figure 2 ), a connector housing 25 (cf. Figure 2 ), a line seal 26 (cf. Figure 2 or Figure 3 ), a cable holder 27 (cf. Figure 3 ), a holding cap or end cap 28 (cf. Figure 2 or Figure 3 ) or an angle cap. In principle, however, the design of the connector component is not important within the scope of the invention. The invention is suitable for equipping a single-core or multi-core electrical cable 2 with any connector components 24, 25, 26, 27, 28.

As part of the assembly of a two- or multi-core electrical cable 2, however, in particular an assembly according to the in Figure 2 The sequence shown consists of a shield sleeve 24, followed by a socket housing or a connector housing 25, followed by a line seal 26, followed by a retaining cap 28 (or an angle cap in the case of an angled connector). In the case of assembling a single-core electrical cable 2, assembly can preferably be carried out according to Figure 3 well suited, after which a cable seal 26, followed by a cable retainer 27, followed by a retaining cap 28, are pushed onto the cable jacket 9 starting from the front end 6 of the cable 2.

The already mentioned sheath clamps 10.1, 10.2, 10.3, 10.4 can, in addition to making the cable 2 identifiable, alternatively or additionally also be suitable for attaching the connector components 24, 25, 26, 27, 28 applied to the cable sheath 9 of the cable 2 as part of the assembly to hold the desired axial positions along the central axis or longitudinal axis L of the cable 2. For this purpose, the sheath clamps 10.1, 10.2, 10.3, 10.4 can be applied to the cable sheath 9 of the cable 2 at the defined axial positions provided, radially in the direction of the central axis or longitudinal axis L of the cable 2. Examples include some sheath clamps 10.1, 10.2, 10.3, 10.4 of different types in the Figures 2 and 3 shown.

In principle, it can be advantageous to surround each of the connector components 24, 25, 26, 27, 28 with two sheath terminals 10.1, 10.2, 10.3, 10.4 in order to prevent unwanted displacement of the connector component 24, 25, 26, 27, 28 in both directions along the longitudinal axis L of the cable 2. However, depending on the connector component 24, 25, 26, 27, 28, the need for this can also be eliminated, for example if the connector component 24, 25, 26, 27, 28 is a seal, for example a line seal 26, which is usually already clamped sufficiently tightly on the cable jacket 9 of the cable 2.

In principle, different types of jacket clamps 10.1, 10.2, 10.3, 10.4 can be provided. For example, those in the Figures 1 and 2 Brackets 10.1 shown are provided be, which have an actuation area 29 and a fastening area 30. By means of the actuation area 29, the clamping jaws located at the opposite end of two clamping legs, which form the fastening area 30, can be opened against the spring force of a return spring 31 and the sheath clamp 10.1 can thus be applied radially to the cable 2. Alternatively, sheath clamps 10.2 with lashing elements 32 in the manner of a cable tie (cf. Figure 3 ), be provided. Another exemplary sheath clamp 10.3, which has a metallic partial ring that can be clamped on the cable sheath 9, is shown in Figure 3 also shown. Furthermore shows Figure 3 another exemplary jacket clamp 10.4, which has an elastic ring, for example a rubber ring, similar to a sealing ring. The exact design of the jacket clamp 10.1, 10.2, 10.3, 10.4 is not necessarily important within the scope of the invention. Preferably, the sheath clamps 10.1, 10.2, 10.3, 10.4 are non-positively and reversibly attached to the cable sheath 9 of the cable 2.

The at least one sheath clamp 10.1, 10.2, 10.3, 10.4 can be removed again from the cable sheath 9 after processing by at least one of the processing modules 41, 43, preferably after processing by all processing modules 41, 43 (after the electrical cable 2 has been completely assembled). the cable 2 must be removed.

In Figure 4 an assembly module 33 with individual chambers 34 for receiving connector components 24, 25, 26, 27, 28 is shown schematically in a side sectional view. The assembly module 33 is set up to equip the cable jacket 9 of the cable 2 with two or more connector components 24, 25, 26, 27, 28 for later connector assembly, starting from one of the two cable ends 6, 7. Only by way of example is the assembly module 33 for assembly of the two-wire cable 2 according to Figure 2 shown.

The assembly module 33 can be additionally designed to accommodate one or more sheath clamps 10.1, 10.2, 10.3, 10.4 in a respective chamber 34, in order to also accommodate the sheath clamp(s) 10.1, 10.2, 10.3, 10.4 starting from the free cable end 6, 7 of the Push the cable 2 onto the cable jacket 9 of the cable 2 until the defined axial position is reached. This is in Figure 4 However, not shown to simplify the presentation. In principle, however, the jacket terminals 10.1, 10.2, 10.3, 10.4 can be handled in the assembly module 33 like the plug connector components 24, 25, 26, 27, 28.

It should be mentioned that the sheath clamps 10.1, 10.2, 10.3, 10.4 can also be pushed axially onto the front, free end 6, 7 of the cable sheath 9 without using an assembly module 33 in the form shown. In principle, a device 1 can Assembling the electrical cable 2 has any assembly module for the non-positive fastening of a sheath clamp 10.1, 10.2, 10.3, 10.4 on the cable sheath 9 of the cable 2.

The chambers 34 are arranged in such a way that the connector components 24, 25, 26, 27, 28 (and/or sheath terminals 10.1, 10.2, 10.3, 10.4) accommodated in the chambers 34 have a common channel K (cf. dashed line illustration in Figure 4 ) with a common central axis M.

As shown in the exemplary embodiment, the assembly module 33 can have a magazine 35 in order to hold the connector components 24, 25, 26, 27, 28 (and/or sheath terminals 10.1, 10.2, 10.3, 10.4) for equipping further cables 2. A shaft magazine is shown in the exemplary embodiment; In principle, however, any magazine can be provided.

The chambers 34 of the assembly module 33 can be arranged in such a way that the connector components 24, 25, 26, 27, 28 (and/or sheath terminals 10.1, 10.2, 10.3, 10.4) accommodated in the chambers 34 are positioned along the central axis M at defined distances d ₁ , d ₂ , d ₃ , d ₄ are spaced apart from one another. Depending on the respective connector component 24, 25, 26, 27, 28 and the subsequent assembly, it can be provided to provide different distances d ₁ , d ₂ , d ₃ , d ₄ from each other for different connector components 24, 25, 26, 27, 28, which can be specified, for example, by a corresponding wall thickness of the chambers 34 and/or the magazine 35.

For example, a first distance d ₁ between the frontmost connector component (in the exemplary embodiment, the shield sleeve 24) and the second connector component (in the exemplary embodiment, the connector housing 25), a second distance d ₂ between the second connector component or the connector housing 25 and a third connector component (im In the exemplary embodiment, the line seal 26) and a third distance d ₃ can be provided between the third connector component or the line seal 26 and a fourth connector component (in the exemplary embodiment, the retaining cap 28). A defined distance d ₄ between the first connector component or the shielding sleeve 24 and the cable end 6, 7 of the cable 2 can also be provided when the electrical cable 2 has been completely inserted into the assembly module 33. The distances d ₁ , d ₂ , d ₃ , d ₄ can finally be found on the equipped cable (cf. Figure 2 ). So that the distances d ₁ , d ₂ , d ₃ , d ₄ are maintained, particularly when handling the cable 2 during assembly, for example during transport between the individual processing modules 41, 43, and connector components 24, 25, 26, 27, 28 as well nor get lost or slip into each other, the jacket clamps 10.1, 10.2, 10.3, 10.4 can be fastened between the connector components 24, 25, 26, 27, 28.

Advantageously, the chambers 34 of the assembly module 33 can also be designed in such a way that through holes for receiving the cable 2 run coaxially with one another through the plug connector components 24, 25, 26, 27, 28 (and/or sheath terminals 10.1, 10.2, 10.3, 10.4). are aligned when the connector components 24, 25, 26, 27, 28 (and/or sheath terminals 10.1, 10.2, 10.3, 10.4) are accommodated in the chambers 34. For this purpose, for example, the support surface or a lower base 36 of the assembly module 33 in the respective chambers 34 can have a depth designed for the plug connector component 24, 25, 26, 27, 28 (and/or sheath terminal 10.1, 10.2, 10.3, 10.4), as in Figure 4 shown. In addition, it can be provided that the chambers 34 of the assembly module 33 are designed to hold the connector components 24, 25, 26, 27, 28 (and/or sheath terminals 10.1, 10.2, 10.3, 10.4) in a rotation-proof manner, especially when within the scope of the following When assembling the electrical cable 2, a specific orientation or orientation of individual connector components 24, 25, 26, 27, 28 is provided.

The assembly module 33 also has an actuator device 37, which is designed to move the cable 2 with its front end 6, 7 along the central axis M through the connector components 24, 25, 26, 27, 28 (and/or sheath terminals 10.1, 10.2, 10.3, 10.4) in order to push the connector components 24, 25, 26, 27, 28 (and/or sheath terminals 10.1, 10.2, 10.3, 10.4) onto the cable jacket 9 of the cable 2. As an alternative to an actuator device 37, manual transport of the cable 2 by a production employee can also be provided. The cable 2 can thus be passed with its front end 6, 7 along the central axis M through the connector components 24, 25, 26, 27, 28 (and/or sheath terminals 10.1, 10.2, 10.3, 10.4) until it reaches a predetermined end position P _END reached, as in Figure 5 shown. In the exemplary embodiment, the actuator device 37 has a roller conveyor device with two rollers, between which the cable 2 is guided in order to move it linearly.

In order to monitor the position of the cable 2 along the central axis M, a sensor device 38 can be provided. In the exemplary embodiment, a light barrier is shown as an example in order to detect when the end position P _END of the electrical cable 2 has been reached in the assembly module 33 and to stop the cable feed (cf. Figures 4 and 5 ). If necessary, further light barriers or other sensors can also be provided in order to detect further discrete positions of the cable 2. In principle it can also be a continuous one Detection of the position of the cable 2 or its front, free end 6, 7 may be provided, in addition or as an alternative to detecting one or more discrete positions.

In particular, in order to avoid that the connector components 24, 25, 26, 27, 28 (and/or sheath terminals 10.1, 10.2, 10.3, 10.4) are displaced along the central axis M while the electrical cable 2 is being passed through, it can be provided that Chambers 34 of the assembly module 33 are designed to hold the connector components 24, 25, 26, 27, 28 (and/or sheath terminals 10.1, 10.2, 10.3, 10.4) in the axial direction, in particular in the insertion direction (see arrow in Figure 4 ) of the electrical cable 2, to be positively blocked along the central axis M. For this purpose, for example, the walls of the magazine 35 can be continued, with a corresponding recess allowing the cable 2 to pass through.

In particular if the through holes of the plug connector components 24, 25, 26, 27, 28 correspond or at least approximately correspond to the diameter of the cable jacket 9, it can be advantageous to clean at least one of the plug connector components 24, 25, 26, 27, 28 using a lubricant. preferably an alcohol or a silicone oil, onto the cable jacket 9. A lubricant may also be suitable for applying or pushing on the jacket clamps 10.1, 10.2, 10.3, 10.4. For example, it can be provided to provide the cable jacket 9, the connector component(s) 24, 25, 26, 27, 28 and/or the jacket clamp(s) 10.1, 10.2, 10.3, 10.4 with a lubricant. In the exemplary embodiment, means 39 are provided (cf. Figure 4 ) to apply the lubricant to the front end 6, 7 of the cable 2 using two brushes before the cable 2 is inserted into the assembly module 33.

A suitable assembly process can be carried out by means of a computer program product with program code means on the control unit 16 of the device 1 for assembling the cable 2, as in the Figures 4 and 5 indicated.

The cable 2 equipped with the connector components 24, 25, 26, 27, 28 (and/or sheath terminals 10.1, 10.2, 10.3, 10.4) can, after the cable 2 has been passed through the connector components 24, 25, 26, 27, 28 (and / or sheath terminals 10.1, 10.2, 10.3, 10.4) can be removed from the assembly module 33, for example laterally to the insertion direction of the cable 2 or against the insertion direction of the cable 2, as in Figure 6 indicated.

In Figure 7 a section of the assembly module 33 is shown enlarged in a perspective sectional view. The detail shows, by way of example, two chambers 34 of the assembly module 33. The chambers 34 are separated from one another by intermediate walls 34.1, which can have different wall thicknesses to realize the distances d ₁ , d ₂ , d ₃ , d ₄ . The intermediate walls 34.1 also serve as a stop for the connector components 24, 25, 26, 27, 28 (and/or sheath terminals 10.1, 10.2, 10.3, 10.4) inserted into the chambers 34. The intermediate walls 34.1 are further designed to provide a recess in the area of the channel K around the central axis M for the cable 2 to pass through the connector components 24, 25, 26, 27, 28 (and/or sheath terminals 10.1, 10.2, 10.3, 10.4). to leave. The bottom 36 of the assembly module 33 has steps in order to provide different height levels within the chambers 34 for the respective connector components 24, 25, 26, 27, 28 (and/or sheath terminals 10.1, 10.2, 10.3, 10.4) in order to create a continuous channel K or to enable coaxial positioning of the connector components 24, 25, 26, 27, 28 (and/or sheath terminals 10.1, 10.2, 10.3, 10.4). In order to prevent the connector components 24, 25, 26, 27, 28 (and/or sheath terminals 10.1, 10.2, 10.3, 10.4) from falling out to the side, side walls 34.2 can also be provided. In the exemplary embodiment, only one rear side wall 34.2 is provided to hold the equipped cable 2, as in Figure 6 indicated, can still be removed from the side of the assembly module 33. The magazine 35 (in.) arranged above the assembly module 33 Figure 7 hidden) but preferably has side walls 34.2 on both sides. The bottom 36, the side walls 34.2 and/or the intermediate walls 34.1 can optionally be designed to hold the connector components 24, 25, 26, 27, 28 (and/or sheath terminals 10.1, 10.2, 10.3, 10.4) in a predefined alignment or orientation to be retained.

Finally shows Figure 8 a system 40 for assembling an electrical cable 2. The system 40 shown comprises the device 1 for assembling the electrical cable 2 with an assembly module 33 for fastening at least one sheath clamp 10.1, 10.2, 10.3, 10.4 on the cable sheath 9 of the cable 2. Preferably the device 1 is designed as described above. The device 1 can also be designed to equip the cable jacket 9 with the plug connector components 24, 25, 26, 27, 28. The device 1 can also be designed to document cable processing.

The system 40 includes further processing modules 41, 43 that are independent of the device 1 for assembling the electrical cable 2.

Preferably, the device 1 within the system 40 is arranged downstream of a processing module (not shown) for aligning, receiving and orienting the cable 2. The cable 2 is preferably fitted with the plug connector components 24, 25, 26, 27, 28 and/or the sheath terminals 10.1, 10.2, 10.3, 10.4 on an initially unprocessed electrical cable 2.

Figure 8 again shows an example of a workpiece carrier system 3 in order to deliver the cable section of the cable 2 to be processed to the individual processing modules 41, 43 or to the device 1 one after the other. Depending on the number of pieces to be produced, the transport device 8 shown can also be omitted. In this case, the cables 2 or the cable sections can also be transported by a production employee between the individual processing modules 41, 43 or the device 1, for example with the aid of a roller conveyor. For example, the transport device 8 is designed in the manner of a conveyor belt and transports several cables 2 fastened on a cable carrier 4 from processing module 41, 43 to processing module 41, 43 in order to utilize all processing modules 41, 43 as permanently as possible and thus achieve a high throughput for cable processing achieve. By way of example, a first processing module 41 for assembling a contact parts carrier 42 of the device 1 is shown downstream. After mounting the contact parts carrier 42, the frontmost sheath clamp 10.1 can be removed in order to push the shielding sleeve 24 from the cable jacket 9 onto the contact parts carrier 42 and press it with the contact parts carrier 42.

A second processing module 43 for assembling the plug connector housing 25 of the plug connector 22 is shown downstream of the first processing module 41 as an example. In order to release the displacement path for the connector housing 25, another sheath terminal 10.1 can be removed.

Any further processing modules can subsequently be provided in order to gradually assemble the connector 22.

As an alternative to the use of sheath clamps 10.1, 10.2, 10.3, 10.4, it can also be provided that the cable 2 is fastened on a cable carrier 4, which has stop elements 44 arranged at defined axial positions along the longitudinal axis L, as in Figure 9 shown as an example.

Figure 9 shows a cable carrier 4 as part of a workpiece carrier system 3, similar to the cable carriers 4 already described above. The cable 2 is held by clamping jaws 5. In order to positively block the displacement path of the connector components 24, 25, 26, 27, 28 on the cable jacket 9 of the cable 2, various stop elements 44 are provided, for example in the form of webs or pins. In Figure 9 Different types of stop elements 44 are shown for clarity. Preferably, two opposing stop elements 44 are provided or two stop elements 44 that extend along the longitudinal axis L of the cable 2 are at the same axial position, which form a common pair of stop elements.

The stop elements 44 can be flexibly mounted or positioned on the cable carrier 4 in order to assume different axial positions as required. The stop elements 44 can be positioned freely or in a predetermined grid on the cable carrier.

The stop elements 44 can optionally be adjusted in the direction of the longitudinal axis L of the cable 2, for example manually along a respective guide rail 45, whereby the end position of the stop elements 44 can be fixed, for example by tightening a screw 46.

The stop elements 44 can optionally also be designed to be elastic in order to rest non-positively against the cable jacket 9 when the cable 2 is inserted (cf., for example, the frontmost pair of stop elements).

Claims (16)

1. A method for manufacturing an electric cable (2), according to which method the cable (2) is processed in mutually independent processing modules (41, 43) in succession, wherein the cable sheath (9) of the cable (2) is fitted with one or more plug-in connector components (24, 25, 26, 27, 28) for later plug-in connector fitting, preferably starting from the front, free end (6, 7) of the cable (2),
   characterized in that
   at least one sheath clamp (10.1, 10.2, 10.3, 10.4), which is independent of the plug-in connector (22) to be fitted on the cable (2) in the course of the manufacturing process, is fastened to a cable sheath (9) of the cable (2) in a non-positively locking fashion at a defined axial position along the longitudinal axis (L) of the cable (2), and is arranged axially adjacent to the at least one plug-in connector component (24, 25, 26, 27, 28) on the cable sheath (9) in order to block the displacement path of the plug-in connector component (24, 25, 26, 27, 28) on the cable sheath (9) in a positively locking fashion.
2. The method as claimed in claim 1,
   characterized in that
   the sheath clamp (10.1, 10.2, 10.3, 10.4) is pushed onto the cable sheath (9) of the cable (2) starting from a front, free end (6, 7) of the cable (2) until the defined axial position is reached.
3. The method as claimed in claim 1,
   characterized in that
   the sheath clamp (10.1, 10.2, 10.3, 10.4) is attached to the cable sheath (9) of the cable (2) at a defined axial position radially in the direction of the center axis (M) of the cable (2).
4. The method as claimed in one of claims 1 to 3,
   characterized in that
   the at least one sheath clamp (10.1, 10.2, 10.3, 10.4) is removed from the cable sheath (9) of the cable (2) again after processing by at least one of the processing modules (41, 43), preferably after processing by all of the processing modules (41, 43).
5. The method as claimed in one of claims 1 to 4,
   characterized in that
   the sheath clamp (10.1, 10.2, 10.3, 10.4) is made identifiable by way of an information carrier (11.1, 11.2) in order to be able to uniquely identify the cable (2) while it is being processed.
6. The method as claimed in claim 5,
   characterized in that
   documentation (13) of the processing of the cable (2) is compiled for at least one processing process of one of the processing modules (41, 43) and is assigned to the sheath clamp (10.1, 10.2, 10.3, 10.4) which is fastened to the cable (2).
7. The method as claimed in claim 6,
   characterized in that
   the documentation (13) is at least partially imprinted into the information carrier (11.1, 11.2) of the sheath clamp (10.1, 10.2, 10.3, 10.4).
8. The method as claimed in one of claims 5 to 7,
   characterized in that
   a unique identifier (14) for the cable (2) is imprinted into the information carrier (11.1, 11.2) or a unique identifier (14) which is already present on the information carrier (11.1, 11.2) is assigned to the cable (2).
9. The method as claimed in one of claims 5 to 8,
   characterized in that
   the information carrier (11.1, 11.2) is of optical and/or electronic form.
10. The method as claimed in claim 9,
    characterized in that
    the optical information carrier (11.1) is formed as a barcode, numerical code and/or 2D code, for example a data matrix code or QR code.
11. The method as claimed in claim 9 or 10,
    characterized in that
    the electronic information carrier (11.2) comprises at least one programmable memory module, for example an RFID transponder, which is modified to identify the cable (2) and/or to document the processing of the cable (2).
12. The method as claimed in one of claims 1 to 11,
    characterized in that
    a fitting module (33) with individual chambers (34) for receiving plug-in connector components (24, 25, 26, 27, 28) and sheath clamps (10.1, 10.2, 10.3, 10.4) is provided, which individual chambers are arranged in such a way that the plug-in connector components (24, 25, 26, 27, 28) and sheath clamps (10.1, 10.2, 10.3, 10.4) which are received in the chambers (34) form a common channel (K) with a common center axis (M), and wherein an actuator device (37) is provided and designed to conduct the cable (2), by way of its front end (6, 7), along the center axis (M) through the plug-in connector components (24, 25, 26, 27, 28) and the sheath clamps (10.1, 10.2, 10.3, 10.4) in order to push the plug-in connector components (24, 25, 26, 27, 28) and the sheath clamps (10.1, 10.2, 10.3, 10.4) axially onto the cable sheath (9) of the cable (2).
13. The method as claimed in one of claims 1 to 12,
    characterized in that
    the fitting module (33) has a magazine (35) in order to keep ready further plug-in connector components (24, 25, 26, 27, 28) or further sheath clamps (10.1, 10.2, 10.3, 10.4) for fitting further cables (2).
14. A device (1) for manufacturing an electric cable (2), by means of which the cable sheath (9) of the cable (2) is fitted with one or more plug-in connector components (24, 25, 26, 27, 28) for later plug-in connector fitting, preferably starting from the front, free end (6, 7) of the cable (2),
    characterized in that

    a) a fitting module (33) is provided and designed to fasten a sheath clamp (10.1, 10.2, 10.3, 10.4), which is independent of the plug-in connector (22) to be fitted on the cable (2) in the course of the manufacturing process, to the cable sheath (9) of the cable (2) in a non-positively locking fashion at a defined axial position along the longitudinal axis (L) of the cable (2) to be arranged axially adjacent to the at least one plug-in connector component (24, 25, 26, 27, 28) on the cable sheath (9) in order to block the displacement path of the plug-in connector component (24, 25, 26, 27, 28) on the cable sheath (9) in a positively locking fashion; or

    b) a cable carrier (4) is provided, to which the cable (2) can be fastened, wherein the cable carrier (4) has at least one stop element (44) which is arranged at a defined axial position along the longitudinal axis (L) of the cable (2) axially adjacent to the at least one plug-in connector component (24, 25, 26, 27, 28) along the longitudinal axis (L) of the cable (2) in order to block the displacement path of the plug-in connector component (24, 25, 26, 27, 28) on the cable sheath (9) in a positively locking fashion.
15. A system (40) for manufacturing an electric cable (2), comprising

    a) a device (1) for manufacturing the electric cable (2) as claimed in claim 14; and

    b) at least two mutually independent processing modules (41, 43) for manufacturing the electric cable (2).
16. A method for manufacturing an electric cable (2), according to which method the cable (2) is processed in mutually independent processing modules (41, 43) in succession, wherein the cable sheath (9) of the cable (2) is fitted with one or more plug-in connector components (24, 25, 26, 27, 28) for later plug-in connector fitting, preferably starting from the front, free end (6, 7) of the cable (2),
    characterized in that
    the cable (2) is fastened to a cable carrier (4), wherein the cable carrier (4) has at least one stop element (44) which is arranged at a defined axial position along the longitudinal axis (L) of the cable (2) axially adjacent to the at least one plug-in connector component (24, 25, 26, 27, 28) along the longitudinal axis (L) of the cable (2) in order to block the displacement path of the plug-in connector component (24, 25, 26, 27, 28) on the cable sheath (9) in a positively locking fashion.

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