Classifications

• • G—PHYSICS
  • G01—MEASURING; TESTING
  • G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
  • G01M3/00—Investigating fluid-tightness of structures
  • G01M3/02—Investigating fluid-tightness of structures by using fluid or vacuum
  • G01M3/04—Investigating fluid-tightness of structures by using fluid or vacuum by detecting the presence of fluid at the leakage point
  • G01M3/16—Investigating fluid-tightness of structures by using fluid or vacuum by detecting the presence of fluid at the leakage point using electric detection means
  • G01M3/18—Investigating fluid-tightness of structures by using fluid or vacuum by detecting the presence of fluid at the leakage point using electric detection means for pipes, cables or tubes; for pipe joints or seals; for valves; for welds; for containers, e.g. radiators
• • G—PHYSICS
  • G01—MEASURING; TESTING
  • G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
  • G01M3/00—Investigating fluid-tightness of structures
  • G01M3/02—Investigating fluid-tightness of structures by using fluid or vacuum
  • G01M3/04—Investigating fluid-tightness of structures by using fluid or vacuum by detecting the presence of fluid at the leakage point
  • G01M3/20—Investigating fluid-tightness of structures by using fluid or vacuum by detecting the presence of fluid at the leakage point using special tracer materials, e.g. dye, fluorescent material, radioactive material
  • G01M3/22—Investigating fluid-tightness of structures by using fluid or vacuum by detecting the presence of fluid at the leakage point using special tracer materials, e.g. dye, fluorescent material, radioactive material for pipes, cables or tubes; for pipe joints or seals; for valves; for welds; for containers, e.g. radiators

Definitions

• the present invention relates to a method for testing an electrical connection device with regard to the leakproofness of at least one component of the connection device by means of a testing device.
• the present invention relates to a device for testing an electrical connection device with regard to the leakproofness of at least one component of the connection device.
• Electrical connection devices such as for example electrical plug-and-socket connection devices may in certain fields of use be exposed to adverse ambient conditions.
• electrical connection devices on vehicles may be exposed to environmental influences, in particular moisture, heat, cold etc., which contribute to elevated stress on such connection devices.
• environmental influences in particular moisture, heat, cold etc.
• an electrical connection device is assembled from two components, one of the components being attached, for instance, to a flange on a vehicle.
• This component may for example be a socket part of an electrical connection device, into which a corresponding plug part is inserted from outside.
• a seal is fitted at the connection point between socket part and plug part, which is intended to prevent water or moisture from being able to penetrate into the inside of the plug- and-socket connection at the connection point.
• connection device In order to check whether an electrical connection device withstands later stresses when in use, it is sometimes conventional to subject such a connection device or a prototype thereof to an appropriate test, in order to be able to establish to what extent a component to be tested with regard to leakproofness of the connection device withstands ambient influences.
• standard test methods for example to DIN, ISO, etc. depending on connector type and instance of use.
• electrical connection devices directly at the subsequent place of use, for instance on a vehicle, which is exposed to corresponding ambient conditions.
• the disadvantage of this procedure is, however, that such a test method is comparatively complex and again under certain conditions does not provide satisfactory results (for example depending on the installation location).
• the present invention relates to a method for testing an electrical connection device with regard to the leakproofness of at least one component of the connection device according to the features of claims 1, 2 and 3. Furthermore, the present invention relates to a device for testing an electrical connection device with regard to the leakproofness of at least one component of the connection device according to the features of claims 17, 18 and 19.
• the latter is fitted to a testing device in such a way that at least one part of the connection device with the component to be tested is arranged in a chamber of the testing device, a fluid being introduced into the chamber of the testing device such that the component to be tested comes into contact with the fluid. Furthermore, at least one part of the testing device is exposed to vibration and the fluid is exposed to a given pressure, the exposure to vibration and the exposure to pressure taking place simultaneously at least for a given period of time. The leakproof function of the component to be tested is then checked, by establishing whether the fluid has penetrated the component to be tested.
• one part of the testing device is exposed to vibration and the electrical connection device in the testing device is exposed to a specific temperature, the exposure to vibration and the exposure to temperature taking place simultaneously at least for a period of time.
• the fluid is exposed to a specific pressure and the electrical connection device in the testing device is exposed to a specific temperature, the exposure to pressure and the exposure to temperature taking place simultaneously at least for a period of time.
• the device according to the invention for testing an electrical connection device accordingly comprises a chamber for accommodating the connection device in such a manner that at least one part of the connection device with the component to be tested is arranged in the chamber.
• a feed opening in the chamber serves for introduction of a fluid into the chamber, so as to allow the component of the connection device to be tested to come into contact with the fluid.
• a pressure- generating device serves to expose the fluid to a specific pressure
• a vibration- generating device serves to expose at least one part of the chamber to vibration.
• the vibration-generating device and the pressure-generating device operate simultaneously at least for a period of time, a detection device serving to check the leakproof function of the component to be tested, whereby penetration of the fluid at the component to be tested is established by the detection device.
• a temperature-generating device may also be provided, in order to expose the electrical connection device in the testing device to a specific temperature.
• the vibration-generating device may additionally or alternatively be operated simultaneously with the temperature-generating device or the pressure-generating device may additionally or alternatively be operated simultaneously with the temperature-generating device.
• the individual parameters need not be varied simultaneously.
• connection device simultaneous testing of an electrical connection device is thus carried out in which the latter is exposed to vibration loading, moisture loading and/or temperature loading, at least two of these parameters acting on the connection device simultaneously for a given period of time.
• the connection device may be exposed to a specific temperature, in order for instance also to simulate heat or cold loading.
• a further advantage of the invention is that such a test method may be performed in a laboratory, in which test conditions may be reproduced at any time.
• the connection device does not consequently have to be fitted under real conditions to the object on which it is subsequently to be used, for instance to a vehicle, so making possible on the one hand an improved test method under laboratory conditions and on the other hand simplified testing of the component to be tested.
• the leakproof function is checked by a detection device, which is arranged in the vicinity of the component to be tested for detection of varying electrical conductivity at a predetermined location as a result of fluid reaching the detection device.
• a detection device which is arranged in the vicinity of the component to be tested for detection of varying electrical conductivity at a predetermined location as a result of fluid reaching the detection device.
• the detection device detects a resultant or varying electrical conductivity.
• the detection device comprises at least two electrodes, any change in the electrical conductivity between the electrodes resulting from penetration by the fluid being detected. As soon as fluid penetrates through a seal to be tested of the connection device, the electrical conductivity between the electrodes is in particular increased, which is accordingly detected by the detection device.
• the detection device is brought into contact with a substance which contributes together with the fluid to the formation of a conductive medium.
• a substance which contributes together with the fluid to the formation of a conductive medium.
• the detection device is brought at least partially into contact with a substance before the fluid reaches the predetermined location, the substance contributing, on contact with the fluid and in cooperation with the fluid, to formation of the conductive medium.
• the fluid may have admixed with it in the chamber a substance which contributes, in cooperation with the fluid, to the formation of a conductive medium.
• the fluid is water or contains water
• the substance contains sodium chloride NaCl (salt), which contributes in cooperation with water to the formation of a conductive medium.
• the salt may be provided in the vicinity of or at the electrodes of the detection device or alternatively or additionally mixed with the water in the chamber.
• another material may also be used, which contributes, in cooperation with water, to an increase in electrical conductivity or to the formation of a conductive medium.
• the electrical connection device is loaded with at least one additional mass, which is situated at a location at which, when the connection device is in use, there is located at least one cable connected with the connection device or a contact. In this way, in the case of vibration of the connection device a cable fitted thereto is additionally simulated, which under certain circumstances increases the forces of the connection device acting on the seal, such that the real conditions of use may be realistically reproduced.
• the additional mass comprises at least one body, to which an additional material, in particular a resin, is at least partially applied to establish a defined weight.
• an additional material in particular a resin
• a specific length of a cable fitted to the connection device may be simulated, by applying an appropriate quantity of additional material to the body, such that a total mass is obtained which corresponds to the respective cable length.
• the electrical connection device comprises a first and second connector part, these being mutually complementary and connected together.
• the connection device is fitted on the testing device in such a way that the first connector part is arranged in the chamber of the testing device.
• the leakproof function is checked by a detection device which is arranged in contact bushings of the second connector part.
• Respective electrodes are arranged for example in the contact bushings, any change in the electrical conductivity between the electrodes resulting from the penetration of fluid being detected.
• contact bushings of the first connector part to be closed with a closing device or at least one closed blind cable to be introduced into the contact bushings of the first connector part.
• a test may in this case be carried out in a comparatively short time, wherein for example exposure of at least one part of the testing device to vibration, exposure of the fluid to a specific pressure and exposure to a specific temperature proceed in such a way that at least one of the parameters of vibration, pressure or temperature or all the parameters are varied during the test in given time steps.
• the variation may take place in comparatively small steps, such that it is possible reliably to record at which respective vibration, pressure and/or respective temperature value a leak is detected.
• the temperature to which the connection device is exposed may additionally be varied in given time steps during the test.
• Figure 1 shows a schematic representation of an embodiment of a testing device according to the invention in partially sectional representation and with highly schematic representation of individual test components which are used during a test procedure
• Figure 2 shows a detailed representation of an embodiment of a test component, which serves in simulation during the test of cables fitted to the connection device
• Figure 3 shows a detailed representation of a blind cable, which may be provided in the connection device during testing.
• FIG. 1 is a partially sectional, schematic representation of an embodiment of a testing device 5 according to the invention for carrying out a method according to the invention.
• a device 1 comprises in particular a testing device 5, which is arranged on a base plate 16, which is part of a vibration-generating device, such that the testing device 5 may be caused to vibrate through vibration of the base plate 16. To this end, the testing device 5 is connected to the base plate 16 by means of appropriate screws.
• the testing device 5 comprises a chamber 51, which is so dimensioned that an electrical connection device 2 may be at least partially inserted therein.
• the electrical connection device 2 comprises a first connector part 21 and a second connector part 22, which takes the form for example of a socket part and is correspondingly complementary to the first connector part 21.
• the second connector part 22 is fitted to a flange 52 of the testing device 5, the connection point between connector part 22 and flange 52 being sealed via a seal 17, in particular a sealing ring.
• the flange 52 of the testing device 5 separates the upper chamber 51 from a lower chamber 53.
• a mounting ring 54 is arranged for mounting the connection device 2.
• the first connector part 21 with the component to be tested in the present case an (invisible) seal 4, is arranged in the chamber 51.
• the seal 4 serves to seal the connection point between connector part 21 and connector part 22 and is designed to be checked in a testing procedure to see whether leaks may arise in the region of the seal 4 so as to allow fluid or moisture to penetrate at a location 8 between the connector parts 21 and 22.
• the chamber 51 of the testing device 5 is filled with a fluid 3 in the form of water, such that the connector part 21 with the seal 4 to be tested is immersed virtually completely in water.
• the chamber 51 is not completely filled with water 3, however, but rather contains a certain proportion of air, which may be compressed via a feed opening 15 at the upper part of the chamber 51.
• the feed opening 15 is connected to a pressure-generating device 6, which serves to expose the water 3 situated in the chamber 51 to a specific pressure P.
• the part of the connection device 2 on the seal side, therefore the first connector part 21, is additionally provided with a standard adapter 11, which serves when in use to connect a cable or a plurality of cables to the connector part 21 or to corresponding contacts in the connector part 21.
• the connector part 21 comprises corresponding contact bushings 211 and 212, which for clarity's sake are not shown in Figure 1, said Figure 1 merely indicating their approximate positioning in the connector part 21. Since the cables cannot be connected in the testing device 5 in the same way as during subsequent use, provision is made according to the invention for the adapter 11 to be loaded with an additional mass 10, by means of which a defined weight may be established, which acts on the adapter 11 and thus on the connector part 21. For example, the mass 10 is used to simulate a cable length of approx. 10 cm.
• FIG. 2 shows a detailed representation of an embodiment of such an additional mass 10 which serves to simulate cables fitted to the connection device 2.
• the mass 10 comprises a body 12 to which an additional material 13, in particular in the form of a resin, is at least partially applied to establish a defined weight.
• the body 12 has a specific length Ll, which is such that, in conjunction with the length L2 of the chamber 51 between the upper end of the connector part 21 and the upper edge of the chamber 51, the additional mass 10 may be accommodated in the chamber 51.
• a detection device 7 which in the present embodiment comprises two electrodes or contacts 71, 72 which are arranged in corresponding contact bushings 221, 222 of the second connector part 22.
• the contacts 71 and 72 take the form of electrical contacts, which correspond to the contacts which are also provided in the connector part 22 in the event of use. Therefore, the originally used contacts, as positioned in the respective contact bushings in the event of use, may also be used as part of the detection device 7.
• the contacts 71, 72 are connected to the detection device 7, which for example contains a display means, for example a lamp, an LED or another display means.
• the detection device 7 it is additionally possible for the detection device 7 to read out an ohmic value. Furthermore, a connected data recorder may for example be provided, which records the parameters pressure, temperature, vibration and/or resistance continuously or at discrete intervals. In this way, automatic detection of a particular status is also possible during a test. In particular, it is possible to establish at what level of pressure, vibration and/or temperature the tested connection device 2 remains leakproof or develops leaks.
• the detection device 7 serves to detect a changed electrical conductivity between the contacts 71, 72, indicating in particular when the resistance between the contacts 71 and 72 decreases from a high initial value to a markedly lower value. To seal the passage of the detection lines between contacts 71, 72 and detection device 7, a seal 18 may be used.
• a basic concept of the embodiment of the invention illustrated in Figure 1 lies in the fact that moisture or water penetrating into the connector part 21 or 22 may be detected with the aid of the contacts 71, 72 and the detection device 7 if, as a result of penetrating moisture or as a result of penetrating water, the electrical conductivity between the contacts 71 and 72 changes markedly, in the present case therefore increases.
• the contacts 71 and 72 are brought at least partially into contact with a substance 9 which contributes to the formation of a conductive medium upon contact with fluid and in cooperation with the fluid.
• the electrodes or contacts 71 and 72 are surrounded by a salt 9 or immersed therein, which contributes to the formation of an electrically conductive medium under the influence of penetrating water or moisture.
• the relatively high initial resistance between the contacts 71 and 72 reduces markedly, wherein this markedly reduced resistance may be measured as soon as a point of the seal 4 or as soon as any other seal of the connector part 21 can no longer withstand the pressure of the water 3, such that water penetrates inside the connector at the corresponding point.
• This increased conductivity is detected by the detection device 7 and displayed accordingly.
• the water 3 in the chamber 51 may have a substance admixed with it, for example again in the form of a salt 9, such that the fluid located in the chamber 51 already constitutes a relatively highly conductive medium.
• a salt 9 such that the fluid located in the chamber 51 already constitutes a relatively highly conductive medium.
• FIG. 3 shows a detailed representation of a blind cable 14, which may be introduced into the contact bushings of the first connector part 21.
• corresponding contacts as are also used in subsequent application are provided in the contact bushings 211 and 212 and connected to the blind cable 14, such that no fluid can penetrate at the contact bushings 211 and 212 since the blind cable 14 is closed.
• the blind cable 14 also constitutes an additional mass 10, this may be provided in combination with the additional mass 10, such that overall an additional mass x is achieved which corresponds to a specific cable length in subsequent application. If the connector part 21 has for example four contact bushings, two blind cables 14 are accordingly provided.
• the mass x corresponds for example to a mass equivalent to 15 cm of cable in quadruplicate embodiment, in each case of 2.5 mm 2 (4 x 2.5 mm 2 ).
• the corresponding contact bushings of the first connector part 21 may also be closed with a closing device ("blind stop"), the mass of contacts and/or cables to be provided at the connector part 21 being simulated solely by the additional mass 10.
• the body 12 of the additional mass 10 ( Figure 2) may be made for example of metal or of plastics.
• the detection device with the contacts 71, 72 it is also possible for example to use a camera as detection device, by means of which it is possible to observe when fluid penetrates into the connector.
• the vibration-generating device is then set in vibration, such that the testing device 5 with the connection device 2 is exposed to vibrations V, as shown schematically in Figure 1.
• the vibrations V may occur in three different directions.
• the fluid 3 situated in the chamber 51 is exposed via the pressure-generating device 6 to a specific pressure P, wherein exposure to vibration and exposure to pressure take place simultaneously at least for a certain period of time.
• the testing device 5 or the connection device 2 may be exposed to a specific temperature T.
• the device 1 also serves at the same time as a temperature-generating device, which comprises corresponding means ((not shown) for establishing the temperature T.
• the starting point is a relatively low initial pressure P, which is increased successively in small steps over a relatively short period of time.
• the vibration V may likewise be varied, or may indeed remain unchanged over a certain period.
• the detection device 7 As soon as increased conductivity is detected at the contacts 71 and 72, which allows the conclusion to be drawn that water is penetrating through the seal 4 at the location 8, this is displayed accordingly by the detection device 7, such that at the time of display the respectively prevailing pressure P and the vibration V (Hz/g with g in m/s 2 ) may be recorded.
• the temperature T may be varied independently in stages and the temperature T then prevailing recorded.
• the invention offers the major advantage that in this way ambient conditions may be simultaneously simulated, just as they prevail in reality for example in a vehicle, wherein the test may nonetheless be performed reproducibly in a laboratory.
• This makes it possible, for example, to compare different connector systems with one another and to vary different ambient conditions in any desired manner. Different connector systems may in this respect be compared directly with one another in one and the same test run. It is additionally possible to use the method according to the invention quickly to determine the maximum sealing level (maximum pressure).
• This type of test method yields better test results than the sequential testing of different ambient conditions carried out at present, since different ambient conditions do act simultaneously on the electrical connection device to be tested.

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• Physics & Mathematics (AREA)
• General Physics & Mathematics (AREA)
• Manufacturing Of Electrical Connectors (AREA)
• Connector Housings Or Holding Contact Members (AREA)

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• 2007
  • 2007-08-29 DE DE200710040864 patent/DE102007040864A1/de not_active Withdrawn
• 2008
  • 2008-08-19 WO PCT/EP2008/006807 patent/WO2009027036A1/en active Application Filing

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