WO2009086992A1

WO2009086992A1 - Dimensionally stable wire harness for engine compartment wiring

Info

Publication number: WO2009086992A1
Application number: PCT/EP2008/066412
Authority: WO
Inventors: Franz-Josef Lietz; York Dlugokinski
Original assignee: Auto-Kabel Managementgesellschaft Mbh
Priority date: 2008-01-07
Filing date: 2008-11-28
Publication date: 2009-07-16
Also published as: DE102008003332A1; DE102008003332B4

Abstract

The application relates to a wire harness for the engine compartment wiring of a motor vehicle. In order to enable safe and easy installation, the invention provides that the wire harness has a first connecting element, a second element, and a flat cable formed between the connecting elements, wherein the flat cable is substantially matched to the shape and dimensionally stable.

Description

Dimensionally stable cable harness for engine compartment wiring

The application relates to a harness for engine compartment wiring of a motor vehicle.

Combustion engines are regularly fully wired before installation in a body. Wiring connects the generator, starter, spark plugs and other electrical loads in the engine. Furthermore, connection points are prepared for cabling with a battery as well as for cabling with other electrical components. To do this, the vehicle fitters have to lay harnesses around the engine block in complex and time-consuming procedures in order to ensure the necessary wiring of the electrical components. The cabling of the electrical components of the motor or the engine block takes place with the aid of prefabricated cable harnesses. In these harnesses, the necessary cables are already provided cut to length, so that only the terminal ends of the cable must be contacted. This is done regularly by screwing or soldering the terminal ends of the cable to the corresponding contacts of the electrical components in the engine block.

When laying the cable strands, however, it is often cumbersome to connect the flexible cables to the engine block Fasten. For this purpose, usually fastening clips or mounting collars are provided to secure the cables to the engine block.

From the European patent application EP 1 502 821 a cable duct is known, which facilitates the laying of the cable strands within an engine block. The cable duct is dimensionally stable, so that it has to be fastened to the engine block with only a few fastenings. When installing this cable channel, however, it is also necessary that the installer laid the harness in the cable channel and then closes the cable channel. Again, this process is time consuming.

For this reason, the application was based on the object to enable an engine room wiring, which is easy to handle and quick to install.

The above-indicated and derived from the prior art object is achieved by a harness for engine compartment wiring of a motor vehicle, having a first connection element, a second connection element, a flat cable formed between the connection elements, wherein the flat cable is substantially conformed and dimensionally stable.

In particular, the flat cable may be formed so that it is resistant to bending in the plane substantially parallel to the propagation direction, and dimensionally stable in a plane substantially normal to the propagation direction, but is easier to deform by external forces than in the plane parallel to the propagation direction. In the Mounting on the engine block, the flat cable retains its shape. This allows the fitter to attach it easily. However, the flat cable can be deformed by the action of external forces, whereby the fitter can compensate for tolerances on the engine.

It has been recognized that the conventional cable strands, which are formed from round conductors, complicate the assembly by their flexibility. Although the flexible cables can be easily threaded through gaps, this just makes them unwieldy. By providing form-adapted, dimensionally stable flat cables, it is possible to determine the course of the electrical line in advance. The installer only has to apply or press the flat cable to the engine.

Adapted for the purposes of the application, for example, be a preformed flat cable, which is adapted to the space requirements within the engine block or on the engine. A cable run is already given by the form-adapted cable.

Space requirements can thus be met, since the course of the cable are determined by the shape adjustment in advance. Narrow radii can be provided by the contoured cable. Hard-to-reach areas within the engine block can be reached by the conformed cable and the installer has to insert this only in these areas. Dimensionally stable in the meaning of the application can mean that the flat cable keeps its predetermined shape in the unloaded state. The flat cable is, as previously explained, conformed to shape, which may mean that the necessary bends and bends are already created within the cable during the manufacture of the cable. The flat cable is dimensionally stable so that the predetermined curvatures and bends remain unchanged in the unloaded state. The cable is not deformed by its own weight substantially. The deformation by its own weight is preferably less than 10%, preferably less than 5% or less than 1%.

During installation of the engine or the engine block, the installer can apply the form-fitting, dimensionally stable flat cable to the engine block or the engine without additional aids at the point provided for the cable and connect the connection elements with the contacts within the motor or the contact elements of the motor Align engine with arranged electrical elements. After the connection elements have been aligned with the contacts, the form-fitting flat cable is already correctly positioned on the motor or engine block. It is then only necessary to electrically contact the connection elements with the contacts to the electrical elements.

Because the flat cable is conformed and dimensionally stable, it can be prefabricated. This means that the flat cable already has the course before installation, which is required when installed. This makes it possible to ensure a cabling of the engine with a small footprint.

According to one embodiment, the flat cable is made of aluminum. Aluminum is so adaptable in terms of its material properties that dimensional stability is maintained. It is possible that pure aluminum with an aluminum content of over 99% is turned. It is also possible that the flat cable made of non-ferrous metal, such as copper, is formed.

In order to enable dimensional stability, it is proposed that the flat cable is formed from work-hardened aluminum. During work hardening, the semifinished product, for example an aluminum strip or an aluminum sheet, is pressed or pulled. In addition, the aluminum can be additionally pulled in the production of flat cable.

In addition, it is proposed that the aluminum is heat treated. For example, it is possible for the preformed aluminum to be solution heat treated. Furthermore, it is possible that after the solution annealing the flat cable is cold-outsourced. In addition, the flat cable can be outsourced warm. It is also possible that the aluminum is relaxed and then outsourced cold or warm.

The flat cable may, in order to be dimensionally stable, have a material state of Hill or T. These Material conditions ensure sufficient dimensional stability.

In addition, it is possible that the flat cable has a tensile strength of 90 N / mm ² to 120 N / mm ² . This tensile strength ensures the necessary dimensional stability. Also, an RP 0.2 value of 30-80 N / mm ² , preferably 40-60 N / mm ² , preferably 55 N / mm ² may be provided.

In addition, the flat cable can have an elongation at break of 20-30%. Such elongation at break makes it possible to produce flat cables with small radii in order to cope with difficult space requirements.

As previously explained, the flat cable can be easily aligned with the assembly by the fitter on the engine block and the connecting elements are contacted with the electrical contacts. Thereafter, a further attachment of the flat cable could be omitted on the engine or engine block, since the dimensional stability is ensured by the flat cable itself. This facilitates the assembly considerably and reduces the installation costs. The advantage of a flat cable in the sense of the application, especially if this is conformed and dimensionally stable, may be that it can be ruled out when marrying the engine block with the body, that the harness gets caught on the body and can be damaged. Rather, the wiring harness is according to the application closely to the engine block or engine and the position of the cable harness is clearly determined by the preformed flat cable. This can be sure To avoid that when marrying the engine block with the body of the wiring harness on the body "threads" and gets stuck in this and possibly damaged.

The dimensional stability ensures that the flat cable rests tightly against the engine block. In addition, the dimensional stability enables the flat cable to be held exclusively by the connections of the connection elements on the motor.

In order to ensure a sufficiently high current carrying capacity, it is proposed that the cable cross-section be between 35 and 50 mm ² . The cable cross sections make it possible to carry high battery currents.

The cable harness can be produced particularly easily if the connection elements and the connection cable are formed in one piece. In this case, it is possible, for example, that the flat cable is electrically insulated and the connection elements are free of insulation material. It is also possible that connecting brackets are provided on the connection elements, such as lugs or holes to contact them with the contacts of the electrical elements within the engine block.

The cable may be coated with a thermoplastic elastomer. For example, insulation may be in the temperature classes D, E, E (180), F. Within an engine, the bypass temperature can vary greatly due to the position. For example, it is considerably hotter directly on the piston than close to the fan. In order to cope with the different temperature conditions within a motor, it is proposed that the flat cable is temperature resistant. In particular, it is possible that the coating is made of a polyamide. This coating can be applied for example by extrusion. The polyamide may be, for example, from the temperature class C to F. Thus, temperatures between 125 and 200 ⁰ C and short-term temperatures (up to 240 ⁰ C) of 150 + 3-225 + 4 can be sustained without damage. The insulating material may also be other than polyamide. The insulation material can have a thickness of 0.1mm to 5mm.

In order to cope with the various temperatures within the engine compartment, it is proposed that the temperature resistance of the coating be variable, such that in areas of elevated temperature, the coating is more temperature-resistant than in areas of lower temperature. This can be made possible, for example, by extruding with different materials.

In order to meet the requirements of electromagnetic compatibility (EMC), especially when used in hybrid vehicles as well as in electric vehicles, it is proposed that the flat cable is shielded. The shielding can be ensured for example by introducing a Schirmungsleiters in the insulation layer. It is also possible that the shielding is ensured by a special processing of the insulation material, for example by introducing metal spurs into the insulation material.

In order to meet various requirements for the flat cable, as well as to meet different customer needs, without having to make a separate harness for each vehicle, it is proposed that the flat cable is modularly assembled from at least two elements. For example, these elements may have predetermined shape factors, and any assembly can be replicated by assembly using the flat cable.

As already explained above, the flat cable is suitable for contacting electrical elements within an engine compartment. It is also possible to enable electrical components within an engine compartment with components arranged outside the engine compartment. It is proposed that the flat cable is shaped for wiring the elements generator, starter, spark plug, radiator, relay, electric motor, battery.

Another object is an engine block of a motor vehicle with a previously described harness.

Another object is a vehicle with a previously described engine block. According to a further aspect, the application relates to a method for wiring an engine block of a motor vehicle with a previously described cable harness, wherein the cable harness is connected to terminals of electrical consumers and / or suppliers within the engine block, that the cable harness rests suitably adapted to the engine block free of brackets.

The subject of the application will be explained in more detail with reference to a drawing showing embodiments.

In the drawing show:

Fig. 1 is a view of a cable harness;

Fig. 2 is a cross section of a wire harness;

3 is a view of a modular cable harness;

4 shows a view of an engine block with a cable harness according to the application;

Fig. 5 is a flowchart of a method according to the application.

FIG. 1 shows a cable strand 2 with a first connection element 4 and a second connection element 6. A flat cable 8 is formed between the connection elements 4, 6. The cable harness 2 is preferably insulated. The insulating material is removed in the region of the connecting elements 4, 6, so that the soul of the flat cable 8 free lies. The core of the flat cable 8 is preferably formed of an aluminum, in particular of pure aluminum AL 99.5%. The aluminum from which the core of the flat cable 8 is formed is preferably work-hardened and heat-treated to achieve a material condition of Hill or T. As a result, a tensile strength of 90-120 N / mm ² or an elongation at break of 20 - 30% is achieved.

According to the application, such an aluminum can be cut from a metal sheet or strip into flat cables. The cut flat cable can be passed through an extruder to apply an insulating material. This insulating material is preferably polyamide.

After the flat cable 8 has been insulated, it is preformed by means of bending devices. This makes it possible to give the flat cable 8 by bending in all three spatial directions a predetermined shape. This shape of the flat cable 8 preferably corresponds to a predetermined space requirement within an engine compartment. The preformed flat cable 8 is according to the application form-fitting and dimensionally stable. In the unloaded state, the flat cable 8 keeps its predetermined shape by bending. A deformation of the flat cable 8 is possible only by using increased forces. The forces occurring during assembly are so low that the flat cable is only slightly elastically deformed. Such elastic deformation may be less than 5%, for example. Due to the dimensional stability of the flat cable 8 is achieved that after the flat cable 8 is mounted on a motor, preferably no or only a very small number of other brackets are necessary. It is also possible that the number of brackets is reduced to one to two. The flat cable 8 fits closely to the engine and does not need to be fastened, or only to a small extent, by additional fastening clips. For the attachment of the flat cable 8 serve the connection elements 4, 6. At the connection elements 4, 6 can be provided, for example, lugs, holes or other means for attachment to a contact of an electrical load, battery or generator. During assembly, the flat cable 8 is connected to the engine block in such a way that an electrical connection to the contacts of the electrical consumers or of the generator is produced at the connection elements 4, 6. In particular, a contact between generator, starter, spark plug, radiator, relay, electric motor, battery or the like is possible. The flat cable 8 can be designed so that in each case two of the aforementioned elements can be contacted with each other.

It is also possible that the wiring harness 2 is branched, so that different flat cables 8 branched from a connection point to ensure an electrical distribution. As can be seen in Figure 1, a connection pin 7 is provided. At this connection pin 7, a flat cable or a round cable 9 may be attached. This can make any necessary flexible Branches are formed to electrical loads in the engine compartment.

After the cable harness 2 has been connected to the connection elements 4, 6 with the electrical contacts of the consumer / generator, the flat cable 8 is mounted in its end position. It is not necessary to provide further fastening devices on the engine block.

Manufacturing tolerances can compensate the fitter by bending the flat cable 7 and thus giving it its final shape.

Figure 2 shows a cross section of a flat cable 8. The core 10 of the flat cable 8 is formed of aluminum. To the soul 10 of the flat cable insulation 12 is provided. This insulation may for example be polyamide or be formed from another temperature-resistant material.

If necessary, an electrically conductive layer 14 can be applied to the insulation layer 12 as a shielding. About this shield 14, an insulation layer 16 can be applied again. The insulators 12, 16 are temperature resistant, such that temperatures within an engine compartment result in no damage.

FIG. 3 shows a modular construction of a cable strand 2. In this case, the cable strand 2 is formed from different flat cables 8a, b, c. The flat cables 8a, b, c can be electrically connected to one another at the transfer points be contacted. The modularity makes it possible to provide the cable harness 2 with a variable temperature-resistant insulation. For example, it is possible that the flat cables 8a, 8c have a temperature-resistant coating designed for lower temperatures than the coating of the flat cable 8b. For example, it is possible that the flat cable 8b is guided in a region of the engine block which is exposed to elevated temperatures. In this case, the flat cable 8b must be provided with a better temperature coating than the flat cables 8a, 8c.

FIG. 4 shows an engine block 26. A cable harness 2 is arranged on the engine block 26. The wiring harness 2 is contacted only in the region of the connecting elements 4, 6 with electrical loads or generators within the engine block 26. Due to the dimensional stability of the flat cable 8, the cable strand 2 remains in the position reached after assembly, which is achieved by fixing the connecting elements 4, 6. This has the advantage that when marrying the engine block 26 with the body, jamming or catching of the harness 2 with elements of the body can be reliably prevented. In addition, a small space consumption can be realized by the close management of the flat cable 2 on the engine block 26. In addition, it is possible to ensure wiring in difficult space requirements.

Also shown is a branch of a round conductor 9 on the connecting bolt 7. The circular conductor 9 is through a Clip 27 is mounted in the engine compartment and branches off to an electrical load.

FIG. 5 shows the sequence of a laying of a cable harness 2 on an engine block. First of all, the cable harness 2 is guided by an installer to the engine block (18) in such a way that the flat cable 8 lies in the region of the intended cable run. It may be possible to thread the flat cable 2 through openings or to introduce it into narrower niches.

After coarse alignment, the flat cable 8 is aligned (20) so that the connection elements 4, 6 rests against the intended contacts of the electrical load / generators.

Then, an electrical and mechanical contact, for example, a frictional, positive or material-locking connection between the connection elements 4, 6 and the contacts of the electrical load / generators produced. This is possible, for example, by welding, screwing, soldering, clipping.

After the connection elements have been mechanically and electrically connected to the contacts (22), the cable harness 2 is in its final position (24). Another attachment with bracket on the engine block is no longer required. Due to the dimensional stability is ensured that the wire harness 2 actually remains in the position that by the shape of the Flat cable is desired. Slipping of the cable can be safely prevented.

By cabling according to the application, it is possible to realize a quick and easy installation of cable harnesses in engine compartments. The marriage of the engine block with the body is simplified and the assembly times shortened.

Claims

PATENT APPLICATIONS

A cable harness for engine compartment wiring of a motor vehicle having a first connection element (4), a second connection element (6), a flat cable (8) formed between the connection elements (4, 6), wherein the flat cable (8) is substantially conformed and at least during the Mounting on an engine is dimensionally stable.

2. Wiring harness according to claim 1, characterized in that the dimensionally stable flat cable is rigid, such that it retains its predetermined shape without external force.

3. Cable harness according to claim 1, characterized in that the flat cable (8) made of aluminum or non-ferrous metal, such as copper, is formed.

4. Wires harness one of the preceding claims, characterized in that the flat cable (8) is formed from work-hardened aluminum.

5. Wires harness one of the preceding claims, characterized in that the flat cable (8 is formed of heat-treated aluminum.

6. Cable harness one of the preceding claims, characterized in that the flat cable (8) has a material state of Hill or T.

7. Cable harness according to one of the preceding claims, characterized in that the flat cable (8) has a tensile strength of more than 90 N / mm ² -120 N / mm ² .

8. Cable harness one of the preceding claims, characterized in that the flat cable (8) has an elongation at break of 20 - 30%.

9. Wires harness one of the preceding claims, characterized in that the flat cable (8) is dimensionally stable so that it is free of cable guides on the engine block (26) can be mounted.

10. Wires harness one of the preceding claims, characterized in that the flat cable (8) is dimensionally stable in such a way that it is mountable free of brackets between the connection elements on the engine block (26).

11. Wires harness one of the preceding claims, characterized in that the flat cable exclusively through the terminals of Connection elements (4, 6) on the engine block (26) is held.

12. Cable harness one of the preceding claims, characterized in that the cable cross-section between 35 and 50 mm ² .

13. Cable harness one of the preceding claims, characterized in that the flat cable (8) and the connection elements (4, 6) are integrally formed.

14. Cable harness one of the preceding claims, characterized in that the flat cable (8) is coated temperature-resistant.

15. Wires harness one of the preceding claims, characterized in that the coating (12, 16) is formed of polyamide.

16. Wiring harness one of the preceding claims, characterized in that the

Temperature resistance of the coating (12, 16) is variable, such that in areas of elevated temperature, the coating (12, 16) is more temperature resistant than in areas of lower temperature.

17. Cable harness one of the preceding claims, characterized in that the flat cable (8) is shielded.

18. Wires harness one of the preceding claims, characterized in that the flat cable (8) is modularly assembled from at least two elements.

19. Cable harness according to one of the preceding claims, characterized in that the flat cable (8) for a wiring of the elements:

A) generator,

B) starters,

C) spark plug,

D) cooler,

E) relays,

F) electric motor,

G) battery is formed.

20. Engine block of a motor vehicle with a harness according to claim 1.

21. Motor vehicle with an engine block according to claim 18.

22. A method for wiring an engine block of a motor vehicle with a cable harness according to claim 1, wherein the cable harness is connected to terminals of electrical consumers and / or suppliers within the engine block, that the cable harness rests mismatched free of brackets on the engine block.