WO2018069300A1 - Procédé de fabrication d'une cosse de câble et cosse de câble pour relier électriquement un câble à un élément conducteur de courant - Google Patents

Procédé de fabrication d'une cosse de câble et cosse de câble pour relier électriquement un câble à un élément conducteur de courant Download PDF

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Publication number
WO2018069300A1
WO2018069300A1 PCT/EP2017/075778 EP2017075778W WO2018069300A1 WO 2018069300 A1 WO2018069300 A1 WO 2018069300A1 EP 2017075778 W EP2017075778 W EP 2017075778W WO 2018069300 A1 WO2018069300 A1 WO 2018069300A1
Authority
WO
WIPO (PCT)
Prior art keywords
cable
lug
region
workpiece
receiving
Prior art date
Application number
PCT/EP2017/075778
Other languages
German (de)
English (en)
Inventor
Herbert Schmidt
Original Assignee
Bremi Fahrzeug-Elektrik Gmbh + Co.Kg
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Bremi Fahrzeug-Elektrik Gmbh + Co.Kg filed Critical Bremi Fahrzeug-Elektrik Gmbh + Co.Kg
Priority to EP17791959.4A priority Critical patent/EP3526860A1/fr
Publication of WO2018069300A1 publication Critical patent/WO2018069300A1/fr

Links

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/16—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for manufacturing contact members, e.g. by punching and by bending
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R11/00—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
    • H01R11/11—End pieces or tapping pieces for wires, supported by the wire and for facilitating electrical connection to some other wire, terminal or conductive member
    • H01R11/12—End pieces terminating in an eye, hook, or fork
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/58—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation characterised by the form or material of the contacting members
    • H01R4/62—Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors
    • H01R4/625—Soldered or welded connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/70—Insulation of connections
    • H01R4/72—Insulation of connections using a heat shrinking insulating sleeve

Definitions

  • the invention relates to a method for producing a cable lug and a cable lug for electrically connecting a cable to a current-carrying element.
  • tubular cable lugs are usually flat-pressed tubes at the gland side.
  • the resulting cable connection sleeve typically has to be front-sealed at the front.
  • sealing is an error-prone process step, requiring 100% gas tightness testing.
  • conventional tubular cable lugs have the disadvantage that they are only partially gas-tight or further process steps are required to ensure their tightness.
  • Two-component cable lugs are known which typically include an aluminum cable termination sleeve having a friction contact-bonded copper contactor.
  • these known two-component cable lugs are characterized by a relatively complicated structure.
  • flat cable lugs made of copper or brass with and without iso-crimp are known.
  • the ultrasonic welding node is typically protected by encapsulation or encapsulation.
  • this is relatively complicated and expensive.
  • An embodiment of a cable lug known from the document EP 2 621 021 A1 is produced in one piece from a CUPAL pipe. During finishing, this tube is processed in an end region such that the aluminum layer is removed on the inside, in particular by unscrewing. Further, in finishing, the opposite end portion on the outside is machined to remove the copper layer of the pipe, particularly by twisting.
  • the known from the document EP 2 621 021 AI embodiment of the cable lug thus has the disadvantage that its production is relatively complicated and expensive.
  • a simple production of a cable lug and a simple and reliable construction of the cable lug is achieved.
  • an existing from a single material, fully cylindrical workpiece is provided.
  • the fully cylindrical workpiece is intermediately worked by extrusion, so that an intermediate machined workpiece is produced.
  • the intermediate machined workpiece has a receiving area for receiving an end of a cable and an end area for creating an end-side contact area.
  • the intermediate machined workpiece is finished by embossing, so that a finished workpiece, which forms the cable lug, is generated.
  • the finished workpiece has the receiving area and the end-side contact area generated from the end area.
  • the finishing comprises only embossing and / or punching in the end region.
  • the intermediate processing is carried out by means of a combination of a forward extrusion and a reverse extrusion.
  • a forward extrusion preferably a forward extrusion
  • a reverse extrusion preferably a reverse extrusion
  • the fully cylindrical workpiece preferably consists of a homogeneous material, in particular copper.
  • a further aspect of the invention relates to a cable lug for electrically connecting a cable to a current-carrying element.
  • the cable lug comprises an integrally formed lug body of a homogeneous material, which has a receiving area for receiving one end of the cable and an end-side contact area for electrically conductive contacting of the current-carrying element.
  • the receiving region has a tubular receptacle for the end of the cable, which is fluid-tight, in particular completely gastight, closed at its end side.
  • FIG. 1 shows a flow chart of a method for producing a
  • Figure 2 is a three-dimensional view of a fully cylindrical
  • Figure 7A is a cross-sectional view of a cable lug with a
  • FIG. 7B shows a perspective cross-sectional view of the cable lug according to FIG. 7A.
  • FIG. 1 shows a flow chart of a method 10 for producing a cable lug.
  • the method 10 comprises in particular the following steps.
  • a step S10 a solid cylindrical workpiece made of a single material is provided.
  • a step S12 the fully cylindrical workpiece is intermediately worked by extrusion, so that an intermediate machined workpiece is produced.
  • the intermediate machined workpiece has a receiving area for receiving an end of a cable and an end area for generating an end-side contact area.
  • the intermediate machined workpiece is finished by embossing so that a finished workpiece forming the cable lug is produced.
  • the finished workpiece has the receiving area and the end-side contact area generated from the end area.
  • the finishing comprises only embossing and / or punching in the end region. Further details of the method 10 are explained in more detail below with reference to FIGS 2 to 6.
  • FIG. 2 shows a three-dimensional view of a fully cylindrical workpiece 12 for use in the method 10 according to FIG. 1.
  • the fully cylindrical workpiece 12 is provided in step S10.
  • the central axis Rl of the fully cylindrical workpiece 12 is shown.
  • the fully cylindrical workpiece 12 is made of a homogeneous material, in particular copper.
  • FIG. 3A shows a cross-sectional view of a first tool 14 in a first operating state to illustrate the intermediate processing in the step S12 of the method 10 of Figure 1.
  • Figure 3B shows a cross-sectional view of the first tool 14 of Figure 3A in a second operating state.
  • the first tool 14 is in particular a press, which has a punch 16.
  • the punch 16 In the first operating state, the punch 16 is in the first position shown in FIG. 3A.
  • the punch 16 is in the second position shown in FIG. 3B.
  • step S12 the fully cylindrical workpiece 12, which is also referred to as a blank, is inserted into the first tool 14. With the aid of the first tool 14, the step S12 is performed.
  • step S12 includes extrusion.
  • the punch 16 presses the exemplary copper material of the fully cylindrical workpiece 12 with a very high pressure in a mold.
  • This shape is formed by the inner region of the first tool 14.
  • the printing direction is indicated in FIG. 3A by the arrow PI.
  • FIG. 3B shows the resulting material flow.
  • This material flow corresponds to a combination of a forward extrusion and a backward extrusion.
  • the partial material flow generated by the forward extrusion is indicated by the arrow P2 in FIG. 3B.
  • the partial material flow generated by the backward extrusion is indicated by the arrow P3 in FIG. 3B.
  • the copper material partially flows backwards, i. in the direction indicated by the arrow P3, and around the punch 16 placed in the second position.
  • FIG. 4A shows a cross-sectional view of the intermediate machined workpiece 18 produced by means of the first tool 14 of FIG. 3A.
  • FIG. 4B shows a three-dimensional view of the intermediate machined workpiece 18 according to FIG. 4A.
  • the intermediate machined workpiece 18 includes the receiving portion 20 for receiving an end of a cable and the end portion 22 for creating an end-side contact portion.
  • the receiving area 20 comprises a tubular receptacle 36 for the end of the cable.
  • the center axis R2 of this tubular receptacle 36 is shown in Figure 4A.
  • the intermediate machined workpiece 18 according to FIG. 4A is subsequently finished.
  • FIG. 5A shows a cross-sectional view of a second tool 24 in a first operating state to illustrate the finishing in step S14 of the method 10 of Figure 1.
  • Figure 5B shows a cross-sectional view of the second tool 24 of Figure 5A in a second operating state.
  • the second tool 24 is in particular a further press.
  • the upper part of the second tool 24 is in the first position shown in FIG. 5A.
  • the second operating state the upper part of the second tool 24 is in the second position shown in FIG. 5B.
  • the intermediate machined workpiece 18 is inserted into the second tool 24.
  • the step S14 is performed.
  • the end-side contact region is embossed from the front, solid part of the intermediate machined workpiece 18 (end region 22).
  • a punching in the end region 22 can take place at the same time.
  • the pressure exerted during embossing pressure force is indicated in Figure 5A by the arrow P4. By embossing or punching the finished workpiece is produced.
  • Figure 6A shows a cross-sectional view of a finished workpiece 26 produced by the second tool 24 of Figure 5A.
  • Figure 6B shows a three-dimensional view of the finished workpiece 26 of Figure 6A.
  • the finished workpiece 26 serves as a cable lug 28. This cable lug 28 is shown in FIGS. 6A and 6B.
  • the cable lug 28 comprises the integrally formed lug body 26 made of the homogeneous material, in particular copper.
  • the cable shoe body 26 comprises the receiving region 20 with the tubular receptacle 36 and the end-side contact region 30 for the electrically conductive contacting of a current-carrying element.
  • the tubular receptacle 36 at its end face 38 is fluid-tight, in particular completely gas-tight, closed.
  • the inner region 37 of the tubular receptacle 36 and the end-side contact region 30 are fluidically separated from one another. As a result, a gas and / or liquid flow from the end-side contact region 30 to the inner region 37 of the tubular receptacle 36 is prevented.
  • an electrical connection of an aluminum cable to the current-carrying element can be produced with the aid of the cable lug 28.
  • the end of the aluminum cable is received by the tubular receptacle 36.
  • the tubular receptacle 36 is formed such that the end of the aluminum cable is inserted into the same.
  • the cable lug 28 is formed such that the inserted end of the aluminum cable is electrically connectable to the inner side 39 of the tubular receptacle 36 by ultrasonic welding.
  • the end-side contact portion 30 has a flat contact portion 32 with a punched-out hole 34. This is particularly the case if hole punching has also occurred in step S14.
  • the end-side contact portion 30 serves as a fastening portion for fastening of the cable lug 28 on the current-carrying element.
  • the punched hole 34 serves to receive a fastening means, such as a screw.
  • Fig. 6A the central axis R3 of the punched hole is shown.
  • the end-closed tubular receptacle 36 shown in FIG. 6A forms a cable connection sleeve for the end of the aluminum cable.
  • the end of the aluminum cable is its stripped section, which comprises only the aluminum line.
  • the inner contour of the cable connection sleeve is formed by the stamp 16 of the first tool 14 used during extrusion molding (see FIGS. 3A and 3B).
  • the end-side sealed and gas-tight cable terminal sleeve is formed by extrusion in step S12.
  • the end-side contact area 30 shown in FIG. 6A with the areal contacting portion 32 is formed by embossing in step S14 (see FIGS. 5A and 5B).
  • FIGS. 7A and 7B show cross-sectional views of the cable lug 28 with the receiving portion 20 in which the end of the aluminum cable 40 is received.
  • the aluminum cable 40 comprises the aluminum line 44 surrounded by the insulation 42.
  • a heat-shrinkable tube 46 is provided which covers the receiving area 20 of the cable lug 28 and the end of the insulation 42 of the aluminum cable 40.
  • the transition region between the receiving region 20 of the cable lug 28 and the end of the insulation 42 of the aluminum cable 40 can be fluidly sealed.
  • an inner adhesive between the shrink tubing 46 and the receiving portion 20 of the cable lug 28 and between the shrink tubing 46 and the end the insulation 42 of the aluminum cable 40 introduced.
  • the inner adhesive can also be omitted.
  • the cable lug 28 shown in FIGS. 7A and 7B comprises two recesses 48 formed in the receiving region 20, which are produced by a suitable joining or connection method, such as, for example, crimping or ultrasonic welding.
  • the invention provides a cable lug 28 which serves for the electrical connection of lines, in particular aluminum lines, in conventional devices, installations or in automobiles, such as passenger cars, commercial vehicles or construction machines, or in rail vehicles.
  • the basic material of the cable lug 28 according to the invention is copper.
  • the geometry of the cable lug 28 can be optimized for the particular application, e.g. to meet the special requirements when using aluminum pipes.
  • the cable lug 28 is particularly suitable for the joining of lines by ultrasonic welding. He is dimensioned for it and geometrically tuned. In addition to the ultrasonic welding, other classic joining techniques for making an electrical connection between a line and the cable lug 28 are possible.
  • the cable cross section of the cable lug 28 can be designed precisely for the current carrying capacity of the respective cable cross section.
  • the cable lug 28 is also particularly suitable after an adaptation of the cable cross-section for the contacting of aluminum cables via ultrasonic Welding, since the cable lug 28 by the special manufacturing process 10 from the Anschraubseite (ie, the end-side contact portion 32) ago is completely gastight.
  • the invention enables the provision of a gas-tight cable connection sleeve for the insulation of the welding node from moisture and other reactants of aluminum. Only the transition between the cable lug 28 and the conductor insulation should be sealed.
  • the cable lug 28 has the following characteristics. It includes a gas-tight cable connection sleeve for improved corrosion protection for aluminum cables. In its manufacture, a reduced material use of the copper material is possible. This leads to a cost and weight optimized geometry. The geometry of the cable lug 28 is designed for ultrasonic welding. Furthermore, it consists of one piece.
  • the invention has the following advantages.
  • the cable connection sleeve is gastight in the front area.
  • the cable lug 28 is reduced to the necessary material.
  • the cable lug 28 consists of a part.
  • the cable lug 28 is produced in a few simple steps.
  • the cable lug 28 is optimized for ultrasonic welding, in particular when using aluminum cables.
  • the welding knot should be sealed with simple means.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
  • Processing Of Terminals (AREA)

Abstract

Dans un procédé (10) de fabrication d'une cosse de câble (28), il est prévu une pièce (12) entièrement cylindrique et constituée d'une seule matière. La pièce (12) entièrement cylindrique est soumise à un traitement intermédiaire par extrusion de façon à produire une pièce intermédiaire (18). La pièce intermédiaire (18) comporte une zone de réception (20) destinée à recevoir une extrémité d'un câble (40) et une zone d'extrémité (22) destinée à créer une zone de contact d'extrémité (28). La pièce intermédiaire (18) est soumise à un traitement final par gaufrage de façon à produire une pièce finie (26) formant la cosse de câble (28). La pièce finie (26) comporte la zone de réception (20) et la zone de contact côté extrémité (30) réalisée à partir de la zone d'extrémité (22).
PCT/EP2017/075778 2016-10-14 2017-10-10 Procédé de fabrication d'une cosse de câble et cosse de câble pour relier électriquement un câble à un élément conducteur de courant WO2018069300A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP17791959.4A EP3526860A1 (fr) 2016-10-14 2017-10-10 Procédé de fabrication d'une cosse de câble et cosse de câble pour relier électriquement un câble à un élément conducteur de courant

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102016119656.8 2016-10-14
DE102016119656.8A DE102016119656A1 (de) 2016-10-14 2016-10-14 Verfahren zum Herstellen eines Kabelschuhs und Kabelschuh zum elektrischen Verbinden eines Kabels mit einem stromführenden Element

Publications (1)

Publication Number Publication Date
WO2018069300A1 true WO2018069300A1 (fr) 2018-04-19

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PCT/EP2017/075778 WO2018069300A1 (fr) 2016-10-14 2017-10-10 Procédé de fabrication d'une cosse de câble et cosse de câble pour relier électriquement un câble à un élément conducteur de courant

Country Status (3)

Country Link
EP (1) EP3526860A1 (fr)
DE (2) DE102016119656A1 (fr)
WO (1) WO2018069300A1 (fr)

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0086036A1 (fr) * 1982-01-11 1983-08-17 The Nippert Company Procédé et dispositif de formage d'une pièce cylindrique, notamment d'un connecteur électrique
US4626126A (en) * 1984-09-21 1986-12-02 General Motors Corporation Connector member
DE102006010622B3 (de) 2006-03-08 2007-08-02 Schulte & Co. Gmbh Verfahren zur Verbindung eines aus Kupfer oder einer Kupferlegierung bestehenden Anschlusselementes, insbesondere eines Kabelschuhs, mit einem elektrischen Kabel sowie nach diesem Verfahren hergestellter Kabelschuh
EP2621021A1 (fr) 2012-01-25 2013-07-31 Intercable GmbH Cosse destinée à relier un élément conducteur à l'aide d'un câble en aluminium
EP2874234A1 (fr) * 2013-11-15 2015-05-20 Nexans Procédé d'isolation étanche d'un point de connexion entre un conducteur et un élément de contact
EP2913895A1 (fr) * 2014-02-27 2015-09-02 Delphi Technologies, Inc. Ensemble de câbles en fils ayant un terminal avec une extrémité de fil encapsulée
DE102014107491A1 (de) * 2014-05-27 2015-12-03 IBB GmbH & Co. KG Verfahren zur Herstellung eines Kabelschuhs

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0086036A1 (fr) * 1982-01-11 1983-08-17 The Nippert Company Procédé et dispositif de formage d'une pièce cylindrique, notamment d'un connecteur électrique
US4626126A (en) * 1984-09-21 1986-12-02 General Motors Corporation Connector member
DE102006010622B3 (de) 2006-03-08 2007-08-02 Schulte & Co. Gmbh Verfahren zur Verbindung eines aus Kupfer oder einer Kupferlegierung bestehenden Anschlusselementes, insbesondere eines Kabelschuhs, mit einem elektrischen Kabel sowie nach diesem Verfahren hergestellter Kabelschuh
EP2621021A1 (fr) 2012-01-25 2013-07-31 Intercable GmbH Cosse destinée à relier un élément conducteur à l'aide d'un câble en aluminium
EP2874234A1 (fr) * 2013-11-15 2015-05-20 Nexans Procédé d'isolation étanche d'un point de connexion entre un conducteur et un élément de contact
EP2913895A1 (fr) * 2014-02-27 2015-09-02 Delphi Technologies, Inc. Ensemble de câbles en fils ayant un terminal avec une extrémité de fil encapsulée
DE102014107491A1 (de) * 2014-05-27 2015-12-03 IBB GmbH & Co. KG Verfahren zur Herstellung eines Kabelschuhs

Also Published As

Publication number Publication date
DE202017007402U1 (de) 2021-03-08
DE102016119656A1 (de) 2018-05-03
EP3526860A1 (fr) 2019-08-21

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