WO2020058094A1

WO2020058094A1 - Method for producing a resistor assembly for a battery sensor, resistor assembly and battery sensor

Info

Publication number: WO2020058094A1
Application number: PCT/EP2019/074410
Authority: WO
Inventors: Henryk Frenzel; Martin Schramme
Original assignee: Continental Automotive Gmbh
Priority date: 2018-09-18
Filing date: 2019-09-12
Publication date: 2020-03-26
Also published as: DE102018215784A1

Abstract

The invention relates to a method for producing a resistor assembly (12) for a battery sensor (10), in particular in a vehicle, said resistor assembly having a battery pole terminal (14) and a cable connection point (16), which are electrically connected to one another by means of a measurement resistor (24), in which method: a planar base material (26), consisting of a first portion (28), a second portion (30), which consists of an electrically conductive material, and an elongate resistor portion (32), is provided, the first portion (28) and the second portion (30) each being electrically connected to one of two opposite edges (34, 36) of the resistor portion (32); a main body (38), having a first connection portion (40), a second connection portion (42) and a measurement resistor (24), is punched from the base material (26), the first connection portion (40) being formed substantially from the first portion (28), the second connection portion (42) being formed substantially from the second portion (30) and the measurement resistor (24) being formed substantially from the resistor portion (32); and a battery pole terminal (14) is formed on the first connection portion (40) by a forming method and a cable connection point (16) is formed from the second connection portion (42). The invention further relates to an resistor assembly of this type and to a battery sensor comprising a resistor assembly of this type.

Description

description

Method for manufacturing a resistance assembly for a battery sensor, resistance assembly and battery sensor

The invention relates to a method for producing a resistance assembly for a battery sensor, in particular a battery sensor in a vehicle, the resistance assembly having a battery terminal and a cable connection, which are electrically connected to one another via a measuring resistor. The invention further relates to such a resistance assembly and a battery sensor with such a resistance assembly.

Battery sensors are used in vehicles to obtain information about the state of the battery, for example the state of charge of the battery. The battery parameters to be recorded are, for example, the battery voltage, the battery current and the temperature of the battery, in particular the battery voltage and the battery current in particular have to be recorded permanently in order, for example, to be able to make an exact statement about the state of the battery, for example the state of charge.

The current is detected, for example, by detecting a voltage drop in a measuring resistor arranged in the load current path. The electrical resistance of the measuring resistor is very well known. Due to the recorded voltage drop, the current flowing through the measuring resistor, i.e. the load current, can be determined very precisely using Ohm's law.

A material with a low temperature dependence of the electrical resistance is usually used for the measuring resistor selected, for example a copper-nickel-manganese alloy. A material with a high electrical conductivity, for example copper or a copper alloy, is usually used for the connection elements of the battery sensor, for example a battery pole terminal or a cable connection for a ground cable. The measuring resistor must be reliably connected to the battery pole terminal and the cable connection in order to ensure reliable current flow and high mechanical stability. In the prior art, the measuring resistor is supplied, for example, with welded-on copper ends, which are connected to the pole terminal and the cable connection by a joining process, for example by soldering or welding, in a material and / or form-fitting manner. For example, a resistance brazing method is used. However, the previously known connection methods of the measuring resistor with the cable connection and the pole terminal are very complex.

The object of the invention is to provide a method for producing a resistance assembly for a battery sensor that enables a simple and inexpensive manufacture of the resistance assembly. Another object of the invention is to provide a resistance assembly and a battery sensor with such a resistance assembly, which can be produced simply and inexpensively.

To achieve the object, a method for producing a resistance module for a battery sensor, in particular in a vehicle, is provided, the resistance module having a battery pole terminal and a cable connection which are electrically connected to one another via a measuring resistor. The process has the following steps:

Providing a flat base material consisting of a first section, a second section and an elongated resistor section, the first section and the second section being made of an electrically conductive material, the elongated resistor section having two opposite edges, and the first section and the second section each being electrically conductively connected to one of the edges of the resistor section,

- Punching out a base body with a first connection section, a second connection section and a measuring resistor from the base material, the first connection section essentially consisting of the first section, the second connection section essentially consisting of the second section and the measurement resistor essentially consisting of the resistance section are educated

- Forming a pole terminal on the first connection section by a forming process, and

- Forming a cable connection from the second connection section.

According to the invention, a flat base material is delivered, into which a strip of a resistance material is incorporated. This base material can be delivered, for example, prefabricated as a strip material, rolled goods as sheet metal. A flat basic body is punched out of this basic material, from which the one-piece resistance assembly is produced by reshaping. No joining processes, in particular no soldering or welding processes, are therefore required to manufacture the resistance module. The manufacture of the resistor assembly is much simpler, since only stamping and forming processes, but no joining processes are required. In addition, changes in the material properties, especially the electrical conductivity of the Materials excluded, since the processes used do not heat the material.

The resistance assembly is preferably produced in a stamping and bending process, as a result of which a simple and fast manufacturing process of the resistance assembly is possible.

In particular, the edges of the resistance section in the base material run parallel to one another. The cutting or punching edges preferably run essentially at right angles to the edges of the resistance section. The base body is thus punched out in such a way that the measuring resistor is essentially rectangular or trapezoidal, with two opposite edges of the rectangular measuring resistor being formed by the edges of the resistance element. The length of the current path across the measuring resistor is thus of the same magnitude over the entire cross section of the measuring resistor, so that the electrical resistance of the measuring resistor is constant over the entire cross section.

However, the cutting or punching edges do not necessarily have to be perpendicular to the edges of the resistance section. In particular, these can also run at a different angle with respect to the edges of the resistor section, for example in order to achieve better material utilization of the basic material.

The first section and the second section can each be welded to an edge of the elongated resistance section before punching, in particular during the production of the base material, so that a base material with high mechanical stability and good electrical conductivity is provided. The base material can have a constant thickness. That is, the thickness of the resistance element corresponds to the thickness of the first and the second section element. This facilitates the transport and processing of the basic material. For example, the base material can be delivered on a roll. The electrical conductivity, in particular of the measuring resistor, can be set by the width of the punched measuring resistor.

Alternatively, the first section, the second section and / or the resistance section can also have a different thickness, for example in order to adjust the electrical conductivity. For example, the resistance element can be made thinner in order to increase the electrical resistance of the measuring resistor. The first section and / or the second section can also be made thicker in order to increase the conductivity of the battery pole terminal or the cable connection and thus to reduce the electrical resistance in these sections.

Before punching out, corrosion protection can be applied to the first section, the second section and / or the resistance section. In the automotive sector in particular, the resistance module or the battery sensor with such a resistance module is exposed to high loads, for example due to road salt or a road salt mist or other corrosive substances. It is therefore necessary to protect the resistance module from these substances, since corrosion would lead to a change in the electrical conductivity and thus to a change in the measurement results. The corrosion protection can be applied to the material before the basic body is punched out and shaped. Since that If the base material is a flat component, it is much easier to apply corrosion protection.

Alternatively, corrosion protection can also be applied to the first section, the second section and / or the resistance section only after the battery terminal has been shaped. This is particularly advantageous if the corrosion protection has a low flexibility, since cracking is prevented by the subsequent application with a relatively rigid corrosion protection.

To achieve the object, a resistance module for a battery sensor is also provided, in particular a battery sensor in a vehicle, the resistance module having a battery pole terminal and a cable connection which are electrically connected to one another via a measuring resistor. The resistor assembly is made of a sheet base material consisting of a first section, a second section and an elongated resistor section, the first section and the second section being made of an electrically conductive material, the elongated resistor section having two opposite edges, and wherein the first section and the second section are each electrically conductively connected to one of the edges of the resistance section. The battery pole terminal is essentially formed from the first section, the cable connection essentially from the second section and the measuring resistor essentially from the resistor section. The Wi derstandsbaugruppe is made in particular with a method described above be.

Furthermore, to solve the problem, a battery sensor with a resistor assembly described above and with a voltage detection device for detecting a Voltage drop across the measuring resistor, wherein the voltage detection device is electrically contacted in front of and behind the measuring resistor with the resistor assembly.

The battery sensor can have, for example, a housing which encloses the measuring resistor, the voltage detection device and at least in sections the battery terminal and the cable connection. For example, the housing is made of plastic and is molded onto the resistor assembly.

Further advantages of features result from the following description in connection with the attached drawings. In this show:

1 shows a battery sensor from the prior art; Figure 2 shows a first manufacturing step for a resistance assembly for a battery sensor according to the invention;

FIG. 3 shows a base material for producing a base body for a resistance assembly according to the invention;

Figure 4 shows a second manufacturing step for the resistance assembly;

Figure 5 is a first view of a resistance assembly according to the invention;

Figure 6 shows a second view of the resistor assembly

Figure 5;

FIG. 7 shows a battery sensor with the resistance assembly from FIGS. 5 and 6; and

FIG. 8 shows a second view of the battery sensor from FIG. 7.

A battery sensor 10 'from the prior art is shown in FIG. The battery sensor 10 'has a resistance module 12' consisting of a battery pole terminal 14 ', a cable connection 16' and a measuring section 18 'which the battery Riepolklemme 14 'and the cable connection 16' electrically connected to each other. The measuring section 18 'consists of two conductive sections 20', 22 ', between which a resistance element 24' is provided. The battery sensor 10 'furthermore has a voltage detection device 25' which is electrically connected to the measuring section 18 'with respect to a current direction in front of and behind the resistance element 24' and can detect a voltage drop across the measuring resistor 24 '. From the detected voltage drop across the measuring resistor 24 'and the known electrical resistance of the measuring resistor 24', the current flowing through the measuring resistor 24 ', that is to say via the battery sensor 10', can be calculated using the ohmic law.

The measuring resistor 24 'usually consists of a material which has the most constant electrical resistance possible both over the service life and in the case of temperature differences. For example, a copper-nickel-manganese alloy is used. The battery terminal 14 'and the cable connection 16' are made of a material with very good electrical conductivity, for example copper or a copper alloy.

However, the connection of the material used for the measuring resistor 24 ', for example the copper-nickel-manganese alloy, is very complex. For this reason, as can be seen in FIG. 1, a measuring section 18 'is provided which, in addition to the measuring resistor 24', has two conductive sections 20 ', 22' which consist of an electrically conductive material. These sections 20 ', 22' can be easily connected to the battery terminal 14 'and the cable connection 16'. In particular, the sections 20 ', 22' can be made of the same or a similar material as the battery terminal 14 'and the cable connection 16', so that they can be easily for example by soldering or welding. However, the manufacture of such a resistance module 12 'is very complex.

In Figures 2 to 6, the manufacture of a resistance assembly 12 is shown, which is much easier and less expensive to manufacture.

In a first manufacturing step, a flat base material 26 is provided (FIG. 2). The flat base material 26 consists of three sections, a first section 28 made of an electrically conductive material, a second section 30 made of an electrically conductive material and a resistance section 32 running between the first section 28 and the second section 30, which is made of a resistance material, for example a copper-nickel-manganese alloy.

The resistance section 32 has a constant width 33 and is delimited by two opposite edges 34, 36. The edges 34, 36 thus run parallel to one another. The first section 28 is electrically conductively and mechanically connected to the resistance section 32 at the first edge 34, the second section 30 at the second edge 36. The base material 26 can be delivered, for example, as an endless material, for example rolled up.

As can be seen in FIG. 2, the sections 28, 30 and the resistance section 32 have a constant width. The base material 26 thus also has a constant width. In the embodiment shown here, the base material 26 also has a constant thickness 37 via the sections 28, 30 and the resistance section 32. For further processing, the base material 26 is brought into a flat shape, that is to say if the base material 26 has a different shape for transport reasons, for example a rolled-up shape, this is first rolled off and brought into a flat shape.

A base body 38 for the resistance assembly 12 is then cut out of the base material 26, in particular punched out (FIG. 3). The base body 38 is punched out in such a way that a first connection section 40 of the base body 38, from which, as will be explained below, the battery terminal 14 is formed, essentially consists of the first section 28 and a second connection section 42, from which a connection 14 is formed, consists essentially of the second section 30. A measuring section 44, which forms the measuring resistor 24 and lies between the first connection section 40 and the second connection section 42, is punched out of the resistance section 32.

Subsequently, the first connection section 40 is formed section by section into a battery pole terminal 14. In particular, the connection section 40 is bent over and / or processed with another forming process. Furthermore, the second connection section 42 is formed into the cable connection 14. Finally, connections 46 for the detection devices 24 can be applied to the first connection section 40 and / or to the second connection section 42 or to the measurement section 44.

As can be seen in FIGS. 2 and 6, the basic body 38 is cut out or punched out in such a way that the measuring resistor 24 is essentially rectangular. This ensures a uniform current distribution of the load current over the entire cross section of the measuring resistor 24. After the battery terminal 14 and the cable connection 16 have been formed, the detection device 25 can be electrically connected to the resistor assembly 12 (FIG. 7).

A housing 46 can then be fastened to the resistance assembly 12, the housing 46 enclosing the measuring resistor 24, the detection device 25 and at least in sections the first connection section 40 and the second connection section 42. For example, the housing is made of plastic and is molded onto the resistor assembly 12.

Optionally, the resistance assembly 12 can be provided with corrosion protection, at least in sections, in order to protect the resistance assembly 12 from corrosive media, for example a salt spray. The corrosion protection can already be applied to the base body 38 or the base material, for example. But it is also possible that the corrosion protection is only applied after the battery terminal 14 and the cable connection 16 have been shaped. In particular, the corrosion protection can also be applied only after the housing 46 has been manufactured.

In the embodiment described above, the base material has a constant thickness over the sections 28, 30 and the resistance section 32. However, it is also possible for the sections 28, 30 and the resistance section 32 to have different thicknesses. For example, the resistance section 32 can have a different thickness in order to set the electrical resistance of the measuring resistor 24. The first section 28 and the second section 30 can be formed depending on the shape and the stability of the battery terminal 14 and the cable connector 16. In particular, the thickness can vary within the section 28 or 30.

Reference list

10, 10 'battery sensor

12, 12 'resistor assembly

14, 14 'battery terminal

1 6, 1 6 'cable connection

1 8, 1 8 'measuring section

20 section

22 section

24, 24 'measuring resistor

25, 25 'voltage detection device 2 6 base material

2 8 first section

30 second section

32 Resistance section

34 first margin

3 6 second margin

38 basic body

4 0 first connection section

42 second connection section 44 measuring section

4 6 housing

Claims

1. A method for producing a resistance assembly (12) for a battery sensor (10), in particular a battery sensor (10) in a vehicle, wherein the resistance assembly (12) has a battery terminal (14) and a cable connection (16) which a measuring resistor (24) are electrically connected to one another, with the following steps:

- Providing a flat base material (26) consisting of a first section (28), a second section (30) and an elongated resistance section (32), the first section (28) and the second section (30) being electrically consist of conductive material, wherein the elongated resistance section (32) has two opposite edges (34, 36), the first section (28) and the second section (30) each being electrically conductive with one of the edges (34, 36) of the resistance section (32) are connected,

- Punching out a base body (38) with a first connection section (40), a second connection section (42) and a measuring resistor (24) from the base material (26), the first connection section (40) essentially consisting of the first section (28), the second connection section (42) is essentially formed from the second section (30) and the measuring resistor (24) is essentially formed from the resistance section (32),

- Forming a battery terminal, on 14) at the first connection section (40) by a forming process, and

- Forming a cable connection (16) from the second connection section (42).

2. The method according to claim 1, characterized in that the resistance assembly (12) in one

Stamping and bending process is produced.

3. The method according to any one of claims 1 and 2, characterized in that the edges (34, 36) of the resistance section (32) run parallel.

4. The method according to any one of the preceding claims, characterized in that the first section (28) and the second section (30) are each welded to one of the edges (34, 36) of the resistance section (32).

5. The method according to any one of the preceding claims, characterized in that the base material (26) has a constant thickness.

6. The method according to any one of claims 1 to 4, characterized in that the first section (28), the second

Section (30) and / or the resistance section (32) each have a different thickness.

7. The method according to any one of the preceding claims, characterized in that a corrosion protection is applied to the first section (28), the second section (30) and / or the resistance section (32) before punching out.

8. The method according to any one of the preceding claims, characterized in that after the molding of the battery pole terminal (14) and / or the cable connection (16)

Corrosion protection is applied to the first section (28), the second section (30) and / or the resistance section (32).

9. resistor assembly (12) for a battery sensor (10), in particular a battery sensor (10) in a vehicle, the resistor assembly (12) having a battery terminal (14) and a cable connection (16) via a measuring resistor (24) are electrically connected to one another, the resistor assembly (12) made from a flat base material (26) consisting of a first section (28), a second section (30) and an elongated resistor section (32), the first section (28) and the second section (30) consist of an electrically conductive material, the elongated resistance section (32) having two opposite edges (34, 36), the first section (28) and the second section (30) each being electrically conductive with one of the Edges (34, 36) of the resistance section (32) are connected, the battery terminal (14) consisting essentially of the first section (28), the cable connection (16) in the we Substantially from the second section (30) and the measuring resistor (24) are essentially formed from the resistor section (32), the resistor assembly (12) being produced in particular with a method according to one of the preceding claims.

10. Battery sensor (10) with a resistance assembly (12) according to claim 9 and with a voltage detection device (25) for detecting a voltage drop across the measuring resistor (24), the voltage detection device (25) in front of and behind the measuring resistor (24) the resistor assembly (12) is contacted.