WO2024061999A1 - Procédé, agencement de raccordement et utilisation d'un agencement de raccordement pour au moins deux câbles toronnés - Google Patents

Procédé, agencement de raccordement et utilisation d'un agencement de raccordement pour au moins deux câbles toronnés Download PDF

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Publication number
WO2024061999A1
WO2024061999A1 PCT/EP2023/075998 EP2023075998W WO2024061999A1 WO 2024061999 A1 WO2024061999 A1 WO 2024061999A1 EP 2023075998 W EP2023075998 W EP 2023075998W WO 2024061999 A1 WO2024061999 A1 WO 2024061999A1
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WO
WIPO (PCT)
Prior art keywords
sleeve
busbar
individual wires
stranded
connection
Prior art date
Application number
PCT/EP2023/075998
Other languages
German (de)
English (en)
Inventor
Thomas Lorenz
Sebastian Martens
Original Assignee
Auto-Kabel Management Gmbh
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 Auto-Kabel Management Gmbh filed Critical Auto-Kabel Management Gmbh
Publication of WO2024061999A1 publication Critical patent/WO2024061999A1/fr

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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
    • H01R43/28—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for wire processing before connecting to contact members, not provided for in groups H01R43/02 - H01R43/26
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R25/00—Coupling parts adapted for simultaneous co-operation with two or more identical counterparts, e.g. for distributing energy to two or more circuits
    • H01R25/16—Rails or bus-bars provided with a plurality of discrete connecting locations for counterparts
    • H01R25/161—Details
    • H01R25/162—Electrical connections between or with rails or bus-bars
    • 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
    • H01R4/02—Soldered or welded connections
    • H01R4/023—Soldered or welded connections between cables or wires and terminals
    • 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
    • H01R4/02—Soldered or welded connections
    • H01R4/029—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
    • H01R4/10—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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/20—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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping using a crimping sleeve
    • 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
    • H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
    • H01R43/0207—Ultrasonic-, H.F.-, cold- or impact welding
    • 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
    • H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
    • H01R43/0221—Laser welding
    • 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
    • H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool

Definitions

  • connection arrangement and use of a connection arrangement for at least two stranded cables The subject matter relates to a method for connecting at least two stranded cables to a busbar as well as a corresponding connection between two stranded cables and a busbar as well as a use of such a connection arrangement.
  • the connection of several electrical lines with a potential busbar in a small space, especially a material connection, is challenging in terms of connection technology as well as the quality and durability of the connection .
  • the object of the task was therefore to provide a welding process that makes it possible to permanently and firmly connect several stranded cables on a common busbar.
  • This task is solved by a method according to claim 1. It is actually proposed to provide at least two stranded cables.
  • Stranded cables are cables with several individual wires that are not separately insulated from each other.
  • the individual wires can be woven, stranded and/or twisted together.
  • the individual wires are metallic, in particular made from a transition metal.
  • Aluminum or copper as well as aluminum alloys or copper alloys are particularly suitable as materials for the individual wires.
  • the individual wires of the stranded cables can be covered with a common insulation. A combination of the materials mentioned above is also possible.
  • Each stranded cable has two distal ends.
  • One end can have an end region in which the individual wires of the stranded cable are free of insulation.
  • a stranded cable can also be completely free of insulation.
  • the stranded wire is preferably part of a cable, the cable being formed at least from the stranded wire and the insulation.
  • the P W/PW 220317WO September 21, 2023 Isolation is missing in one end area, in particular it is removed there.
  • An end region can extend from a front end of the stranded cable towards the center of the stranded cable and in particular have a longitudinal dimension of between 0.5 cm and 5 cm or more.
  • An insulation material can in particular be silicone, PVC, VPE, PTFE, PES, PE or the like.
  • a sleeve be pushed onto an end region of a respective stranded cable.
  • a sleeve can be pushed onto only one end region or the two distal end regions of a stranded cable .
  • Each stranded cable that is physically contacted with the busbar has a pushed-on sleeve on at least one of its end regions.
  • the sleeve is preferably metallic, in particular made of the same material as the stranded cable and/or the busbar.
  • the sleeve can also be made of a different material for the stranded cable and/or busbar.
  • the sleeve may be formed from aluminum, copper, an aluminum alloy or a copper alloy .
  • the sleeve can be pushed from the front end of the stranded cable over the individual wires of the stranded cable.
  • the sleeve is preferably pushed onto the end region in the longitudinal direction of the stranded cable.
  • the sleeve can be formed as a one-piece component or as a multi-part component.
  • the sleeve has a longitudinal opening into which the individual wires of the stranded cable are inserted.
  • the sleeve can also be formed from a band, which is placed circumferentially around the individual wires of the stranded cable in the end area and, if necessary, welded.
  • the respective sleeve is pressed onto the individual wires.
  • the sleeve is radially compressed (pressed).
  • the sleeve connects positively and positively to the individual wires, in which the opening of the sleeve radially inwards P W/PW 220317WO September 21, 2023 is compressed.
  • the individual wires can be compacted.
  • the individual wires are preferably compacted in such a way that a degree of compaction of over 90%, preferably over 95%, in particular over 98% is achieved.
  • a degree of compaction preferably results from the ratio of the metallic cross-sectional area and the cross-sectional area with air inclusion, preferably in a cross-section perpendicular to the longitudinal axis of the stranded wire.
  • a single wire has a cross-sectional area of 4*Dwire2/ ⁇ .
  • the cross-sectional area of all N individual wires is N*4*Dwire2/ ⁇ .
  • the cross-sectional area of the sleeve results from the difference between the cross-sectional area at the outer diameter (outside) of the sleeve (4* outer2/ ⁇ ) and the cross-sectional area at the inner diameter (inside) of the sleeve (4* outer2/ ⁇ ), i.e. (4* outer2/ ⁇ )-( 4* Dinnen2/ ⁇ ).
  • the total cross-sectional area of the stranded cable with the individual wires and the sleeve, without air inclusions is (4*Dwire2/ ⁇ )+ ((4*Dinnen2/ ⁇ )-( 4*Dinnen2/ ⁇ )).
  • This is the cross-sectional area of the of the pressed sleeve including wires and any remaining air inclusions is (4* Dcompressed2/ ⁇ )
  • the degree of compaction results from the quotient of the total cross-sectional area and the cross-sectional area of the pressed sleeve, i.e.
  • the degree of compaction is: D Wire2 + ⁇ ⁇ ⁇ ß ⁇ ⁇ 2 ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ 2 ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ 2 ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ 2 P W/PW 220317WO September 21, 2023 Assuming that the sleeve and wires are not axially stretched during pressing, a completely pressed sleeve, without air inclusions, results in a degree of compaction of 1 (100%).
  • the degree of compaction be between 90% and 100%, preferably between 95% and 100%, in particular between 98% and 100%.
  • at least the sleeve is stretched axially during pressing. This means that for a pressed sleeve the value ⁇ ⁇ ⁇ ß ⁇ ⁇ 2 ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ 2 is smaller than for an unpressed sleeve. This in turn means that the pressed sleeve has a cross-sectional area that is smaller than the total cross-sectional area in the unpressed state. Then the degree of compaction becomes greater than 100%.
  • a degree of compaction of greater than 100% is achieved, in particular between 100% and 110%, preferably between 100% and 105%, in particular between 100% and 102%.
  • the respective sleeve is cut to length on the end face in such a way that the individual wires and the sleeve essentially form a flat connection area on the end face of the sleeve.
  • the connection area preferably lies in a plane perpendicular to the longitudinal axis of the stranded cable.
  • connection area is preferably planar, formed from the end face of the cut-to-length sleeve and the end face of the cut-to-length individual wires of the stranded cable.
  • the cutting to length is preferably such that all individual wires of the stranded cable are cut to length.
  • all individual wires which may stand back from the end face in the longitudinal direction , are cut to length so that all individual wires rest on the end face of the connection area and span a common plane with the end face of the sleeve.
  • Cutting to length can preferably be done using laser cutting. However, cutting to length can also be done using milling or sawing.
  • the end face of the individual wires and the sleeve can also be cut to length by grinding, so that P W/PW 220317WO September 21, 2023 the connection area forms. It is also possible to carry out the cutting to length using a combination of the methods mentioned.
  • the sleeve and the individual wires arranged therein are then placed with their connection area onto the busbar.
  • at least two stranded cables and two sleeves are provided.
  • the explanations for each sleeve including individual wires naturally apply to all at least two stranded cables with a sleeve. It should be noted that the respective process steps in this document are partly only described for a stranded cable and/or a sleeve.
  • the method steps preferably apply to all sleeves connected to the busbar, but at least to two sleeves and stranded cable connected to the busbar.
  • each is sometimes used to express the fact that not just one, but several sleeves and stranded cables with their connection areas are connected to spaced-apart contact areas of the busbar.
  • the respective connection areas be placed on the busbar in contact areas that are spatially spaced apart from one another .
  • the busbar has an area where the stranded wires are to be attached. In this area, at least two spatially spaced contact areas are provided, which are intended to accommodate the connection areas of the respective stranded wires.
  • the connection areas are placed on the two spaced-apart contact areas.
  • the number of contact areas corresponds to the number of connection areas, that is, with two stranded cables, two contact areas and with N stranded cables, N contact areas with N ⁇ N.
  • PW/PW 220317WO September 21, 2023 It is proposed that the contact areas are arranged on a common side of the busbar.
  • the connection areas are placed on a common side on the contact areas of the busbar.
  • the busbar is preferably formed as a flat part and has two wide surfaces that lie opposite one another. These wide surfaces preferably run parallel to one another.
  • the contact areas preferably consist of a common, wide surface.
  • the busbar is preferably metallic, in particular made of the same material as the stranded cable and/or the sleeve.
  • the busbar can also be made of a different material from the stranded cable and/or sleeve.
  • the bus bar may be formed of aluminum, copper, an aluminum alloy or a copper alloy.
  • the connection areas are placed on the contact areas.
  • the sleeve and the individual wires are then welded to the busbar. It is specifically proposed that, starting from a second side of the busbar opposite the first side, the sleeve, the individual wires and the busbar are welded together in a respective contact area. This means that the welding takes place starting from the second side opposite the first side.
  • various welding processes are suitable for this, on the one hand , in which the sleeve including the strand can be pushed through the busbar and, on the other hand, welding processes in which the welding takes place through the busbar into the stranded cable and the sleeve, e.g. a friction point welding process.
  • Welding Because the welding is carried out starting from the second side, only a small amount of heat is introduced into the individual wires, especially in an area away from the welding node.
  • the individual wires extend from the flat connection area in the longitudinal direction towards the center of the stranded cable.
  • the heat input preferably occurs only in the connection area and only penetrates insignificantly into the individual wires in the longitudinal direction.
  • the sleeve means that in the area of the weld seam the mechanical load on the weld seam and the individual wires is reduced under dynamic stress compared to conventional welding processes. By welding starting from the second side and in particular by using the sleeve, strand breakage under dynamic, mechanical stress is largely prevented.
  • the sleeve absorbs the mechanical loads directly next to the weld/heat affected zone.
  • the busbar has openings, in particular through openings, in particular bores, in the contact areas. It should be noted that an opening can form a contact area. The openings preferably run parallel to the surface normal of that surface of the busbar in which the contact area lies.
  • the opening preferably has a diameter that corresponds to the diameter of the pressed sleeve.
  • the opening may be a clearance fit, a transition fit, or an interference fit with the sleeve .
  • the sleeve is inserted into the opening.
  • the sleeve is inserted into the opening with its connection area starting from the first side towards the second side.
  • the sleeve is preferably inserted into the opening in such a way that after insertion the connection area is flat with the surface of the second side of the busbar or looks slightly beyond it (in particular with a tolerance of between 0.2mm-2.0mm.
  • the sleeve is inserted through the opening in the busbar in such a way that the sleeve and the individual wires with their connection area (after insertion) lie approximately in a plane with the surface of the second side.
  • the busbar , the sleeve and the individual wires are welded together using a laser, starting from the second side. P W/PW 220317WO September 21, 2023 When welding the sleeve, the individual wires and the busbar, the individual wires in particular are welded to one another.
  • the end faces of the individual wires can be welded together using the laser, so that the weld knot that forms only extends a few 1/10 of a millimeter to a few millimeters into the stranded wire. This reduces the temperature load on the individual wires.
  • the welding node only extends into the stranded wire in accordance with the distance between the first and second sides of the busbar.
  • the sleeve can also be welded to the individual wires.
  • an inner side surface of the sleeve opening is welded to the individual wires.
  • the individual wires that lie on the outside of the sleeve are welded to the inner surface of the opening of the sleeve.
  • the sleeve can also be welded to the busbar.
  • the opening of the busbar will be welded to the sleeve.
  • an outer lateral surface of the sleeve is welded to an inner lateral surface of the opening of the busbar.
  • the welding can be such that a uniform welding node is formed from individual wires, sleeve and busbar. A uniform weld knot is formed across the individual wires, the sleeve and the busbar.
  • This uniform welding node seals any gaps between the individual wires, between the individual wires and the sleeve and between the sleeve and the busbar, preferably completely, so that moisture can no longer penetrate into the stranded cable through this welding node in the longitudinal direction along the sleeve and the individual wires.
  • the welding node is preferably located only at the front end of the individual wires and the sleeve and in particular exclusively within the busbar. This means that the welding node preferably spreads out in the longitudinal direction of the stranded cable to a maximum in accordance with the material thickness of the busbar.
  • the busbar and its material thickness ensure that the individual wires P W/PW 220317WO September 21, 2023 are preferably only exposed to such heat input in the area of the busbar , which leads to an influence on the material.
  • the individual wires that lie in the sleeve outside the busbar on the first side are not or only slightly affected by the welding.
  • the connection between busbar, sleeve and strand is therefore permanently stable and significantly less sensitive to alternating bending stresses than conventional welds.
  • the respective sleeve is placed with its connection area on the contact area of the first side of the busbar.
  • the busbar has no openings to accommodate the sleeves and individual wires.
  • the sleeves and the individual wires are placed with their flat connection area directly on the contact area on the first side . Welding then takes place starting from the second side. Laser welding can be used here , but friction spot welding is preferred. It is proposed that the sleeve with its connection area be placed on the contact area of the first side of the busbar in such a way that the sleeve and the individual wires with their connection areas lie essentially in a plane with the first side. It is preferred that the sleeve together with the individual lines is pressed with its connection area with a contact force against the contact area of the first side. This contact pressure is preferably greater than the force that a friction spot welding tool exerts on the sleeve and the strand from the first side.
  • a reaming tool preferably at least three parts, is first placed on the second side.
  • the reaming tool is preferably placed on the second side concentrically to the sleeve to be welded.
  • the reaming tool comprises a stamp, a sleeve guided in the stamp and a pin arranged in the sleeve. During friction spot welding, the punch and sleeve are placed on the second side.
  • the pin is then placed rotating within the sleeve on the second side.
  • frictional energy is introduced into the busbar in the area of the contact surface of the pin and the material of the busbar melts.
  • sufficient frictional energy is introduced into the busbar in such a way that the busbar melts in the contact area, in particular over its entire material thickness, and in particular up to the first side. and the sleeve resting there and the individual wires. The sleeve resting on the first side and the individual wires in the connection area are then melted.
  • the sleeve of the welding tool which is guided within the stamp, is preferably moved from the second side towards the first side , so that the melted material of the busbar, individual wires and sleeve are mixed with one another and are mixed with one another in particular through the busbar .
  • the pin is then pulled out of the sleeve of the welding tool with continuous rotation while the sleeve is moved towards the second side, the bus bar. This enables a point connection between the busbar, sleeve and individual wires without the impression of holes.
  • the stamp and sleeve of the welding tool as well as the pin of the welding tool are lifted from the second side and a uniform welding node is formed which extends through the busbar into the sleeve and the individual wires.
  • the punch and sleeve are placed on the second side.
  • the sleeve is then rotated to the second side P W/PW 220317WO September 21, 2023 put on. By rotating the sleeve, frictional energy is introduced into the busbar in the area of the contact surface of the pin and the material of the busbar melts.
  • busbar melts in the contact area, in particular over its entire material thickness, and in particular up to the first side and the sleeve resting there and the individual wires.
  • the sleeve resting on the first side and the individual wires in the connection area are then melted.
  • the pin of the welding tool which is guided within the sleeve, is preferably moved from the second side towards the first side, so that the melted material of the busbar, individual wires and sleeve are mixed with one another and are mixed with one another in particular through the busbar .
  • the sleeve is then pulled out of the weld metal with continuous rotation while the pin is moved towards the second side, the busbar .
  • This enables a point connection between the busbar, sleeve and individual wires without the impression of holes.
  • the stamp and sleeve of the welding tool as well as the pin of the welding tool are lifted from the second side and a uniform welding node is formed which extends through the busbar into the sleeve and the individual wires. It is preferred if the individual wires are welded together.
  • the rotating pin preferably melts all of the individual wires on the front side and a uniform welding knot is formed over preferably all of the individual wires.
  • the individual wires are welded to the sleeve.
  • the rotating pin preferably melts the individual wires and the sleeve on the front side and a uniform weld knot is formed over preferably the individual wires and the sleeve.
  • the individual wires on the outer circumference of the stranded cable are welded to the inner surface of the sleeve.
  • the sleeve is welded to the busbar.
  • the end face of the sleeve is welded to the busbar on the first side. It is also preferred if the individual wires are welded to the busbar.
  • the rotating pin preferably melts the individual wires and the busbar and a uniform welding knot is formed over preferably the individual wires and the busbar. It is preferred if the end faces of the individual wires are welded to the busbar on the first side. A uniform, continuous welding joint across the busbar, sleeve and individual wires is preferred . This welding node preferably completely closes a gap between the end face of the sleeve and the first side of the busbar.
  • the welding node extends through the busbar into the sleeve and the individual wires that rest on the contact surface on the first side.
  • the busbar is formed as a flat part.
  • the busbar can be formed from sheet metal or strip.
  • the busbar can be cut or punched from a sheet metal or strip.
  • the collective notes can be designed in such a way that the contact area or areas are part of a cantilevered tab.
  • the busbar can have at least one, preferably two opposite tabs or four opposite tabs in pairs. The tabs protrude outwards from one side edge of the flat part of the busbar. The tabs can protrude from opposite side edges of the busbar.
  • a tab can also protrude on each or more than two side edges of the busbar .
  • the busbar can initially be provided as a flat part and the stranded cable including the sleeve can be materially connected to the busbar in the manner described above .
  • it can make sense if the longitudinal axes of the stranded cables are at an angle to the surface normal of the flat part P W/PW 220317WO September 21, 2023 get lost.
  • the stranded wires run in a plane to the busbar that is parallel to the plane of the first and/or second side of the busbar.
  • a bend of more than 45°, in particular between 45 and 135°, in particular 90°, can make sense. With a bend of 90°, the plane in which the two longitudinal axes of the stranded cables lie is essentially parallel to the plane of the first and/or second side.
  • a further aspect is a connection arrangement according to claim 11. This connection arrangement has the advantage that stranded cables are arranged on a busbar without significant structural damage and are therefore permanently secured even under dynamic loads.
  • the individual wires of the stranded cable are made of aluminum or aluminum alloys.
  • the material of the busbar can be the same as the material of the stranded cable and/or sleeve and in particular can also be aluminum or an aluminum alloy, or copper or a copper alloy. It is also possible that the material of the busbar is different from the material of the individual wires. It is also possible that the material of the busbar is different from the material of the sleeve. As already explained, the end region of the stranded cables is inserted into the sleeve. For this reason, it is proposed that the sleeve has a through opening running in the longitudinal direction.
  • the P W/PW 220317WO September 21, 2023 Sleeve has a blind hole running in the longitudinal direction.
  • the individual wires of the stranded cable are inserted into the opening .
  • the sleeve can have a bottom on one end face , wherein the bottom can have an opening or taper that has a different cross section than the opening into which the individual wires are inserted.
  • a cross section of the bottom opening or taper is advantageous, in which areas extending radially further outwards alternate with areas extending radially less outwards.
  • Non-circular outline shapes of the opening/tapering are preferred , with multiple axial symmetry being possible, for example. In the simplest case this is a threefold axial symmetry.
  • a possible particularly preferred embodiment variant provides that the outline shape of the opening/tapering is approximately similar to an epicycloid.
  • the opening/taper could also have angular outline shapes, for example a polygon outline. Combinations of angular and cycloidal outline shapes could also be chosen.
  • Such a design of the floor has several advantages. First of all, the presence of the base ensures that the individual wires are inserted into the sleeve to a defined depth and are not pushed too far through the through-opening of the sleeve. The floor therefore forms a natural stop for the strands.
  • the taper/opening in the base enables the sleeve to be pressed radially, so that the individual wires and the sleeve can be pressed together.
  • the sleeve can be shaped as a tube.
  • the sleeve can also be formed from a sheet metal.
  • the sleeve can be shaped as a sheet metal wrapped around the individual wires.
  • the sleeve can be formed in one piece or in several pieces.
  • a further aspect is the use according to claim 15. In particular in motor vehicles, watercraft, aircraft, a launch vehicle or a spacecraft and satellites. considerable mechanical stress occurs.
  • connection in question is particularly suitable for this purpose , as it provides a permanently stable connection even under the highest mechanical loads due to the lack or only slight impairment of the individual wires during the connection process.
  • 1a, b a stranded cable according to an exemplary embodiment
  • 2a, b sleeves according to exemplary embodiments 3a, b placing a sleeve on a stranded cable according to an exemplary embodiment
  • 5a shows a busbar according to an exemplary embodiment
  • 5b shows a connection between a busbar and a stranded wire according to an exemplary embodiment
  • 6a shows a busbar according to an exemplary embodiment
  • 6b shows a connection between a busbar and a stranded wire according to an exemplary embodiment
  • 7a, b show a friction spot welding method according to an exemplary embodiment
  • P W/PW 220317WO September 21, 2023 8 shows a busbar with projecting tabs according to an exemplary embodiment
  • 9 shows a connection arrangement with several busbars and several stranded wires according to an exemplary embodiment
  • FIG. 1a shows a front end of a cable 2. It can be seen that the cable 2 has insulation 2a.
  • the cable 2 has an electrically conductive core, which is formed as a stranded cable 4.
  • Fig. 1b shows the front end of the cable 2 in a stripped state. In an end region 6, the insulation 2a is removed and the individual wires of the stranded cable 4 are bare. Such a cable 2 is made available for subsequent processing. It goes without saying that instead of the cable 2, only the stranded cable 4 can be provided without the insulation 2a.
  • the end region 6 extends from the front end of the stranded cable 4 in the longitudinal direction of the stranded cable 4.
  • FIG. 2a shows a sleeve 8, which extends in a longitudinal direction 8a. Along the longitudinal direction 8a, the sleeve 8 has an opening 10 formed as a through opening .
  • the sleeve 8 can have a radial offset, so that a first area can be pushed onto the insulation 2a and a second area onto the bare individual wires of the stranded cable 4.
  • the sleeve 8 of FIG. 2a is free of a bottom and the opening 10 is continuous.
  • Fig. 2b shows a sleeve 8 with a base 12. The base 12 closes the opening 10 in an end region of the sleeve 8.
  • FIG. 3a shows the sleeve 8 being pushed onto the cable 2 or the end region 6 along the longitudinal direction 8a . After the sleeve 8 has been pushed onto the cable 2, it is preferably compressed radially inwards in the end region 6, as in the figure. 3b is indicated by arrows .
  • the sleeve 8 is pressed with the individual wires of the stranded cable 4.
  • the pressed sleeve 8 with the stranded cable 4 is shown in FIG. 4a.
  • the bottom 12 of the sleeve 8 is removed. This can be done , for example, by cutting by grinding or milling as well as by cutting, laser cutting or the like.
  • Fig. 4a shows that the parting plane 15 runs perpendicular to the longitudinal axis 8a.
  • the front ends of the sleeve 8 and the stranded wire 4 are exposed along the parting plane 15 , as shown in FIG. 4b .
  • the front ends are preferably plane-parallel to one another.
  • FIG. 5a shows an example of a bus bar 18, which is formed as a flat part.
  • the bus bar 18 has a first side 18a and a second side 18b.
  • the sides 18a, 18 are on opposite sides of the busbar 18.
  • the sides 18a, b are preferably parallel to one another on wide surfaces of the busbar 18.
  • the busbar 18 has at least two contact areas 20 spaced apart from one another.
  • the contact areas according to FIG. 5a have through openings , through which the sleeve 8 including the stranded cable 4 is inserted.
  • the sleeve 8 including the stranded wire 4 is pushed in the insertion direction 22 from the first side 18a towards the second side 18b through the through opening in the contact area 20 .
  • the end face of sleeve 8 and stranded cable 4 is preferably plane-parallel to side 18b.
  • the sleeve 8 including the stranded cable 4 is fixed in this position relative to the busbar 18.
  • a welding node 16 is then formed with a laser 24, which extends over the busbar 18, the end face of the sleeve 8 and the end face of the stranded wire 4.
  • a uniform welding node 16 is formed, which extends over the entire area over the stranded wire 4, sleeve 8 and an area of the busbar 18 adjacent to the contact area and has a depth extension which preferably reaches the material thickness of the busbar 18 in the longitudinal direction 8a.
  • the busbar 18 can have more than two contact areas 20, via each of which a connection can be formed with the stranded wire 4 and the sleeve 8 in the manner shown .
  • Fig. 6a shows a further exemplary embodiment in which the busbar 18 has several contact areas 20. In contrast to Figure 5a, the contact areas 20 are not through openings.
  • a sleeve 26b and a bolt/pin 26c are movably arranged within the stamp 26a.
  • the bolt 26c is set in rotation in the direction of rotation 28 and pressed with a contact pressure against the material of the busbar 18, starting from the second side 18b.
  • the material of the collecting notes 18 is first melted by the rotation of the bolt 26c .
  • the bolt is driven further in the direction of the stranded wire 4 into the material of the busbar 18 until it also at least partially melts the material of the stranded wire 43 and sleeve 8.
  • the sleeve 26b is moved away from the bus bar 18 in the opposite direction and thereby generates a negative pressure so that the melted material is mixed.
  • the bolt 26c is moved away from the first side 18b, transporting the melted material to the second side .
  • the sleeve 26b is moved in the direction of the stranded wire 4. This opposing movement mixes the melted material and creates a uniform weld knot.
  • P W/PW 220317WO September 21, 2023 The bolt 26b is preferably raised to such an extent that its end face remains in the plane of the second side 18b, so that after lifting the welding node 16 is plane-parallel to the second plane 18b.
  • Fig. 8 shows a busbar 18, which has tabs 28 on two longitudinal edges 18'. The tabs 28 protrude outwards from the longitudinal edge 18'.
  • the tabs 28 can be bent around the longitudinal edge 18' along the longitudinal edge 18', so that a U- or Z-shaped profile of the busbar 18 is formed in section.
  • the contact areas 20 are provided on the tabs 28. It is preferred that the stranded wire 4 together with the sleeve 8 are arranged on the contact areas 20 in the manner described above and then the tabs 28 are bent around the longitudinal edges 18 '.
  • Fig. 9 shows a configured connection arrangement in which, starting from a central bus bar 18, three cables 2 are arranged on opposite tabs 28 and run in opposite directions. The cables 2 are connected at their respective other distal ends to further tabs 28 on busbars 18 in the manner described. With the help of the method shown, it is possible to provide permanently stable connections between stranded cables and busbars.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)

Abstract

L'invention concerne un procédé de raccordement d'au moins deux câbles toronnés à une barre omnibus, dans lequel procédé lesdits câbles toronnés sont fournis, chaque câble toronné ayant une région d'extrémité dans laquelle les fils individuels du câble toronné sont exempts d'isolation, un manchon est poussé sur chaque région d'extrémité, chaque manchon est pressé sur les fils individuels, chacune des régions de raccordement est placée sur la barre omnibus au niveau de deux régions de contact espacées, les régions de contact étant sur un premier côté commun de la barre omnibus et, à partir d'un second côté de la barre omnibus opposé au premier côté, le manchon, les fils individuels et la barre omnibus sont soudés ensemble au niveau de chaque région de contact.
PCT/EP2023/075998 2022-09-21 2023-09-21 Procédé, agencement de raccordement et utilisation d'un agencement de raccordement pour au moins deux câbles toronnés WO2024061999A1 (fr)

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DE102022124222.6 2022-09-21
DE102022124222.6A DE102022124222A1 (de) 2022-09-21 2022-09-21 Verfahren, Verbindungsanordnung und Verwendung einer Verbindungsanordnung für zumindest zwei Litzenleitungen

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WO2024061999A1 true WO2024061999A1 (fr) 2024-03-28

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Citations (6)

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JPH11220823A (ja) * 1998-01-30 1999-08-10 Harness Syst Tech Res Ltd 電気接続箱のバスバー構造
US7128620B2 (en) * 2002-04-12 2006-10-31 Abb Service S.R.L. Element for connecting a flexible conductor and method for connecting a flexible conductor to a connection terminal
JP2014235777A (ja) * 2013-05-30 2014-12-15 矢崎総業株式会社 電線と端子の接合構造及び接合方法
DE102017106742B3 (de) * 2017-03-29 2018-03-08 Auto-Kabel Management Gmbh Verbindung eines Anschlussteils mit einer Litzenleitung
EP3609023A1 (fr) * 2018-08-10 2020-02-12 Nexans Procédé et dispositif de fabrication d'un raccordement électrique et conduite électrique
US20200266595A1 (en) * 2017-10-13 2020-08-20 Lisa Dräxlmaier GmbH Electric Line Assembly with Direct Contacting and Method for Producing Same

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Publication number Priority date Publication date Assignee Title
DE10346160B3 (de) 2002-05-25 2005-07-14 Feindrahtwerk Adolf Edelhoff Gmbh & Co. Verfahren und Verbindung zur Kontaktierung eines Aluminiumkabels
DE202013000978U1 (de) 2013-02-01 2014-05-08 Auto-Kabel Management Gmbh Kabelendhülse
DE102017114994B3 (de) 2017-07-05 2018-05-09 Lisa Dräxlmaier GmbH Verfahren zum herstellen einer elektrischen leitungsanordnung
DE102018131640A1 (de) 2018-12-10 2020-06-10 Volkswagen Aktiengesellschaft Vorrichtung und Verfahren zur Herstellung einer Fügeverbindung, Verwendung eines Kontaktabschnitts und Kraftfahrzeug

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH11220823A (ja) * 1998-01-30 1999-08-10 Harness Syst Tech Res Ltd 電気接続箱のバスバー構造
US7128620B2 (en) * 2002-04-12 2006-10-31 Abb Service S.R.L. Element for connecting a flexible conductor and method for connecting a flexible conductor to a connection terminal
JP2014235777A (ja) * 2013-05-30 2014-12-15 矢崎総業株式会社 電線と端子の接合構造及び接合方法
DE102017106742B3 (de) * 2017-03-29 2018-03-08 Auto-Kabel Management Gmbh Verbindung eines Anschlussteils mit einer Litzenleitung
US20200266595A1 (en) * 2017-10-13 2020-08-20 Lisa Dräxlmaier GmbH Electric Line Assembly with Direct Contacting and Method for Producing Same
EP3609023A1 (fr) * 2018-08-10 2020-02-12 Nexans Procédé et dispositif de fabrication d'un raccordement électrique et conduite électrique

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