Device, tool and method for producing such a device

Abstract

The invention relates to a device, a tool and a method for manufacturing the device by means of the tool, the device having a contact means and a cable, the cable having a first electric conductor, the contact means having a crimp barrel and a contact element in mechanical and electrical connection with the crimp barrel, the crimp barrel extending along an axis, the crimp barrel having a first inner peripheral side and a first outer peripheral side, at least in a first sub-portion of the crimp barrel a first and a second impression are pressed, the second impression being circumferentially offset from the first impression with respect to the axis, the first inner peripheral side being shaped by the first and the second impression such that the first inner peripheral side is pressed against a second outer peripheral side of the first electric conductor and the first inner peripheral side is in electrical contact with the second outer peripheral side, the first inner peripheral side tightly fits against the second outer peripheral side.

Description

Technical Field

[0001] The present invention relates to an apparatus, a tool, and a method for manufacturing the apparatus. Background Technology

[0002] There are many known designs for contact devices that connect to the electrical conductors of a cable via crimping. In this case, crimping is achieved by pressing a portion of the contact device into the cable, and during this process, the electrical conductor may shift or be damaged due to the shaped portion of the contact device. Summary of the Invention

[0003] The object of the present invention is to provide an improved device, an improved tool, and an improved method for manufacturing such a device.

[0004] This objective is achieved by the apparatus, tools, and methods proposed in this disclosure. Advantageous embodiments are specified in the dependent claims.

[0005] It has been recognized that an improved device can be provided, as the device has a contact device and a cable having a first electrical conductor. The contact device has a crimping cylinder and a contact element mechanically and electrically connected to the crimping cylinder. The crimping cylinder extends along an axis. The crimping cylinder has a first inner circumferential side and a first outer circumferential side. A first imprint and a second imprint are pressed into at least a first sub-section of the crimping cylinder, the second imprint being offset circumferentially from the first imprint relative to the axis. The first inner circumferential side is formed by the first imprint and the second imprint such that the first inner circumferential side presses against the second outer circumferential side of the first electrical conductor, and the first inner circumferential side is in electrical contact with the second outer circumferential side. The first inner circumferential side is in close contact with the second outer circumferential side.

[0006] When pressing the first inner circumferential side onto the first electrical conductor, the basic shape of the first inner circumferential side is generally maintained, but its radial extent can be reduced. This has the advantage of preventing mechanical damage to the electrical conductor. Additionally, it prevents the crimping cylinder from being subjected to uneven mechanical loads, which could cause it to break. This ensures a particularly good electrical and mechanical connection between the contact device and the electrical conductor, making the device exceptionally reliable and durable even under high vibration conditions.

[0007] Since the basic shape of the first inner circumference side relative to the crimping cylinder is basically maintained, that is, before the crimping of the crimping cylinder, or the first inner circumference side is concentrically reduced, the contact surface between the crimping cylinder and the first electrical conductor is particularly large.

[0008] Furthermore, the tight fit of the first inner circumference side prevents damage to individual wires of the first electrical conductor, such as shearing or cutting.

[0009] In another embodiment, the shape of the first inner circumferential side is substantially circular with respect to the axis. Therefore, the crimping cylinder is particularly mechanically stable and will not be mechanically damaged during the crimping process.

[0010] In another embodiment, a protrusion is formed on the first outer peripheral side in the circumferential direction between the first and second embossing portions, and the maximum material thickness of the crimping cylinder at the protrusion in the radial direction is greater than that at the first and second embossing portions. The advantage of this design is that the maximum material thickness within the radial interior of the first and / or second embossing portions is substantially constant.

[0011] In another embodiment, the cable has an electrically insulating intermediate layer and a second conductor, the intermediate layer circumferentially covering the second conductor and electrically insulating it from the first conductor. The first conductor is disposed outside the intermediate layer and covers it. A contact element has an opening through which the intermediate layer and the second conductor pass. In this design, the first conductor is implemented, for example, as a shield and is contacted by a contact device. The second conductor may be electrically contacted by another contact device.

[0012] In another embodiment, the contact element has a connecting portion and a contact portion, the connecting portion being electrically and mechanically connected to the contact portion. The connecting portion and the contact portion are preferably formed as a single piece and made of the same material. The connecting portion is implemented as a hollow cylinder. An annular gap is formed between the first inner circumferential side of the crimping cylinder and the connecting portion, in which the first electrical conductor is arranged. This design is particularly suitable for ensuring the shielding effect of the electrical conductor is maintained through the crimping cylinder and the connecting portion when the first electrical conductor is designed as a shield for contacting the first electrical conductor.

[0013] In another embodiment, a third embossed portion is embossed in the crimping cylinder to create a protrusion on the first inner circumferential side. A fourth embossed portion is formed as a connecting portion through the protrusion, the protrusion engaging in the fourth embossed portion and achieving a positive connection. The crimping cylinder is connected to the connecting portion through the positive connection.

[0014] In another embodiment, the crimping cylinder is circumferentially gapless relative to the axis.

[0015] A tool particularly suitable for producing the above-described device may be provided, wherein the tool has a guide device, at least one first pressing claw and a second pressing claw, the second pressing claw being circumferentially spaced from the first pressing claw, the first pressing claw and the second pressing claw being arranged to be radially movable between a first position radially outward and a second position radially inward via the guide device.

[0016] The first pressing claw has a radially inward first pressing surface, and the second pressing claw has a radially inward second pressing surface. The first and second pressing surfaces together define a tool receiving portion for receiving the crimping cylinder and the first electrical conductor. The guiding device is designed to introduce radially inward pressing force into the first and second pressing claws, respectively. The first and second pressing claws are respectively designed to press the first and second imprinted portions into the crimping portion by pressing force, and to press the first inner peripheral side onto the second outer peripheral side.

[0017] The advantage of this design is that the tool deforms the crimping cylinder uniformly without the crimping cylinder material being pressed into the electrical conductor by the tool.

[0018] In another embodiment, the guiding device is designed to move the first and second pressing claws synchronously between a first position radially outward and a second position radially inward. This synchronous movement of the two pressing claws ensures that the crimping cylinder is pressed particularly evenly onto the electrical conductor.

[0019] In another embodiment, the first pressing surface and the second pressing surface are implemented in a first position radially outward and a second position radially inward, such that in each case they extend together on a common circular path around the axis of the tool receptacle.

[0020] Particularly advantageous is that a gap exists between the first and second pressing claws in the circumferential direction relative to the axis, the gap having a width in the circumferential direction. The first pressing surface has a first range in the circumferential direction, the gap width being smaller than the first range. The ratio of the first range to the gap width is in the range of at least 1.5 to 10, preferably in the range of 2 to 9, and particularly in the range of 3 to 8.

[0021] In another embodiment, the tool has at least one additional first pressing claw, the first and second pressing claws being arranged in a predetermined pattern, particularly at regular intervals, offset from each other in the circumferential direction. The additional first pressing claw is coupled to the guide device and is movable between a first position radially outward and a second position radially inward. Alternatively, the additional first pressing claw is arranged in a fixed manner.

[0022] In particular, in the case of a fixed design, the cable can be placed on the first fixed pressing claw, and when the imprinting part is pressed, the pressing claw advances onto the cable without moving the cable.

[0023] It is particularly advantageous to use the above-described tool in the manufacture of the above-described device, wherein the tool, cable, and contact device are provided. A first electrical conductor is pushed into the crimping cylinder. The crimping cylinder, together with the first electrical conductor, is inserted into the tool receiving portion. The first and second pressing claws move radially from a first position radially outward to a second position radially inward. The first pressing claw presses in the first imprinted portion, and the second pressing claw presses in the second imprinted portion into the crimping cylinder. The first and second pressing claws press the first inner circumferential side against the second outer circumferential side, so that the first inner circumferential side fits tightly against the second outer circumferential side.

[0024] Therefore, the first inner circumferential side retains its basic shape, but its radial range is reduced. In other words, the first inner circumferential side before the pressing of the first and second imprinted portions is concentric with the first inner circumferential side after the pressing of the first and second imprinted portions.

[0025] In this case, it is particularly advantageous that the first pressing claw and the second pressing claw move radially inward in sync with the axis. Attached Figure Description

[0026] The invention will now be explained in more detail with reference to the accompanying drawings. The drawings show:

[0027] Figure 1 This is a perspective view of the device according to the first embodiment.

[0028] Figure 2 yes Figure 1 A perspective view of the contact elements of the contact device in the illustrated apparatus.

[0029] Figure 3 yes Figure 2 The longitudinal cross-sectional view of the contact element is shown.

[0030] Figure 4 It is along Figure 1 The cross section AA shown passes through Figure 1 A cross-sectional view of the device shown.

[0031] Figure 5 yes Figure 1 The longitudinal section of the device shown.

[0032] Figure 6 It is used for production Figures 1 to 5 A perspective view of the tools of the apparatus shown.

[0033] Figure 7 yes Figure 6 The top view of the tool shown.

[0034] Figure 8 Through Figure 7 The tool production shown Figures 1 to 5 A flowchart of the method using the apparatus shown.

[0035] Figure 9 It is the crimping cylinder during the third step of the method.

[0036] Figure 10 This is a perspective view of the device according to the second embodiment.

[0037] Figure 11 It is along Figure 10 The cross section BB shown passes through Figure 10 A cross-sectional view of the device shown.

[0038] Figure 12 yes Figure 6 and 7 The top view of the tool's development is shown.

[0039] Figure 13 This is a perspective view of the device according to the third embodiment.

[0040] Figure 14 yes Figure 13 A longitudinal sectional view of the device shown.

[0041] Figure 15 yes Figure 6 and 7 The perspective view of the development of the tool shown. Detailed Implementation

[0042] Figure 1 Details of a perspective view of the device 10 according to the first embodiment are shown.

[0043] The device 10 has a contact device 15 and a cable 20. The cable 20 is exemplary implemented as a shielded cable. The cable 20 has a first electrical conductor 25. The first electrical conductor 25 can be implemented as a shield or an outer conductor. The first electrical conductor 25 extends along an axis 30. In this case, the first electrical conductor 25 is implemented approximately as a hollow cylinder relative to the axis 30. In this case, the first electrical conductor 25 can have a braided fabric, which is fine or ultra-fine wire. The braided fabric can be woven or composed of single wires extending parallel to the axis 30.

[0044] To aid understanding, the device 10 is described below based on a cylindrical coordinate system relative to axis 30.

[0045] The first electrical conductor 25 is covered radially outward by a sheath 35. The first sheath 35 is made of an electrically insulating first material and electrically insulates the first electrical conductor 25 from the environment 40. The sheath 35 preferably completely surrounds the first electrical conductor 25 circumferentially.

[0046] The cable 20 has, for example, an electrically insulating intermediate layer 45 on its radially inner side. In this embodiment, the electrically insulating intermediate layer 45 is circumferentially surrounded by a first electrical conductor 25. The cable 20 has, for example, a second electrical conductor 50 on its radially inner side of the intermediate layer 45.

[0047] The second electrical conductor 50 can be formed from a single wire. It can also be formed from a bundle of wires, such as fine or ultra-fine wires. The second electrical conductor 50 can also be referred to as an internal conductor. The second electrical conductor 50 can be used, for example, to transmit data signals. In this case, the current to be transmitted is less than 1A. The second electrical conductor 50 can also be designed for the transmission of electrical energy, for example, to power an electric motor. For this purpose, the second electrical conductor 50 preferably has a diameter of at least 2mm. 2 5mm is preferred 2 Especially at least 10mm 2 Preferably at least 25mm 2 The cross-sectional area. For example, the second conductor 50 can be designed such that the cross-sectional area of ​​the second conductor 50 is less than or equal to 200 mm². 2 Less than or equal to 100mm 2 Less than or equal to 50mm 2 .

[0048] The first electrical conductor 25 and / or the second electrical conductor 50 comprise a conductive second material, preferably copper and / or aluminum and / or gold and / or silver. The first electrical conductor 25 and the second electrical conductor 50 may comprise the same material or different materials.

[0049] The intermediate layer 45 electrically insulates the second conductor 50 from the first conductor 25. In this embodiment, the first conductor 25 is designed to electromagnetically shield the second conductor 50 from the environment 40. Specifically, the first conductor 25 is designed to prevent large currents (e.g., 100A) transmitted by the second conductor 50 from generating electromagnetic fields that could interfere with other electrical equipment near the cable 20. Therefore, the first conductor 25 improves the electromagnetic compatibility of the device 10.

[0050] Contact device 15 has a crimping cylinder 60 and a contact element 65 connected to the crimping cylinder 60. The crimping cylinder 60 and the contact element 65 are arranged close to each other with respect to an axis 30. The crimping cylinder 60 is implemented in its basic shape, for example, as a hollow cylinder with respect to the axis 30, and extends along the axis 30. The crimping cylinder 60 includes a third material that is conductive. The contact element 65 may also include a third material. The contact element 65 is also conductive and is used to achieve electrical contact with another contact device 70 (in... Figure 1 (Used as dashed lines).

[0051] The crimping cylinder 60 defines a crimping receiving portion 80 on the inner side of the first inner circumferential side 75. In this embodiment, the crimping cylinder 60 has a continuous design, specifically without gaps. This means that, in this embodiment, the crimping cylinder 60 does not have any slits or gaps extending radially outward from the first inner circumferential side 75 to the first outer circumferential side 85 along the entire range of the axis 30.

[0052] The crimping cylinder 60 also has a first face 90 and a second face 95, the first face 90 being disposed on the side of the crimping cylinder 60 facing the contact element 65, and the second face 95 being disposed on the side of the crimping cylinder 60 facing away from the contact element 65. The first end face 90 and the second end face 95 are substantially perpendicular to the axis 30 and have a substantially annular basic shape in plan view. In this case, the first face 90 is offset from the second face 95 in the direction of the axis 30. The cable 20 has a sheath portion 100 and a stripped portion 105, in which the cable 20 is implemented as described above. In the stripped portion 105, the sheath 35 has been removed from the first electrical conductor 25, such that the first electrical conductor 25 is electrically accessible radially outward and is not protected by the first sheath 35. The first electrical conductor 25 has a second outer peripheral side 109, which is freely accessible in the stripped portion 105.

[0053] When the contact device 15 is mounted on the cable 20, the crimping cylinder 60 has at least one first imprinted portion 115 in the first sub-part 110 and a second imprinted portion 120 offset from the first imprinted portion 115 in the circumferential direction. The first sub-part 110 is, for example, adjacent to the second end face 95 in the direction of the axis 30. The first sub-part 110 may also be arranged at a distance from the second end face 95.

[0054] The first imprinting portion 115 and the second imprinting portion 120 have substantially the same range in the circumferential direction and in the direction of the axis 30. For example, in Figure 1 In the middle, the first embossing portion and / or the second embossing portion extend substantially over the entire maximum range of the crimping cylinder 60 in a direction parallel to the axis.

[0055] Extending between the first embossed portion 115 and the second embossed portion 120 is a protrusion 130, which is implemented in the form of a rib. The protrusion 130 protrudes radially outward beyond the first embossed portion 115 and the second embossed portion 120. The protrusion 130 is much narrower than the first embossed portion 115 and / or the second embossed portion 120 in the circumferential direction.

[0056] Figure 2 It shows Figure 1 A perspective view of the contact element 65 of the contact device 15 shown.

[0057] The contact element 65 has a connecting portion 135 and a contact portion 140, with the connecting portion 135 abutting the contact portion 140 in the direction of the axis 30. The contact portion 140 has a third end face 145 on the side facing the connecting portion 135, which is aligned perpendicularly to the axis 30. In this case, the contact portion 140 can extend radially outward on the connecting portion 135 as an edge and radially protrude beyond the connecting portion 135.

[0058] The connecting portion 135 is implemented, for example, as a hollow cylinder. The contact element 65 has an opening 150 on its inner side, which extends along the axis 30 through the entire contact element 65. In this case, the axis 30 is located at the center relative to the opening 150.

[0059] The contact portion 140 is implemented, for example, in the form of a disk relative to the axis 30. The contact portion 140 is in... Figure 2 The contact portion 140 is shown only symbolically and is used to provide contact with another contact device 70. The contact portion 140 may, for example, have a connection with... Figure 3 The designs shown are different.

[0060] The connecting portion 135 and the contact portion 140 are mechanically and electrically connected to each other. Preferably, the connecting portion 135 and the contact portion 140 are integrally formed and made of the same material.

[0061] Figure 3 yes Figure 2 The longitudinal cross-sectional view of the contact element 65 shown.

[0062] The contact element 65 is, for example, rotationally symmetrical about axis 30. The connecting portion 135 is preferably made of the same material as the contact portion 140 and is integrally formed with the contact portion 140. The connecting portion 135 has a third outer peripheral side 155 on its radially outer side, which is realized, for example, in the form of a cylinder around axis 30. The connecting portion 135 is longer than the crimping cylinder 60 in a direction parallel to the axis.

[0063] Figure 4 It is along Figure 1 The cross section AA shown passes through Figure 1 A cross-sectional view of the device 10 shown.

[0064] Preferably, a plurality of first imprinted portions 115 and second imprinted portions 120 are pressed into the crimping cylinder 30 on the first outer peripheral side 85. In this case, it is particularly advantageous that each of the first imprinted portions 115 and / or the second imprinted portions 120 extends over a corresponding angular segment of approximately 20 to 60°, preferably 30 to 45°. The protrusion 130 is much narrower in the circumferential direction than the first imprinted portions 115 and / or the second imprinted portions 120. In the circumferential direction relative to the axis 30, the protrusion 130 may extend over an angular segment of approximately 0.5° to 2°, particularly 0.7° to 1.5°.

[0065] In this embodiment, a plurality of first imprint portions 115 and second imprint portions 120 of the crimping cylinder 60 are arranged in the circumferential direction. The first and second imprint portions 115 and 120 are substantially identical to each other and have substantially the same distance in the circumferential direction.

[0066] The intermediate layer 45 is radially spaced from the second inner peripheral side 160 of the contact element 65. In this case, the second inner peripheral side 160 defines an opening 150 in the radial direction.

[0067] Figure 5 yes Figure 1 A half longitudinal section view of the device 10 shown.

[0068] The crimping sleeve 60 forms an annular gap 210 together with its first inner circumferential side 75 and third outer circumferential side 155, and the first electrical conductor 25 is arranged in the annular gap 210. As a result, the first electrical conductor 25 is wider than the sheath portion 100 of the cable 20. The first inner circumferential side 75 fits tightly against the second outer circumferential side 109 of the first electrical conductor 25.

[0069] During assembly, the first and second imprinted portions 115, 120 are implemented such that the crimping cylinder 60 is pressed or pressed against the first electrical conductor 25, such that the first inner peripheral side 75 is substantially flat against and tightly fitted against the second outer peripheral side 109. By pressing the first inner peripheral side 75 against the second outer peripheral side 109, the crimping cylinder 60 makes electrical contact with the first electrical conductor 25. Additionally, the first inner peripheral side 75 and the second outer peripheral side 109 form a frictional connection. By pressing the crimping cylinder 60 against the first electrical conductor 25, the first inner peripheral side 75 is pressed with a pressing force FC in the direction of the axis 30 from the radially outer side to the radially inner side. In this case, the pressing force FC presses the first electrical conductor 25 radially inner against the third outer peripheral side 155 of the connecting portion 135. The connecting portion 135 is designed to be pressure-stable in the radial direction and provides a reaction force FG corresponding to the pressing force FC, which is opposite to the pressing force FC from the radially inner side to the radially outer side. The reaction force FG supports the first electrical conductor 25 radially inward. Through the action of the pressing force FC and the reaction force FG, the first electrical conductor 25 forms a frictional connection with the connecting portion 135 radially inward and a frictional connection with the first inner circumferential side 75 of the crimping cylinder 60 radially outward. Due to the frictional connection, both the crimping cylinder 60 and the first electrical conductor 25 are frictionally connected to the connecting portion 135.

[0070] The intermediate layer 45 and the second conductor 50 pass through the opening 150. The connecting portion 135 protects them from compression.

[0071] Figure 6 A perspective view of tool 165 is shown.

[0072] Tool 165 is designed as a crimping tool and has at least one first pressing claw 170 and at least one second pressing claw 175, the second pressing claw 175 being arranged circumferentially relative to the first pressing claw 170. Preferably, tool 165 has a plurality of pressing claws 170, 175, which are arranged spaced apart from each other in the circumferential direction. Additionally, tool 165 may have at least one guide device 180, which guides... Figure 6 The image is shown only symbolically. The guide device 180 is connected to each pressing claw 170, 175.

[0073] The first pressing claw 170 has a first pressing surface 185. The first pressing surface 185 is located radially inside the first pressing claw 170 and extends along a cylindrical section about the axis 30. The second pressing claw 175 has a second pressing surface 190, which extends along another cylindrical section relative to the axis 30.

[0074] In this embodiment, tool 165 has, for example, six pressing claws 170, 175, which are, for example, identical in design. In this case, each of the pressing claws 170, 175 extends at equal angular segments relative to axis 30. The pressing claws 170, 175 may also be different in design. In this embodiment, the pressing claws 170, 175 are arranged circumferentially spaced apart from each other, with a corresponding gap 191 extending between the first pressing claw 170 and the second pressing claw 175, the gap 191 extending radially inward from the pressing surfaces 185, 190 to the radially outward. In this case, the pressing claws 170, 175 are implemented in such a way that, for example, the gap 191 has a substantially the same gap width in the circumferential direction as the radial distance from axis 30 increases. The gap width of the gap 191 may also increase with increasing distance from axis 30.

[0075] The first and / or second pressing surfaces 185, 190 have a first range in the circumferential direction, and the gap width of the gap 191 is smaller than the first range. The ratio of the first range to the gap width is preferably in the range of at least 1.5 to 10, preferably in the range of 2 to 9, and particularly in the range of 3 to 8.

[0076] Figure 7 A top view of tool 165 is shown.

[0077] The guide device 180 is designed to move the pressing claws 170, 175 between a first position on the radially outer side and a second position on the radially inner side.

[0078] exist Figure 7 In this case, the pressing claws 170 and 175 are shown in solid lines in a first radially outer position. The pressing surfaces 185 and 190 are arranged on a common first circular path 195 in the first radially outer position. The pressing surfaces 185 and 190 define the tool receiving portion 205 in the radial direction.

[0079] Guide device 180 (not shown for clarity) Figure 7 (As shown in the figure) The pressing claws 170, 175 can be moved simultaneously and synchronously between a first radially outer position and a second radially inner position. The guide device 180 may include, for example, a linkage guide. The guide device 180 may also include a hydraulic actuation element and an actuator designed to move the pressing claws 170, 175 between the first radially outer position and the second radially inner position.

[0080] At the second position in the radial interior (e.g.) Figure 7 As shown by the dashed line in the diagram, the first and second pressing surfaces 185 and 190 are arranged together around axis 30 on a common second circular path 200. The first circular path 195 and the second circular path 200 are concentric with axis 30.

[0081] If the pressing claws 170 and 175 are in the second radially inner position, the gap 191 is narrower in the circumferential direction compared to if the pressing claws 170 and 175 are in the first radially outer position.

[0082] Figure 8 It is used for production Figures 1 to 6 A flowchart of the method of the apparatus 10 shown. Figure 9 A perspective view of the crimping cylinder 60 during step 310 of the third method is shown.

[0083] In the first method step 300, the pressing claws 170 and 175 are moved to a first position radially outward.

[0084] In the second method step 305 following the first method step 300, the cable 20, for example, from the reel is cut, and immediately after cutting, the sheath 35 is removed from the first electrical conductor 25 to achieve the stripped portion 105.

[0085] In the third method step 310, the crimping cylinder 60 and the contact element 65 are set in an uncrimped state.

[0086] In the uncrimped state (see...) Figure 9 In this embodiment, the crimping cylinder 60 is essentially a hollow cylinder. In this case, the crimping cylinder 60 has a substantially constant material thickness bU in the radial direction relative to the axis 30. The crimping cylinder 60 can be formed from a thin-walled material, such as a sheet metal plate. In this embodiment, the inner diameter d of the crimping cylinder 60 is, for example, larger than the range l along the axis 30. In this embodiment, the inner diameter d is chosen to be larger than the maximum outer diameter dMAX of the connecting portion 135.

[0087] In the fourth method step 320 following the third method step 310, the crimping sleeve 60 is screwed onto the cable 20, or the cable 20 is inserted through the crimping sleeve 60.

[0088] In the fifth method step 320, following the fourth method step 315, the first electrical conductor 25 is widened, for example. This can be achieved, for example, by means of a mandrel.

[0089] Additionally, the intermediate layer 45 and the second electrical conductor 50 are inserted through the opening 150 such that the second electrical conductor 50 and the intermediate layer 45 protrude on the side of the contact element 65 opposite to the connection portion 135.

[0090] In this configuration, the contact element 65 is positioned such that the connection portion 135 is radially engaged between the intermediate layer 45 and the first electrical conductor 25. The first electrical conductor 25 radially surrounds the connection portion 135 externally and abuts against the third outer peripheral side 155.

[0091] In the sixth method step 325, immediately following the fifth method step 320, the crimping cylinder 60 is pushed onto the connecting portion 135 and onto the first electrical conductor 25 disposed at the connecting portion 135. In this case, the crimping cylinder 60 forms an annular gap 210 through the third outer peripheral side 155 (see...). Figure 5 The widened first electrical conductor 25 is arranged in the annular gap 210.

[0092] In the seventh method step 330, following the sixth method step 325, the device 10 is positioned in the tool receiving portion 205 such that the pressing surfaces 185, 190 are positioned to radially overlap with the crimping cylinder 60. In this case, radial overlap is understood to mean that when projected in the radial direction onto the plane in which the axis 30 extends, the two components, for example, the pressing claws 170, 175 and the crimping cylinder 60, overlap. Similarly, the pressing claws 170, 175 radially overlap with the connecting portion 135 and the widened first electrical conductor 25 in the peeling portion 105.

[0093] In this embodiment, the crimping cylinder 60 and the pressing claws 170, 175 have the same range along axis 30. In this case, the pressing claws 170, 175 and the crimping cylinder 60 are positioned in such a way that they have complete radial overlap.

[0094] In the eighth method step 335 following the seventh method step 330, the guide device 180 introduces a radially inward pressing force FC into the pressing claws 170, 175 in each case. Additionally, the guide device 180 moves the pressing claws 170, 175 from a first radially outer position to a second radially inner position. Each pressing claw 170, 175 abuts flat against the second outer peripheral side 109 of the crimping cylinder 60 with its corresponding pressing surface 185, 190.

[0095] The connecting portion 135 is harder than the crimping cylinder 60. This is achieved by making the wall thickness of the connecting portion 135 significantly greater than the wall thickness d of the crimping cylinder 60 (preferably 1.5 to 10 times).

[0096] When the pressing force FC is applied, the connecting portion 135 provides a reaction force FG, which acts radially outward. By introducing the pressing force FC into the crimping cylinder 60, the crimping cylinder 60 presses against the first electrical conductor 25, such that the first inner circumferential side 75 fits tightly against and substantially flattenes against the first outer circumferential side 85 of the first electrical conductor 25. The geometry of the first pressing surface 185 and the first pressing claw 170 causes the first imprint 115 to be imprinted into the first outer circumferential side 85 by means of the pressing force FC. Similarly, the second pressing claw 175 imprints the second imprint 120 into the first outer circumferential side 85 by means of the second pressing surface 190. Similarly, Figure 7The other pressing claws 170 and 175 shown press the first and second imprinted portions 115 and 120 into the first outer peripheral side 85, respectively, so that the first inner peripheral side 75 fits tightly against the first outer peripheral side 85 of the first electrical conductor 25, thereby maintaining a substantially circular shape.

[0097] During the embossing process, a portion of the material from the crimping cylinder 60 flows into each gap 191 and forms a corresponding protrusion 130. As a result, the crimping cylinder 60 has a different material thickness d in the circumferential direction, such that the material thickness dW on the radially inner side of the first and second embossing portions 115, 120 is less than the material thickness at the protrusion 130. The embossing of the first and second embossing portions 115, 120 also has the advantage of reinforcing the crimping cylinder 60, thereby preventing undesirable widening of the crimping cylinder 60 after the removal of the pressing claws 170, 175. In addition, the crimping cylinder 60 presses the first electrical conductor 25 against the connecting portion 135, such that the connecting portion 135 and the crimping cylinder 60 together frictionally fix the first electrical conductor 25.

[0098] As the imprinting of the first and second imprinting portions 115, 120 and the related decrease in the inner diameter d of the crimping cylinder 60 decrease, in the ninth method step 340 after the eighth method step 335, after the removal of the pressing claws 170, 175, the crimping cylinder 60 maintains a pressing force FC that is at least locally uniform, and thus presses the first electrical conductor 25 radially inward against the third outer peripheral side 155, so that a frictional connection is still maintained between the crimping cylinder 60 and the first electrical conductor 25 or between the first electrical conductor 25 and the connecting portion 135.

[0099] The fact that the first inner circumferential side 75 fits tightly against the first electrical conductor 25 prevents a portion of the crimping cylinder 60 from penetrating into the first electrical conductor 25 during the crimping of the first and second crimping portions 115, 120. Instead, after the crimping of the first and second crimping portions 115, 120, the crimping cylinder 60 still has a generally cylindrical shape on the first inner circumferential side 75, but now has a reduced inner diameter d.

[0100] The advantage of this design is that it avoids damaging the first electrical conductor 25 by pressing the crimping cylinder 60. On the one hand, this ensures particularly good electrical contact between the first electrical conductor 25 and the connecting portion 135, and on the other hand, it ensures particularly good mechanical connection between the first electrical conductor 25 and the contact device 15.

[0101] In the tenth method step 345 following the ninth method step 340, the second electrical conductor 50 may be electrically contacted, for example, by another contact device 70.

[0102] Figure 10 This is a perspective view of the apparatus 10 according to the second embodiment.

[0103] Device 10 and Figures 1 to 9The apparatus 10 described herein is essentially the same. In the following discussion, only the following will be addressed. Figure 10 The device 10 shown is with Figures 1 to 9 The differences between the devices 10 described in the text.

[0104] Figure 10 The illustrated device 10 further includes at least one third embossing portion 215 in the crimping cylinder 60. The third embossing portion 215 is narrower along the axis 30 than, for example, the first or second embossing portions 115, 120. In this case, the third embossing portion 215 may also be embossed into the first embossing portion 115 and / or the second embossing portion 120. The third embossing portion 215 is, for example, made deeper radially than the first embossing portion 115 and / or the second embossing portion 120. Additionally, the third embossing portion 215 is narrower circumferentially than the first and / or second embossing portions 115, 120. In this case, the third embossing portion 215 may be elongated.

[0105] In this embodiment, two third embossed portions 215 are provided as an example, offset from each other in the circumferential direction by, for example, 180°. Different numbers of third embossed portions 215 may also be provided. In the positioning of the third embossed portions 215, it is particularly advantageous if the third embossed portions 215 are offset circumferentially from the protrusion 130.

[0106] Figure 11 It shows along Figure 10 The cross-sectional view of section BB passing through device 10 is shown.

[0107] For example, the third embossed portion 215 is shaped such that a protrusion 220 is formed on the first inner peripheral side 75. The protrusion 220 abuts against the third outer peripheral side 155 and protrudes through the annular gap 210. When the third embossed portion 215 is pressed into the crimping cylinder 60, the protrusion 220 causes the first electrical conductor 25 to shift in the circumferential direction (in... Figure 11 (Illustrated schematically by an arrow).

[0108] Particularly advantageous is that, when the third imprinting part 215 is imprinted into the pressing cylinder 60, the fourth imprinting part 225 (in) is pressed into the cylinder by the protrusion 220. Figure 11 (Indicated by dashed lines) The protrusion 220 is imprinted into the connecting portion 135 and engages in the fourth imprinted portion 225, so that in addition to the frictional connection between the protrusion 220 and the third outer peripheral side 155, a form-fit connection is also achieved by the engagement of the protrusion 220 in the fourth imprinted portion 225.

[0109] Figure 12 It shows in Figure 6 and 7 Side view of the first pressing claw 170 of tool 165, a further development of the tool shown.

[0110] Tool 165 was designed to implement Figure 10 and 11 The device 10 shown. The second pressing claw 175 and Figure 6 and Figure 7 The second pressing claw 175 shown is essentially the same. In the following discussion, only... Figure 12 The first pressing claw 170 shown is... Figure 6 and 7 The difference between the first pressing claws 170 shown.

[0111] On the first pressing surface 185, the first pressing claw 170 has a forming portion 230 that protrudes radially inwardly onto the first pressing surface 185, which in this embodiment extends about an axis 30 along a circular path 200. The forming portion 230 may be elongated, for example, in a direction parallel to the axis 30, and may extend substantially along the axis 30 in its main extending direction.

[0112] The forming part 230 is designed to correspond to the third imprinting part 215. Therefore, in the direction parallel to the axis 30, the forming part 230 is shorter than the first pressing claw 170.

[0113] The method for manufacturing device 10 is to be consistent with Figure 8 The method described herein is implemented in essentially the same manner. Furthermore, in step 335 of the eighth method, while the first imprinted portion 115 is pressed in by means of the first pressing surface 185, the third imprinted portion 215 is also pressed into the crimping cylinder 60, and the protrusion 220 is formed, or simultaneously pressed in. In this case, the forming portion 230 can protrude inward in the radial direction, such that the forming portion 230 similarly forms / presses the fourth imprinted portion 225 into the connecting portion 135 and reliably fixes the crimping cylinder 60 to the connecting portion 135.

[0114] Figure 13 This is a perspective view of the apparatus 10 according to the third embodiment.

[0115] Device 10 and Figures 1 to 12 The device 10 shown is essentially the same. In the following discussion, only the following will be addressed. Figure 13 The device 10 shown is Figures 1 to 9 The differences between the devices 10 shown.

[0116] For example, with Figures 1 to 9Compared to the design shown, cable 20 is implemented solely by a first electrical conductor 25. The first electrical conductor 25 is used, for example, to transfer electrical energy between two components. In this case, the first electrical conductor 25 is used to transmit power, i.e., the current transmitted by the first electrical conductor 25 is at least 1A, preferably at least 5A, at least 10A, at least 20A, at least 50A, at least 100A and less than 200A, less than 400A, and less than 500A. The current to be transmitted is transmitted through the first electrical conductor 25 for at least 5 seconds.

[0117] The first electrical conductor 25 is arranged, for example, along axis 30 and preferably has a thickness of at least 5 mm. 2 Preferably at least 10mm 2 Preferably at least 25mm 2 Preferably at least 50mm 2 And less than 200mm 2 The cross-sectional area. In this case, the first electrical conductor 25 can be implemented as a single wire, a fine wire, or an ultrafine wire, and multiple single wires are combined to form a bundle. The individual wires extend parallel to each other or are twisted together, for example. The first electrical conductor 25 is electrically insulated from the environment 40 by a sheath 35.

[0118] Figure 14 yes Figure 13 The longitudinal cross-sectional view of the device 10 shown.

[0119] In this embodiment, the connecting portion 135 is omitted. Figure 13 and 14 The crimping cylinder 60 is integrally formed with the contact portion 140 and has the same material as the contact portion 140. The contact portion 140 is implemented, for example, in the form of a disc, wherein the opening 150 in the contact element 65 is omitted.

[0120] Basically the same execution Figure 8 The production method described in the text is for the production of Figure 13 and 14 The device 10 shown is discussed below. Only the device 10 shown is discussed in relation to the following text. Figure 8 The differences compared to the methods described in [the original text].

[0121] In the third method step 310, the crimping cylinder 60 and the contact element 65 are made of the same material in the uncrimped state.

[0122] In the fourth method step 315, the first electrical conductor 25 is inserted into the contact element 65 such that it abuts against the contact portion 140 at its end face or is at a predetermined distance from the contact portion 140.

[0123] The fifth and sixth method steps 320 and 325 are omitted, and the seventh method step 330 is performed on the fourth method step 315, so that the tool 165 is radially overlapped.

[0124] In the eighth method step 335 following the seventh method step 330, the guide device 180 introduces a radially inward pressing force FC into the pressing claws 170, 175 in each case. Additionally, the guide device 180 moves the pressing claws 170, 175 from a first radially outer position to a second radially inner position. Each pressing claw 170, 175 abuts flat against the second outer peripheral side 109 of the crimping cylinder 60 with its corresponding pressing surface 185, 190.

[0125] By introducing a pressing force FC into the crimping cylinder 60, the crimping cylinder 60 presses against the first electrical conductor 25, such that the first inner peripheral side 75 fits tightly against the first outer peripheral side 85 of the first electrical conductor 25 and rests substantially flat against it. The geometry of the first pressing surface 185 and the first pressing claw 170 is such that the first imprint 115 is imprinted into the first outer peripheral side 85 by means of the pressing force FC. Similarly, the second pressing claw 175 imprints the second imprint 120 into the first outer peripheral side 85 by means of the second pressing surface 190.

[0126] Furthermore, the tight fit between the pressing force FC and the first inner circumferential side 75 causes the wires of the first electrical conductor 25 to be pressed together and compressed until the crimping cylinder 60 and the first electrical conductor 25 are fully compressed. The first electrical conductor 25 provides the reaction force FG required for pressing.

[0127] Figure 15 It shows Figures 1 to 9 The device 10 shown and Figure 6 and Figure 7 A perspective view of a further development of tool 165 shown.

[0128] Tools 165 and Figure 6 The tool 165 shown is essentially the same. Unlike the latter, the guide device 180 is implemented such that all pressing claws 170, 175, except for the first pressing claw 170 located at the bottom, are movable between a first radially outer position and a second radially inner position. The first pressing claw 170 located at the bottom is fixed and not coupled to the guide device 180. In this case, the guide device 180 is designed to move the other pressing claws 170, 175 between the first radially outer position and the second radially inner position, such that the fixed first pressing claw 170 and the first pressing surface 185 remain in the first and second circular paths 195, 200 in each case, as... Figure 6 As shown. As a result, when the pressing claws 170 and 175 move between the first radially outer position and the second radially inner position, the axis 30 moves relative to the first immovable pressing claw 170 in a direction perpendicular to the axis 30.

[0129] The advantage of this design is that the components used to implement the device 10, namely the contact device 15 and the cable 20, can be placed on the immovable first pressing claw 170, thereby preventing unwanted displacement during the imprinting process of the imprinting sections 115 and 120.

[0130] List of reference numerals

[0131] 10 devices

[0132] 15 Contact Devices

[0133] 20 cable

[0134] 25 First electrical conductor

[0135] 30 axis

[0136] 35 sheath

[0137] 40 Environment

[0138] 45 Intermediate Layer

[0139] 50 Second electrical conductor

[0140] 60 crimping sleeve

[0141] 65 contact element

[0142] 70 Other contact devices

[0143] 75 First inner circumferential side

[0144] 80 crimping housing

[0145] 85 First peripheral side

[0146] 90 First end face

[0147] 95 Second end face

[0148] 100 (cable) sheath portion

[0149] 105 (cable) stripped section

[0150] 109 Second peripheral side

[0151] 110 First Sub-part

[0152] 115 First Imprint Section

[0153] 120 Second Imprint Section

[0154] 125 Second Sub-part

[0155] 130 protrusion

[0156] 135 connection part

[0157] 140 contact part

[0158] 145 Third end face

[0159] 150 opening

[0160] 155 Third peripheral side

[0161] 160 Second inner circumferential side

[0162] 165 Tools

[0163] 170 First pressing claw

[0164] 175 Second Pressing Claw

[0165] 180 boot device

[0166] 185 First pressing surface

[0167] 190 Second pressing surface

[0168] 191 gap

[0169] 195 First circular path

[0170] 200 Second Circular Path

[0171] 205 Tool Reservoir

[0172] 210 annular gap

[0173] 215 Third Imprint Section

[0174] 220 protrusion

[0175] 225 Fourth Imprint Section

[0176] 230 forming part

[0177] 300 First Method Steps

[0178] 305 Second Method Steps

[0179] 310 Third Method Steps

[0180] 315 Fourth Method Steps

[0181] 320 Fifth Method Steps

[0182] 325 Sixth Method Steps

[0183] 330 Seventh Method Steps

[0184] 335 Eighth Method Steps

[0185] 340 Ninth Method Steps

[0186] 345 Tenth Method Steps

Claims

1. A device (10), It has a contact device (15) and a cable (20), the cable having a first electrical conductor (25). The contact device (15) has a crimping cylinder (60) and a contact element (65) that is mechanically and electrically connected to the crimping cylinder (60). The crimping cylinder (60) extends along the axis (30), The crimping cylinder (60) has a first inner circumferential side (75) and a first outer circumferential side (85). At least in the first sub-section (110) of the crimping cylinder (60), there is a first embossed portion (115) and a second embossed portion (120), the second embossed portion being offset from the first embossed portion (115) in the circumferential direction relative to the axis (30). The first inner peripheral side (75) is formed by the first imprinted portion (115) and the second imprinted portion (120) such that the first inner peripheral side (75) presses against the second outer peripheral side (109) of the first electrical conductor (25), and the first inner peripheral side (75) is in electrical contact with the second outer peripheral side (109). The implementation of the first embossing portion (115) and the second embossing portion (120) ensures that when the crimping cylinder (60) is pressed onto the first electrical conductor (25), the first inner peripheral side (75) flatly abuts against the second outer peripheral side (109) in a tight fit. in, The first imprinted portion (115) and the second imprinted portion (120) are configured such that when the first inner circumferential side is pressed onto the first electrical conductor, the basic shape of the first inner circumferential side is maintained while the radial range of the first inner circumferential side is reduced. The first inner circumferential side before the first imprinted portion and the second imprinted portion are pressed into the first inner circumferential side and the first inner circumferential side after the first imprinted portion and the second imprinted portion are pressed into the first inner circumferential side.

2. The apparatus (10) according to claim 1. The first inner circumferential side (75) is shaped to have a substantially circular cross-section relative to the axis (30).

3. The apparatus (10) according to claim 1 or 2. A protrusion (130) is formed in the circumferential direction between the first embossing portion (115) and the second embossing portion (120). The maximum material thickness of the crimping cylinder (60) in the radial direction at the protrusion (130) is greater than the maximum material thickness at the first embossed portion (115) and / or the second embossed portion (120).

4. The apparatus (10) according to claim 1 or 2. The cable (20) has an electrically insulating intermediate layer (45) and a second electrical conductor (50). The intermediate layer (45) circumferentially covers the second electrical conductor (50) and electrically insulates the second electrical conductor from the first electrical conductor (25). The first electrical conductor (25) is arranged outside the intermediate layer (45) and covers the intermediate layer (45). The contact element (65) has an opening through which the intermediate layer (45) and the second electrical conductor (50) pass (150).

5. The apparatus (10) according to claim 1 or 2. The contact element (65) has a connecting portion (135) and a contact portion (140). The connecting portion (135) is electrically and mechanically connected to the contact portion (140). The connecting portion (135) is implemented as a hollow cylinder. An annular gap (210) is formed between the first inner circumferential side (75) of the crimping cylinder (60) and the connecting portion (135). The first electrical conductor (25) is arranged in the annular gap (210).

6. The apparatus (10) according to claim 5. The connecting portion (135) and the contact portion (140) are formed as one piece and are made of the same material.

7. The apparatus (10) according to claim 1 or 2. The crimping cylinder (60) has no gap in the circumferential direction relative to the axis (30).

8. A tool (165) The tool (165) has a guide device (180), at least one first pressing claw (170) and a second pressing claw (175) spaced circumferentially from the first pressing claw (170). The first pressing claw (170) and the second pressing claw (175) are arranged to be radially movable between a first position in the radially outer direction and a second position in the radially inner direction by means of the guide device (180). The first pressing claw (170) has a first pressing surface (185) that is radially inward, and the second pressing claw (175) has a second pressing surface (190) that is radially inward. The first pressing surface (185) and the second pressing surface (190) together define the tool receiving portion (205) for receiving the crimping cylinder (60) and the first electrical conductor (25). The guide device (180) is designed to introduce radially inward pressing force (FC) into the first pressing claw (170) and the second pressing claw (175), respectively. The first pressing claw (170) and the second pressing claw (175) are designed to press the first imprinting part (115) and the second imprinting part (120) into the crimping part respectively by pressing force (FC), and to press the first inner peripheral side (75) onto the second outer peripheral side (109). in, The implementation of the first and second embossing portions ensures that when the crimping cylinder is pressed onto the first electrical conductor, the first inner circumferential side (75) flatly abuts against the second outer circumferential side (109) for a tight fit. The first imprinted portion (115) and the second imprinted portion (120) are configured such that when the first inner circumferential side is pressed onto the first electrical conductor, the basic shape of the first inner circumferential side is maintained while the radial range of the first inner circumferential side is reduced. The first inner circumferential side before the first imprinted portion and the second imprinted portion are pressed into the first inner circumferential side and the first inner circumferential side after the first imprinted portion and the second imprinted portion are pressed into the first inner circumferential side.

9. The tool (165) according to claim 8. The guide device (180) is designed to move the first pressing claw (170) and the second pressing claw (175) synchronously between a first position in the radially outer direction and a second position in the radially inner direction.

10. The tool (165) according to claim 8 or 9. The first pressing surface (185) and the second pressing surface (190) are implemented in a first position radially outward and a second position radially inward, such that in each case they extend together on a common circular path (195, 200) around the axis (30) of the tool receiving portion (205).

11. The tool (165) according to claim 8 or 9. There is a gap (191) between the first pressing claw (170) and the second pressing claw (175) in the circumferential direction relative to the axis (30). The gap (191) has a gap width in the circumferential direction. The first pressing surface (185) has a first range in the circumferential direction. The gap width is less than the first range. The ratio of the first range to the gap width is in the range of 1.5 to 10.

12. The tool (165) according to claim 8 or 9. It has at least one additional first pressing claw (170). The first pressing claw (170) and the second pressing claw (175) are arranged in a predetermined pattern, in particular at regular intervals, and offset from each other in the circumferential direction. The additional first pressing claw (170) is coupled to the guide device (180) and is movable between a first position radially outward and a second position radially inward, or The additional first pressing claw (170) is arranged in a fixed manner.

13. The tool (165) according to claim 11, wherein, The ratio of the first range to the gap width is in the range of 2 to 9.

14. The tool (165) according to claim 11, wherein, The ratio of the first range to the gap width is in the range of 3 to 8.

15. A method for producing the apparatus (10) according to any one of claims 1 to 7 using the tool (165) according to any one of claims 8 to 14. Provide tools (165), cables (20) and contact devices (15). Insert the first electrical conductor (25) into the crimping cylinder (60), and insert the crimping cylinder (60) and the first electrical conductor (25) together into the tool receiving part (205). The first pressing claw (170) and the second pressing claw (175) move radially from a first position on the outer side to a second position on the inner side. The first pressing claw (170) presses the first imprinting part (115) into the cylinder, and the second pressing claw (175) presses the second imprinting part (120) into the cylinder (60). The first pressing claw (170) and the second pressing claw (175) press the first inner peripheral side (75) onto the second outer peripheral side (109) so that the first inner peripheral side (75) fits tightly against the second outer peripheral side (109).

16. The method according to claim 15, The first pressing claw (170) and the second pressing claw (175) move radially inward toward the axis (30) in a synchronized manner.

Images