Method for manufacturing wiring system and wiring system

Abstract

The invention relates to a method for manufacturing a wiring system (10) for transmitting electric power in an electric vehicle or a charging station for an electric vehicle, and to a wiring system (10), providing a cable (20) having at least one twisted electric conductor (30) and a contact element (80) having a terminal portion (85), the cable insulation (25) being removed in a first sub-portion (50) of the cable (20), and the cable insulation (25) remaining on the electric conductor (30) in a second sub-portion (55) of the cable (20) arranged to deviate from the first sub-portion (50), the electric conductor (30) being welded to a terminal surface (95) of the terminal portion (85) via the first sub-portion (50), the first sub-portion (50) being pressed against the terminal portion (85) during welding. The retaining device (320) at least partially surrounds the second sub-portion (55), preferably over its entire circumference, and the retaining device (320) supports the second sub-portion (55) and maintains the position of the second sub-portion (55) at least during compression and welding of the first sub-portion (50).

Description

Technical Field

[0001] The invention relates to a method for producing a wiring system according to claim 1 , and to a wiring system according to claim 7 . Background Art

[0002] From US Pat. No. 6,854,637 B2 a wiring system is known in which an electrical conductor is ultrasonically welded on both sides of a contact surface.

[0003] It has been found that the distance in the vertical direction between the two contact surfaces in the routing region varies greatly in different batches of cables, depending on the orientation of the strands of the electrical conductor. Therefore, the production machine must be reset for each batch of cables. Summary of the invention

[0004] The object of the present invention is to provide an improved method for producing a wiring system for transmitting electrical power in a motor vehicle or a charging station for a motor vehicle, and a wiring system produced accordingly by using this method.

[0005] This object is achieved by a method according to claim 1 and a wiring system according to claim 7. Advantageous embodiments are specified in the dependent claims.

[0006] An improved method for manufacturing a wiring system can be provided, wherein a cable is provided, which has at least one preferably twisted electrical conductor and a contact element with a terminal portion. The cable insulation is removed in a first sub-portion of the cable, and the cable insulation remains on the electrical conductor in a second sub-portion of the cable arranged to deviate from the first sub-portion. The electrical conductor is welded to a terminal surface of the terminal portion via the first sub-portion. It is particularly advantageous if the first sub-portion is ultrasonically welded to the terminal portion. During welding, the first sub-portion is pressed against the terminal portion. A retaining device at least partially surrounds the second sub-portion, preferably over its entire circumference. The retaining device supports the second sub-portion and maintains the position of the second sub-portion at least during compression and welding of the first sub-portion.

[0007] The advantage of this design is that, due to the support, the position of the second subsection relative to the first subsection is maintained even after welding, thereby preventing undesired deformation of the second subsection. In addition, the distance between the first center axis along which the first subsection extends after compression and the second center axis along which the second subsection extends can be defined with narrow tolerances.

[0008] If the second subsection passes through the sealing element, the sealing element completely abuts against the cable insulation in the circumferential direction, thereby preventing the fluid from passing between the cable insulation and the sealing element.

[0009] In another embodiment, in a first subsection of the cable, the electrical conductor extends along a first center axis. In a second subsection of the cable, the electrical conductor extends along a second center axis. The first and second center axes overlap before compression. The first subsection is oriented so that the first center axis is oriented parallel to the terminal surface. The advantage of this design is that the first subsection extends parallel to the terminal surface over a large area and can therefore be welded to the terminal surface in an advantageous manner in terms of stress.

[0010] In another embodiment, in a first subsection of the cable, the electrical conductor extends along a first central axis, and in a second subsection of the cable, the electrical conductor extends along a second central axis, and the first and second central axes overlap before compression, the first subsection is bent relative to the second subsection so that the first subsection and the second subsection are arranged at a predetermined angle relative to each other. This ensures that the first subsection and the second subsection are aligned at the correct angle relative to each other.

[0011] In another embodiment, the retaining device surrounds the second subsection in the region of the contact surface for the sealing element, so that the outer contour of the second subsection remains unchanged throughout the compression and welding process. The advantage of this design is that crushing, in particular crushing of the cable insulation, is avoided. Thereby, displacement of the center axis of the first subsection and damage to the contact surface during welding of the first subsection can be prevented. This ensures a reliable fluid seal at the contact surface, for example at the sealing device, for passing the cable out of the housing of the contact device. In particular, the concentricity of the cable insulation in the second subsection is ensured.

[0012] In another embodiment, the sonotrode is applied to the first subsection on the side facing away from the terminal surface. The sonotrode introduces a pressing force acting in the direction of the terminal surface into the first subsection, which is supported to be inclined transversely relative to the terminal surface. This design has the advantage that the first subsection is compressed in a simple manner and the strands of the electrical conductor are welded together during ultrasonic welding.

[0013] In another embodiment, the electrical conductor has an original cross-sectional area spanning the first and second sub-portions before welding, the original cross-sectional area being 6 mm 2 Up to 200mm 2 The electrical conductor is compacted in the first subsection, and a first cross-sectional area of ​​the first subsection is smaller than the original cross-sectional area.

[0014] A wiring system for high current transmission in a motor vehicle or a charging station manufactured according to the above method has a cable and a contact device having at least one contact element. The cable has a stranded electrical conductor and a cable insulation. The contact element has a terminal portion. In a first sub-portion of the cable, the electrical conductor is welded to the terminal portion. It is particularly advantageous that in the first sub-portion of the cable, the electrical conductor is ultrasonically welded to the terminal portion. The cable insulation at least partially covers the electrical conductor in a second sub-portion of the cable arranged to deviate from the first sub-portion. In the first sub-portion, the electrical conductor extends along a first central axis. In the second sub-portion, the electrical conductor extends along a second central axis. The first central axis is arranged to deviate from the second central axis toward the terminal portion at a predetermined distance.

[0015] This design has the advantage that the second subsection is surrounded by the sealing element in a sealed manner over its entire circumference when passing through the sealing element, without any gap being formed at the sealing element.

[0016] In another embodiment, the electrical conductor has a first cross-sectional area in the first subsection and a second cross-sectional area in the second subsection. The first cross-sectional area is smaller than the second cross-sectional area. This is achieved by compression. As a result, the electrical contact resistance between the terminal section of the contact element and the first subsection is particularly low.

[0017] In another embodiment, the first subsection is arranged eccentrically with respect to the second center axis of the second subsection.

[0018] It is particularly advantageous if the first center axis is aligned parallel to the terminal section, the parallelism between the terminal section and the first center axis having a tolerance of ±0.5 mm, in particular ±0.2 mm, in particular ±0.1 mm over the extent of the first subsection.

[0019] In a further embodiment of the wiring system, the first centre axis and the second centre axis are arranged in a common plane, the common plane being inclined relative to the terminal surface, preferably oriented vertically. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The present invention will be explained in more detail below with reference to the accompanying drawings. It is shown in the drawings:

[0021] Figure 1 is a schematic diagram of a wiring system of a motor vehicle or a charging station according to a first embodiment;

[0022] Figure 2 Is manufacturing Figure 1 A flowchart of a method for wiring a system as shown;

[0023] Figure 3 is a side view of the production machine and the wiring system during a fifth method step;

[0024] Figure 4 It is along the production machinery and wiring system. Figure 3 A cross-sectional view of section AA is shown;

[0025] Figure 5 is during the sixth method step along Figure 3 A cross-sectional view of section BB is shown;

[0026] Figure 6 is a longitudinal cross-sectional view of a portion of a production machine during a seventh method step for producing a wiring system;

[0027] Figure 7 Is when executing according to manufacturing Figure 1 The method of the second embodiment of the wiring system is shown in a longitudinal section through a production machine;

[0028] Figure 8 is during the seventh method step along Figure 3 A cross-sectional view of section AA is shown;

[0029] Fig. 9 is a schematic diagram of a wiring system of a motor vehicle or a charging station for charging a motor vehicle according to a second embodiment. DETAILED DESCRIPTION

[0030] In the following Figure 1 , 3 In order to help understanding, reference is made to a coordinate system in FIGS. 9 to 10. The coordinate system has an x-axis (longitudinal direction), a y-axis (lateral direction) and a z-axis (vertical direction).

[0031] Figure 1 A schematic diagram of a wiring system 10 of a motor vehicle or a charging station for charging a motor vehicle according to a first embodiment is shown.

[0032] The wiring system 10 has at least one contact device 15 and at least one cable 20. In this embodiment, the contact device 15 is realized, for example, as a charging socket of a motor vehicle. The contact device 15 can also be realized, for example, as a charging plug of a charging station for electric vehicles. On the side facing away from the contact device 15, the cable 20 is electrically connected, for example, to an electrical energy storage device for storing electrical drive energy for the motor vehicle.

[0033] The cable 20 has a cable insulation 25 and an electrical conductor 30. The electrical conductor 30 may be formed by a stranded wire bundle 35 including a plurality of strands 45. The strands 45 may be twisted to form one or more strand braids 40, which in turn are twisted to form the electrical conductor 30. The electrical conductor 30 may also have only a single strand braid 40.

[0034] The strands 45 are ultra-fine stranded and comprise a conductive material such as copper and / or aluminum. Other conductive materials are obviously possible. The electrical conductor 30 is designed to transmit power in a high current range between 100 and 1000 amperes, preferably between 100 and 500 amperes.

[0035] The cable 20 has at least a first subsection 50 and a second subsection 55, in which the cable insulation 25 circumferentially surrounds the electrical conductor 30. The cable insulation 25 comprises a non-conductive material, such as plastic, in particular polyurethane or silicone. In the first subsection 50, the cable insulation 25 is circumferentially removed from the electrical conductor 30.

[0036] The first subsection 50 extends from the free end 140 of the cable 20 along the first central axis 65. The centroid of the first subsection 50 is located on the first central axis 65. In the first subsection 50, the electrical conductor 30 has a first cross-sectional area. The first centroid of the first cross-sectional area is also located on the first central axis 65. The first subsection 50 can have, for example, a substantially square configuration. The first central axis 65 is parallel to the x-axis.

[0037] The second subsection 55 extends along a second central axis 70. The second central axis 70 is oriented in a direction (z direction) perpendicular to the first central axis 65, and is offset from the first central axis 65. In the second subsection 55, the electrical conductor 30 has a second cross-sectional area, and the second cross-sectional area in the second subsection 55 is 6 mm. 2 and 150mm 2 The center of mass of the second subsection 55 and the center of mass of the electrical conductor 30 are located on the second center axis 70. The first center axis 65 and the second center axis 70 are parallel to each other. In this case, the first center axis 65 and the second center axis 70 can be arranged in a common plane. The common plane can be realized as an xz plane. The second center axis 70 can be arranged to deviate from the first center axis 65 by a distance H in the z direction.

[0038] In the second subsection 55, the electrical conductor 30 can have a first, for example substantially circular, outer contour. In the second subsection 55, the cable insulation 25 is concentric with the first outer contour of the electrical conductor 30. The cable insulation 25 has a second outer contour on the outer first circumferential side 60, which second outer contour is for example circular.

[0039] In addition to the first subsection 50 and the second subsection 55, the cable 20 may have, for example, a third subsection 56 and a fourth subsection 57. The third subsection 56 may also be omitted.

[0040] In the third subsection 56 and the fourth subsection 57, as in the first subsection 50, the cable insulation 25 is removed so that the electrical conductor 30 is exposed in the circumferential direction. In the third subsection 56, the electrical conductor 30 has a second cross-sectional area. The third subsection 56 is arranged longitudinally adjacent to the second subsection 55 on the side of the second subsection 55 facing the first subsection 50. On the side facing the first subsection 50, the fourth subsection 57 is arranged directly adjacent to the third subsection 56, and the third subsection 56 connects the fourth subsection 57 to the second subsection 55. In the fourth subsection 57, the electrical conductor 30 tapers from the second cross-sectional area present in the second and third subsections 55, 56 to the first cross-sectional area. The fourth subsection 57 is realized, for example, in the manner of a truncated cone, while the second and third subsections 55, 56 are substantially cylindrical.

[0041] In the second to fourth subsections 55, 56, 57, the strands 45 can abut against each other in the circumferential direction. However, the strands 45 are not connected together by material bonding, but at most by form fit, for example by twisting to form a strand braid 40 or a strand bundle 35. The strand bundle 35 and the individual strands 45 extending in the strand bundle 35 are also held together by the cable insulation 25 in a press-fit and form-fit manner. In the first subsection 50, the strands 45 are at least partially welded together along the circumference. This prevents the strands 45 from loosening from each other in the first subsection 50.

[0042] Furthermore, the electrical resistance of the electrical conductor 30 in the first subsection 50 is particularly low. Furthermore, the electrical conductor 30 in the first subsection 50 is compacted relative to the second subsection 55, which means that for the same number of strands 45, the first cross-sectional area in the first subsection 50 is reduced relative to the second cross-sectional area in the second subsection 55.

[0043] The contact device 15 has a contact housing 75 and at least one contact element 80. The contact element 80 has a terminal portion 85, a contact device 90 and preferably a connecting portion 100. The terminal portion 85 and the connecting portion 100 are integrally formed from a plate-shaped material and are made of the same material. The terminal portion 85 has a terminal surface 95 which is flat and extends in the xy plane. Figure 1 The terminal portion 85 is defined by side surfaces 370 on the side facing the viewer and the side facing away from the viewer, respectively. The side surfaces 370 each extend in a different xz plane. Therefore, the side surfaces 370 are each oriented perpendicularly relative to the terminal surface 95.

[0044] The first subsection 50 is welded, preferably ultrasonically welded, to the terminal portion 85 at the terminal surface 95. Figure 1In the embodiment of the present invention, the connecting part 100 is arranged at an angle to the terminal part 85. In this case, the fixed end 105 of the contact device 90 is attached to the side of the connecting part 100 facing away from the terminal surface 95. The contact device 90 can be a contact pin or a contact socket. The connecting part 100 connects the contact device 90 electrically and mechanically to the terminal part 85.

[0045] The contact housing 75 has, for example, a housing interior 125 in which the contact element 80 is arranged. In the housing interior 125, the contact device 90 extends along the insertion axis 115. The housing interior 125 is open at the contact device 90 in order to insert a socket contact (not shown) of another contact device for contacting the contact device 90 along the insertion axis 115. The insertion axis 115, the first center axis 65 and the second center axis 70 may be arranged in a common xz plane.

[0046] On the side facing away from the contact device 90, the cable 20 in the second subsection 55 is led out of the housing interior 125 of the contact housing 75 through a guide-through device 120 of the contact housing 75. Preferably, a sealing element 130 is arranged in the guide-through device 120. The sealing element 130 can be made of silicone, for example, and can be connected to the contact housing 75, for example, in a material-bonded manner. The sealing element 130 rests circumferentially on a contact surface 131 of the first outer circumferential side 60 of the cable 20 in the second subsection 55 and isolates the housing interior 125 from the environment 135 of the wiring system 10 in a fluid-tight manner. The contact surface 131 is part of the first outer circumferential side 60 and has a cylindrical shape relative to the second center axis 70. In particular, this prevents corrosive media, in particular water, from penetrating into the housing interior 125, thereby preventing corrosion of the contact element 80 and / or the electrical conductor 30, in particular in the first subsection 50.

[0047] The distance H between the first center axis 65 and the second center axis 70 is preferably 0.5 to 15 mm, with a maximum tolerance of ±0.5, preferably ±0.2 mm, in particular ±0.1 mm. The predetermined distance H ensures that the sealing element 130 does not press against the contact surface 131 in the guide-through device 120 on one side, for example on the side facing the terminal surface 95, and is released on the side facing away from the terminal surface 95, and a gap may form between the contact surface 131 and the sealing element 130. Thus, a complete circumferential bearing contact of the sealing element 130 with the first outer circumferential side 60 of the cable insulation 25 is ensured. In addition, a good electrical and mechanical connection between the first subsection 50 and the terminal surface 95 is ensured due to the avoidance of mechanical stresses in the cable 20. This ensures a high fatigue strength of the welded connection between the first subsection 50 and the terminal surface 95, even in the case of high vibrations, such as those occurring in a motor vehicle, for example on uneven road sections. It is particularly advantageous if the first center axis 65 extends parallel to the flat terminal surface 95. The parallelism between the first center axis 65 and the terminal surface 95 preferably has a tolerance between 0° and 1°, preferably between 0° and 0.5°.

[0048] The second center axis 70 is likewise parallel to the terminal surface 95 and is offset in the x direction relative to the terminal surface 95. The second center axis 70 also has a particularly high degree of parallelism relative to the terminal surface 95. The parallelism between the second center axis 70 and the terminal surface 95 preferably has a tolerance of preferably between 0° and 3°, preferably between 0° and 2°.

[0049] In this embodiment, the second subsection 55 extends along the second center axis 70 in the housing interior 125 to the outside of the contact housing 75. Due to the distance H, bending or deflection of the cable 20, in particular of the electrical conductor 30 in the second subsection 55 according to the first embodiment, can be omitted.

[0050] Figure 2 Shows the manufacturing Figure 1 A flow chart of a method of wiring system 10 is shown. Figure 3 A partial side view of the production machine 300 and the wiring system 10 is shown during the first to fifth method steps 205 - 225 . Figure 4 The wiring system 10 and the production machine 300 are shown. Figure 3 A cross-sectional view of section AA is shown. Figure 5 The diagram shows the path along which the wiring system 10 and the production machine 300 are passed during the sixth method step 230. Figure 3 A cross-sectional view of section BB is shown. Figure 6 A longitudinal section through a portion of a production machine 300 during a seventh method step 235 for producing a wiring system 10 is shown.

[0051] Refer to the following Figure 3 The first to fifth method steps 205 to 225 are explained.

[0052] In a first method step 205, a cable 20 and a contact element 80 are provided. The contact element 80 can be connected to, for example, a conveyor belt (not shown). The conveyor belt can be arranged, for example, on one side adjacent to the terminal portion 85. The conveyor belt is used to automatically transport the contact element 80 from a magazine of the production machine 300 to an anvil 305 of the production machine 300. The cable 20 can, for example, be prepared in the first method step 205 for cutting into a certain length.

[0053] In a second method step 210, the production machine 300 removes the cable insulation 25 from the first subsection 50 starting from the free end 140 and, if applicable, also from the third and fourth subsections 56, 57. In the second subsection 55, the cable insulation 25 remains on the electrical conductor 30 and electrically insulates the electrical conductor 30. After removing the cable insulation 25 from the first, third and fourth subsections 50, 56, 57, the electrical conductor 30 is exposed along the circumference. In the second method step 210, the electrical conductor 30 has an original cross-sectional area corresponding to the second cross-sectional area on the subsections 50, 55, 56, 57. The first and second center axes 65, 70 overlap. In addition, on the subsections 50, 55, 56, 57, the first outer contour is identical and, for example, substantially cylindrical.

[0054] Furthermore, in a second method step 210 , the terminal portion 85 may be cleaned in order to remove contaminants from the terminal surface 95 , for example contaminants from the production of the contact element 80 .

[0055] In a third method step 215, the terminal portion 85 of the contact element 80 is positioned on an anvil 305 of the production machine 300. The anvil 305 is arranged, for example, in a fixed position. In this case, the terminal portion 85 lies flat on a planar first pressing surface 315 of the anvil 305, on a side facing away from the terminal surface 95 and which is planar and parallel to the terminal surface 95. The first pressing surface 315 is, for example, planar and extends in the xy plane.

[0056] In a fourth method step 220 following the third method step 215, the first subsection 50 is located at the terminal surface 95. In this embodiment, the positioning is effected such that in the transverse direction (y direction), the first center axis 65 which overlaps with the second center axis 70 in the fourth method step 220 is located relative to the maximum extent b of the terminal section 85 (see Figure 5 ) is centered.

[0057] In a fifth method step 225 (see Figure 3 and4 ), a holding device 320 of the production machine 300 is applied to the second sub-portion 55. The holding device 320 is arranged at a distance from the anvil 305 and the terminal portion 85 in the x-direction.

[0058] Holding device 320 (see Figure 4 ) has a first retaining shell 325 and at least one second retaining shell 330. The first retaining shell 325 can be arranged, for example, on the top side of the second sub-section 55, such as Figure 4 The first retaining shell 325 is preferably annular, for example extending 180° around the second central axis 70. Figure 4 In the embodiment, the second retaining shell 330 is arranged on the lower side of the second subsection 55 and, like the first retaining shell 325, has a partial annular shape, for example extending 180° around the second center axis 70. The number of retaining devices 325, 330 is not fixed. Therefore, the retaining device 320 can also have a larger number of retaining shells 325, 330, such as Figure 4 As shown. It is important that each retaining shell 325, 330 rests flatly with the inner circumferential side 335 on the first outer circumferential side 60 of the second subsection 55. In this case, the cable 20 in the second subsection 55 is preferably surrounded by the retaining shell 325, 330 over its entire circumference. In this case, the inner circumferential side 335 can be realized to correspond to the first outer circumferential side 60. It is particularly advantageous that the retaining shell 325, 330 rests on the contact surface 131 of the second subsection 55 of the cable 20, against which the sealing element 130 rests in the assembled state.

[0059] In a sixth method step 230 following the fifth method step 225, the welding device 341, preferably a sonotrode 345 (see Figure 3 and Figure 5 ) is placed on the first subsection 50, on the side facing away from the terminal section 85. The welding device 341 can also be implemented in different ways. Thus, for example, an electric welding process is also possible.

[0060] The welding device 341 has, on the side facing the terminal portion 85, a second pressing surface 350, which is oriented parallel to the first pressing surface 315 of the anvil 305 and the terminal surface 95. Preferably, the second pressing surface 350 extends in the xy plane.

[0061] In addition, the first clamping jaws 355 (see Figure 5) and a second jaw 360 are preferably arranged on one side of the ultrasonic welding electrode 345 on the terminal portion 85. The first and second jaws 355, 360 each have a holding surface 365 laterally on the side facing the first subsection 50, each holding surface 365 extending, for example, in the yz plane. In this case, the holding surface 365 of the first jaw 355 is arranged parallel to the second jaw 360 arranged opposite the holding surface 365.

[0062] Preferably, the jaws 355, 360 are placed directly on the terminal surface 95 in the z-direction. There may also be a gap between the jaws 355, 360 and the terminal surface 95 in the z-direction, but the gap in the z-direction is preferably narrower than a single diameter of the strands 45 or strand braid 40.

[0063] In a seventh method step 235 following the sixth method step 230 (see Figure 6 ), the first subsection 50 is welded to the terminal surface 95 by a welding process, in particular ultrasonic welding. Ultrasonic welding is achieved by a known ultrasonic welding method. In this case, mechanical vibrations with a frequency in the ultrasonic range are introduced into the first subsection 50 via the ultrasonic welding electrode 345 on the side facing away from the terminal surface 95.

[0064] In addition, the welding device 341 uses the extrusion force F P The sonotrode 345 is pressed against the first subsection 50. The pressing force F P The anvil 305 acts vertically on the first pressing surface 315 and is oriented in the z direction. At the first pressing surface 315, the anvil 305 provides a first reaction force F G1 , which is directed to the extrusion force F P On the contrary. This prevents the terminal portion 85 from deflecting in the z direction. P The second pressing surface 350 is selected so that during welding, in particular during ultrasonic welding, the second pressing surface 350 presses and compresses the first sub-portion 50. In this case, the pressing force F P The compression reduces the cavities between the individual strands 45 so that despite the reduction in the first cross-sectional area, the conductivity in the first subsection 50 and the second subsection 55 is the same.

[0065] The second cross-sectional area, which corresponds to the original cross-sectional area of ​​the first subsection 50 of the electrical conductor 30, is in this case reduced to the first cross-sectional area of ​​the first subsection 50. Furthermore, the first subsection 50 is formed. During the welding process, in particular the ultrasonic welding process, the strands 45 of the electrical conductor 30 in the first subsection 50 are welded together. Due to the compression, the first center axis 65 is displaced from the overlapping arrangement with the second center axis 70 toward the terminal surface 95. The compression force F P and the first reaction force F G1The predetermined distance H is precisely set. Furthermore, within the range of the first sub-portion 50 along the first center axis 65 , the parallelism of the first center axis 65 and the terminal surface 95 may be maintained with a small tolerance of ±0.5 mm, particularly ±0.2 mm, particularly ±0.1 mm.

[0066] In order to limit the lateral deflection of the first subsection 50, during the seventh method step 235, the jaws 355, 360 are arranged on the side of the first subsection 50, in the lateral direction (y direction) inside the side surface 370. The jaws 355, 360 may include a ceramic material or a material on the holding surface 365 that prevents the first subsection 50 from adhering to the jaws 355, 360 during welding.

[0067] During welding, the position of the retaining shells 325, 330 is maintained and remains unchanged throughout the welding process (see Figure 6 ). The first retaining shell 325 provides a second reaction force F G2 , the second retaining shell 330 provides a third reaction force F G3 The second reaction force F G2 and the third reaction force F G3 Preferably, each acts in the z direction. In this case, the third reaction force F G3 Directional extrusion force F P , and prevents the second subsection 55 from shifting in the z direction. This ensures that when the first subsection 50 is compressed, the first subsection 50 is arranged eccentrically relative to the second center axis 70 after compression, so that the first center axis 65 has a predetermined distance H between the first center axis 65 and the second center axis 70.

[0068] Depend on Figure 6 The second reaction force F provided by the first retaining shell 325 arranged at the top G2 Parallel to the extrusion force F P The second sub-portion 55 is prevented from bending upward in the z direction during the compression of the first sub-portion 50. The cylindrical shape of the second sub-portion 55 during the compression process is thereby ensured. In addition, the third and fourth sub-portions 56, 57 are realized during the compression and welding process. In this case, the third sub-portion 56 is formed in a truncated cone shape, and its third center axis 375 is inclined at a certain angle relative to the first and second center axes 65, 70 and intersects with the first and second center axes 65, 70.

[0069] After the end position of the second pressing surface 350 has been obtained and after the first subsection 50 has been finish welded to the terminal section 85, in an eighth method step 240, the second pressing surface 350 is removed from the first subsection 50. Furthermore, the jaws 355, 360 are removed laterally in the y-direction from the first subsection 50. After the second pressing surface 350 and the jaws 355, 360 have been removed, the retaining shells 325, 330 are removed. The advantage of subsequently removing the retaining shells 325, 330 is that the retaining shells 325, 330 can support the release forces during the removal of the jaws 355, 360 and / or the sonotrode 345.

[0070] In a ninth method step 245 following the eighth method step 240 , the wiring system 10 with the soldered contact element 80 is installed in the contact housing 75 .

[0071] The advantage of the method described above is that the distance H can be set in a defined manner independently of the layout of the strands 45, so that after the wiring system 10 has been installed in the contact housing 75, the sealing element 130 bears against the cable insulation 25 in a completely circumferential contact manner, thereby ensuring a reliable sealing of the housing interior 125 from the environment 135. In addition, the time-consuming setting up of the production machine 300 after the batch replacement of the cables 20 can be omitted. As a result, the wiring system 10 can be manufactured particularly economically.

[0072] exist Figure 3 In a development of the method described, during compression and welding of the first subsection 50, the anvil 305 can be moved together with the second pressing surface 350 in the z direction in order to set a particularly large distance H of the first subsection 50 with the first center axis 65 relative to the second subsection 55. In particular, since the distance H in the z direction is established during compression and welding, it is possible to dispense with deflection of the cable 20. Furthermore, additional deflection, bending, etc. of the cable 20 in the contact housing 75 can be dispensed with.

[0073] Figure 7 A longitudinal section of a production machine 300 is shown which carries out the method of manufacturing a wiring system 10 according to the second embodiment.

[0074] This method and Figure 3 The method explained in is basically the same. In the following, we will only discuss Figure 7 The methods explained in Figure 3 The retaining shells 325, 330 are located at the third subsection 56. It is particularly advantageous that the first and second retaining shells 325, 330 are positioned on the electrical conductor 30 directly adjacent to the axial end of the cable insulation 25 and surround the electrical conductor 30 with the inner circumferential side 335.

[0075] Figure 8During the seventh method step 235, the Figure 3 A cross-sectional view of section AA is shown.

[0076] In this case, during the seventh method step 235, the inner circumferential side 335 of the shell 325, 330 is held against the third subsection 56 and provides the second and third reaction forces F G2 、F G3 , which is introduced directly into the electrical conductor 30. Figure 3 In comparison, the advantage of this design is that bending of the third subsection 56 during compression of the first subsection 50 is avoided.

[0077] Fig. 9 A schematic diagram of a wiring system 10 of a motor vehicle or a charging station for charging a motor vehicle according to a second embodiment is shown.

[0078] Fig. 9 The second embodiment of the wiring system 10 shown is Figure 1 The first wiring system 10 explained in FIG. 1 is substantially the same. In the following, only Fig. 9 The wiring system 10 shown and Figure 1 The difference between the wiring systems 10 shown is that, for example, the second to fourth subsections 55 to 57 are bent at a predetermined angle α relative to the first subsection 50. The angle α is preferably an obtuse angle. In particular, the angle α has a value from 125° to 180°.

[0079] The first center axis 65 and the second center axis 70 are also arranged at an angle α. The first center axis 65 and the second center axis 70 are arranged in a common plane 145 which is inclined relative to the terminal surface 95, preferably perpendicularly inclined.

[0080] To manufacture Fig. 9 The wiring system 10 shown can be used Figure 2 . In addition, in a sixth method step 230, the electrical conductor is bent in the third and fourth subsections 56, 57 so that the second subsection 55 is arranged at an angle α relative to the first subsection 50. The bending can be achieved, for example, by moving the holding device 320 relative to the anvil 305 and the ultrasonic welding electrode 345. In order to obtain the predetermined angle α, the second subsection 55 can also be bent relative to the first subsection 50 during the bending of the cable 20. When welding the first subsection 50, the holding device 320 keeps the second subsection 55 tilted. The advantage of this method is that after performing the method, the second subsection 55 is accurately aligned at the predetermined angle α.

[0081] Reference numerals list

[0082] 10 Wiring System

[0083] 15 Contact device

[0084] 20 Cables

[0085] 25 Cable insulation

[0086] 30 Electrical conductors

[0087] 35 Twisted wire harness, electrical conductor

[0088] 40 strands braid

[0089] 45 stranded wire

[0090] 50 First subsection

[0091] 55 Second subsection

[0092] 56 Third subsection

[0093] 57 Fourth Subsection

[0094] 60 first outer circumferential side

[0095] 65 First Central Axis

[0096] 70 Second central axis

[0097] 75 contact housing

[0098] 80 contact elements

[0099] 85 Terminal part

[0100] 90 contact pin

[0101] 95 terminal surface

[0102] 100 connection parts

[0103] 105 fixed end

[0104] 110 contact receiver

[0105] 115 Insert axis

[0106] 120 Guide through device

[0107] 125 Shell interior

[0108] 130 Sealing element

[0109] 135 Environment

[0110] 140 free end

[0111] 205 First Method Step

[0112] 210 Second method step

[0113] 215 The third method step

[0114] 220 Fourth Method Step

[0115] 225 Fifth Method Step

[0116] 230 Sixth Method Step

[0117] 235 Seventh Method Step

[0118] 240 Eighth Method Step

[0119] 245 Ninth Method Step

[0120] 300 production machines

[0121] 305 anvil

[0122] 310 Another contact surface

[0123] 315 first pressing surface (of anvil)

[0124] 320 holding device

[0125] 325 first retaining shell

[0126] 330 Second retaining shell

[0127] 335 inner circumference side

[0128] 340 second outer circumference side

[0129] 341 welding device

[0130] 345 Ultrasonic welding electrode

[0131] 350 second extrusion surface

[0132] 355 first jaw

[0133] 360 second gripper

[0134] 365 Keep Surface

[0135] 370 side surface

[0136] 375 The third central axis

[0137] H distance

[0138] F P Extrusion force

[0139] F G1 First reaction force

[0140] F G2 The second reaction force

[0141] F G3The third reaction force

Claims

1. A method of manufacturing a wiring system (10) for transmitting electric power in an electric vehicle or a charging station for an electric vehicle, - providing a cable (20) having at least one electrical conductor (30) and a contact element (80) having a terminal portion (85), - the cable insulation (25) is removed in a first subsection (50) of the cable (20), and the cable insulation (25) remains on the electrical conductor (30) in a second subsection (55) of the cable (20) arranged to be offset from the first subsection (50), wherein the first subsection (50) and the second subsection (55) have an original cross-sectional area corresponding to the second cross-sectional area, in the first subsection (50) of the cable (20), the electrical conductor (30) extends along a first central axis (65), and in the second subsection (55) of the cable (20), the electrical conductor (30) extends along a second central axis (70), wherein the first central axis (65) coincides with the second central axis (70); - the electrical conductor (30) is welded to the terminal surface (95) of the terminal portion (85) via the first sub-portion (50), - during welding, the first subsection (50) is pressed against the terminal section (85), the electrical conductor (30) is compressed in the first subsection (50), so that the first cross-sectional area of ​​the first subsection (50) is smaller than the original cross-sectional area, - wherein the holding device (320) surrounds the second subsection (55) over its entire circumference, - the retaining device (320) supports the second subsection (55) and maintains the position of the second subsection (55) at least during compression and welding of the first subsection (50), the sealing element (130) circumferentially abuts against a contact surface (131) of a first outer circumferential side (60) of the cable (20) in the second subsection (55) so as to isolate the housing interior (125) from the environment (135) of the wiring system (10) in a fluid-tight manner, in, The terminal portion (85) of the contact element (80) is positioned on the anvil (305), and during compression and welding of the first sub-portion (50), the anvil (305) is moved in the z direction so that a distance (H) is formed between the first center axis (65) and the second center axis (70).

2. The method according to claim 1, The first sub-portion (50) is extruded such that the first central axis (65) is oriented parallel to the terminal surface (95).

3. The method according to claim 1, The first subsection (50) is bent relative to the second subsection (55) such that the first subsection (50) and the second subsection (55) are arranged at a predetermined angle (α) relative to each other.

4. The method according to any one of the preceding claims, In the region of the contact surface (131) for the sealing element (130), the retaining device (320) surrounds the second subsection (55) so that the outer contour of the second subsection (55) remains unchanged throughout the compression and welding process.

5. The method according to any one of the preceding claims, - a sonotrode (345) is applied to the first subsection (50) on the side facing away from the terminal surface (95), - the sonotrode (345) introduces a pressing force (FP) into the first sub-portion (50) which acts in the direction of the terminal surface (95), - The first sub-portion (50) is supported in a transversely inclined manner relative to the terminal surface (95).

6. The method according to any one of the preceding claims, -Original cross-sectional area is 6mm 2 Up to 150mm 2 .

7. A wiring system (10) for high current transmission in a motor vehicle or a charging station, produced according to the method of any of the preceding claims, - a contact device (15) having a cable (20) and having at least one contact element (80), - the cable (20) has a stranded electrical conductor (30) and a cable insulation (25), - the contact element (80) has a plate-like terminal portion (85), - in a first subsection (50) of the cable (20), the electrical conductor (30) is welded, in particular ultrasonically welded, to the terminal section (85), and the cable insulation (25) at least partially covers the electrical conductor (30) in a second subsection (55) of the cable (20) arranged offset from the first subsection (50), - in the first subsection (50), the electrical conductor (30) extends along a first central axis (65), and in the second subsection (55), the electrical conductor (30) extends along a second central axis (70), - the retaining device (320) surrounds the second subsection (55) over its entire circumference and the retaining device (320) supports the second subsection (55) and maintains the position of the second subsection (55) at least during compression and welding of the first subsection (50), the sealing element (130) circumferentially abuts against a contact surface (131) of a first outer circumferential side (60) of the cable (20) in the second subsection (55) in order to isolate the housing interior (125) from the environment (135) of the wiring system (10) in a fluid-tight manner, The first center axis (65) is arranged to deviate from the second center axis (70) towards the terminal portion (85) by a predetermined distance (H) and / or a predetermined angle (α).

8. The wiring system (10) according to claim 7, - the electrical conductor (30) has a first cross-sectional area in the first subsection (50), - the electrical conductor (30) has a second cross-sectional area in the second subsection (55), The first cross-sectional area is smaller than the second cross-sectional area.

9. The wiring system (10) according to any one of claims 7 or 8, The first subsection (50) is arranged eccentrically relative to the second center axis (70) of the second subsection (55).

10. The wiring system (10) according to any one of claims 7 to 9, - the first central axis (65) is aligned parallel to the terminal portion (85), The parallelism between the terminal portion (85) and the first center axis (65) has a tolerance of ±0.5 mm, in particular ±0.2 mm, in particular ±0.1 mm over the extent of the first sub-portion (50).

11. The wiring system (10) according to any one of claims 7 to 10, - the first center axis (65) and the second center axis (70) are arranged in a common plane, - The common plane is inclined relative to the terminal surface (95), preferably oriented vertically.

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