Device for automated establishment of a plug connection

Abstract

The invention relates to a device for automated establishing of a plug connection of a plug provided on a cable with a plug mating element, in particular for wiring of a battery module, in particular in the manufacture of a vehicle having a hybrid drive and / or an electric drive, comprising a first gripper for gripping the plug, an operating unit having a plurality of axes for moving the gripper, wherein the operating unit is in particular a multi-axis robot and / or a regional gantry, and a controller for controlling the first gripper and the operating unit. It is proposed that the device comprises at least one second gripper for gripping the cable or a second plug provided on the other end of the cable.

Description

Technical Field

[0001] The present invention relates to a device for automatically establishing a plug-in connection between a plug and a plug mating element disposed on a cable; and a clamp that can be used in such a device. Background Technology

[0002] Document DE 10 2017 217601 A1 illustrates a method for inserting an electrical plug using a gripper mounted on a robot. Here, the plug is first moved upwards onto a socket, causing it to mechanically contact the socket, and the associated plug position is determined by the plug's search movement in a search plane transverse to its direction. However, due to the mechanical load on the plug and socket, this solution is only feasible for specific plugs and sockets. Furthermore, the solution is time-consuming and complex.

[0003] A charging station for charging electric vehicles is known from document US 2015 / 0210174 A1, in which the plug of the charging cable is automatically connected to the charging socket by means of a robot. Summary of the Invention

[0004] The purpose of this invention is to provide an improved device for automatically establishing a plug-in connection between a plug and a plug mating element mounted on a cable.

[0005] This objective is achieved by the device according to the invention. Preferred embodiments of the invention are the subject of the following discussion.

[0006] In a first aspect, the invention includes apparatus for automating the establishment of a plug-and-plug mating connection on a cable, comprising: a clamp for holding the plug; and an operating unit having multiple axes for moving the clamp. It is proposed that the apparatus includes at least one second clamp for holding the cable or a second plug disposed at the other end of the cable. Longer cables with plugs and / or cables with plugs at both ends can also be mounted using additional clamps.

[0007] Operating units, especially multi-axis robots and / or area gantry cranes.

[0008] The device according to the invention is particularly useful for the automated wiring of battery modules, especially in the manufacture of vehicles with hybrid drive and / or electric drive.

[0009] The controller of the device according to the invention is preferably programmed in such a way that the method described below for establishing the plug-to-plug mating connection is executed automatically. With regard to the use of the operating unit and / or these clamps described below, unless otherwise stated, this is always accomplished by the corresponding manipulation of the controller, which is programmed accordingly for this purpose.

[0010] In one possible embodiment of the invention, the second clamp is disposed on a second operating unit having multiple axes.

[0011] The second operating unit is especially a multi-axis robot and / or a regional gantry crane.

[0012] In one possible embodiment of the invention, the first and second clamps can move together via at least one and preferably multiple motion axes of the operating unit.

[0013] In one possible embodiment of the invention, a first clamp is mounted on a common support element via a first operating unit and a second clamp via a second operating unit, the support element being movable via a third operating unit. In particular, the third operating unit can be used for coarse positioning of the two clamps, while the first and second operating units are used for fine positioning.

[0014] In one possible embodiment of the present invention, the movement space of the first operating unit and the second operating unit is smaller than the movement space of the third operating unit.

[0015] In one possible embodiment of the invention, the first and second operating units are area gantry cranes and / or space gantry cranes. The third operating unit may also be an area gantry crane and / or a space gantry crane. Preferably, the longest travel distance of the motion axis of the first and second operating units is shorter than the longest travel distance of the motion axis of the third operating unit, and more preferably, it is shorter than the shortest travel distance of the motion axis of the third operating unit.

[0016] In one possible embodiment of the invention, the second clamp is connected to the clamp via at least one motion axis.

[0017] In particular, a first clamp may be mounted on a carrier element, on which a second clamp is movably mounted via a motion axis. The carrier element is preferably moved by an operating unit.

[0018] In one possible embodiment of the invention, the motion axis is a linear axis.

[0019] Preferably, the linear axis is oriented in a plane perpendicular to the insertion direction and / or parallel to the direction of the cable guided away from the plug along a straight line.

[0020] In one possible embodiment of the invention, the controller is configured such that the second clamp holds the cable to position the cable during and / or after plugging in the connector.

[0021] In one possible embodiment of the invention, the cable is bent at the point where it exits the second clamp.

[0022] In one possible embodiment of the invention, it is preferred to provide two first clamps for clamping two plugs disposed on the cable, and two second clamps for clamping the cable and bending the cable by means of the second clamps.

[0023] In one possible embodiment of the invention, the second clamp has two clamping elements, particularly jaws, that clamp a cable between the two clamping elements, wherein at least one of the clamping elements has a curved side edge and the cable extends on the clamping element.

[0024] In one possible embodiment of the invention, the clamping element has a length of at least 2 cm, and preferably at least 3 cm, along the cable direction. Alternatively or additionally, two second clamps are provided along the cable between the bend and the plug.

[0025] This keeps the load caused by bending on the cable away from the plug.

[0026] In one possible embodiment of the invention, the clamping element is formed by a roller.

[0027] In one possible embodiment of the invention, the roller is rotatably mounted. In one possible design, the rotatability of at least one roller can be prevented, particularly by means of an actuator that secures the roller.

[0028] In one possible embodiment of the invention, the roller has a lower engagement portion for the cable on its outer circumference. The lower engagement portion may be configured, for example, as a protruding edge and / or formed by the sidewall of a groove surrounding the outer circumference of the roller, by means of which the cable is at least partially wrapped and clamped.

[0029] The second clamp can be connected to one of the first clamps via a motion axis and / or move together with the first clamp via a common operating unit, as described above.

[0030] In one possible embodiment of the invention, the second clamp has a pressing element for pressing the cable into the receiving portion.

[0031] In one possible embodiment of the invention, the press-in element is movably mounted on the second clamp via an actuator.

[0032] In one possible embodiment of the invention, the clamping element of the second clamp is configured as a guide element by means of which the second clamp can be moved along the cable to guide the cable along a defined path. The guide element may be rotatably mounted and roll along the cable.

[0033] In one possible embodiment of the invention, the second clamp has a pressing element, which is preferably rotatably mounted on the clamp and rolls on the cable.

[0034] In one possible embodiment of the invention, the press-in element can be moved between the clamping elements of the clamp by an actuator in order to remove the cable from the clamping elements into the press-in receptacle.

[0035] In one possible embodiment of the invention, the pressing element may be disposed behind the clamping element of the clamp along the direction of movement so as to press the cable into the receiving portion after it leaves the clamping element.

[0036] In one possible embodiment of the invention, the device includes two clamps for holding and inserting plugs disposed at both ends of a cable.

[0037] Preferably, the device further includes at least one additional clamp for holding the cable.

[0038] In one possible embodiment of the invention, the first clamp includes a plug actuator for moving the plug into a plug-in position with a plug mating element.

[0039] In one possible embodiment of the invention, the plug-in actuator is a linear actuator. For example, the plug-in actuator may be a pneumatic cylinder and / or an electromechanical linear actuator.

[0040] In one possible embodiment of the invention, the first clamp is a mechanical clamp for holding the plug.

[0041] The clamp preferably includes at least two mechanical clamping elements that can be moved relative to each other via actuators, the mechanical clamping elements being particularly jaws and / or fingers.

[0042] The motion axis of the plug-in actuator is preferably perpendicular to the motion axis of the clamping element.

[0043] In one possible embodiment of the invention, the plug actuator moves the plug via a pushing element to move it into a final plugged position. In another possible embodiment, the pushing element may be a clamping element of a clamp. However, in a preferred embodiment, the pushing element is a separate element from the clamping element.

[0044] In one possible embodiment of the invention, the pushing element presses against the upper side of the plug. In another possible embodiment of the invention, the pushing element is positioned above a receiving area for the plug disposed between the gripping elements.

[0045] In one possible design of the invention, the controller is configured to operate the first clamp such that the clamp's grip is released or released before the plug actuator moves the plug into the final plug position by means of a pushing element. Here, the clamp's grip can be released or released before the pushing element moves the plug, or at least before the plug has been moved into the final plug position.

[0046] In one possible design of the invention, the controller is configured to operate the operating unit to move the plug to an engagement position with the plug mating element, and to operate the plug actuator to move the plug to a final plug-in position with the plug mating element when the operating unit is fixed.

[0047] In one possible embodiment of the invention, the first clamp includes a compensation unit that allows for compensated movement of the clamp relative to the operating unit at least in one operating state.

[0048] In one possible embodiment of the invention, the compensation unit includes one or more springs, and the clamp can overcome the lateral and / or axial deflection of the preload of the springs.

[0049] In one possible embodiment of the invention, the compensation unit can switch from a first operating state to a second operating state. In the first operating state, the compensation unit allows the clamp to move relative to the operating unit in a compensating manner, while in the second operating state, the clamp is rigidly mounted on the operating unit.

[0050] Here, the plug-in actuator is preferably disposed on the base of the first clamp, which is connected to the end member of the operating unit via a compensation unit.

[0051] In one possible embodiment of the invention, the first clamp includes a locking device for locking the plug and / or the plug mating element. In another possible embodiment, the locking device includes a contact element for engaging the locking element in the plug insertion position. Furthermore, the clamp preferably includes an actuator for moving the contact element relative to the plug.

[0052] In one possible embodiment of the invention, a plug actuator is used to move a contact element relative to a plug. For this purpose, a push element for moving the plug is movably and more preferably resiliently connected to the plug actuator, thereby allowing the plug actuator to move further after the plug has been moved into the plugged position, by which the contact element moves against a locking element.

[0053] The contact element is preferably movably connected to the plug actuator and is preferably preloaded in the plugging direction via a spring. Thus, the spring transmits the force used to lock the locking element to the contact element.

[0054] In one possible embodiment of the invention, the end position of the plug actuator is identified via a sensor. Once the end position where the locking element is locked is reached, the movement of the plug actuator preferably stops. In one possible design, the sensor can detect proximity between the sensor and the actuating element.

[0055] In an alternative design, the fixture may have an additional actuator for moving the contact element.

[0056] In one possible embodiment of the invention, the terminal position of the actuator for moving the contact element is identified via a sensor. Preferably, the movement of the actuator stops once the terminal position where the locking element is locked is reached.

[0057] In one possible embodiment of the invention, the first clamp includes an orienting element that can abut against at least one side of the plug mating element to orient the plug relative to the plug mating element. In another possible design of the invention, the device is configured such that the orienting element abuts against a side surface of the plug mating element.

[0058] In one possible embodiment of the invention, the orientation element and the plug held by means of the clamping element can be moved relative to each other by means of the actuator of the clamp to orient the plug toward the plug mating element. Orientation is therefore performed not by, or at least not only by, movement of the operating unit.

[0059] In one possible embodiment of the invention, the clamp includes at least two orientation elements that surround a plug mating element located on opposite sides and can be moved toward each other via at least one actuator to orient the plug relative to the plug mating element.

[0060] In one possible embodiment of the invention, the orientation element clamps the plug mating element. In another possible embodiment of the invention, the plug is oriented by orienting the clamp.

[0061] In one possible embodiment of the invention, the controller is configured such that the plug enters an engagement position with a plug mating element, while at least one directional element contacts the plug mating element and preferably clamps the plug mating element. When at least one directional element contacts the plug mating element and preferably clamps the plug mating element, the plug is preferably also moved to a final insertion position.

[0062] In one possible embodiment of the invention, the orientation element is movably mounted on the fixture by an actuator, and the orientation element is moved relative to the operating unit.

[0063] In a preferred design, the orientation element is movably mounted on the fixture by an actuator and moves relative to the operating unit, wherein this movement is achieved by a compensation unit disposed between the fixture and the operating unit, the compensation unit deflecting the orientation element to orient the fixture.

[0064] In one possible embodiment of the invention, the device includes a camera for detecting the position of a plug mating element, wherein the camera is preferably mounted on a clamp, and wherein the controller is preferably configured such that a plug housed on the clamp moves to an insertion position in front of the plug mating element based on the detected position.

[0065] In one possible design of the invention, the camera is mounted on the clamp, wherein the controller is preferably configured such that the camera first moves to a measuring position in front of the plug mating element to detect the position of the plug mating element, and then moves the plug contained on the clamp to the insertion position by repositioning the first clamp.

[0066] In one possible design of the invention, position detection is used to determine the offset between the actual and expected positions of the plug mating element, and the position of the clamp for inserting the plug is corrected accordingly.

[0067] In one possible embodiment of the invention, the position of the plug mating element is detected and / or the plug is moved to the insertion position by means of a rigidly connected compensation element and the plug is moved to the insertion position by means of a plug actuator together with a flexibly connected compensation unit.

[0068] The invention also includes a clamp for the above-described device, wherein a second clamp is involved for clamping the cable.

[0069] In particular, the second clamp here includes a pressing element for pressing the cable into the receiving portion.

[0070] Alternatively or additionally, the second clamp can be combined with the first clamp. In particular, the two clamps can be connected to each other via a motion axis.

[0071] One or more clamps may be configured herein as described above with respect to the device according to the invention.

[0072] In particular, the second clamp may include a roller as a clamping element, as described above.

[0073] The present invention also includes a method for automatically establishing a plug-in connection between a plug and a plug mating element disposed on a cable by means of one of the devices described above, wherein two plugs disposed at the ends of the cable are held and plugged in by first and second clamps, and / or wherein the plugs are held and plugged in by the first clamp and the cable is held and positioned by the second clamp.

[0074] The method is preferably performed as described above.

[0075] This method is particularly useful for wiring battery modules, especially in vehicles with hybrid and / or electric drives.

[0076] In particular, this allows for the installation of cables that serve as module connectors for connecting battery modules. Attached Figure Description

[0077] The present invention will now be described in detail with reference to embodiments and accompanying drawings.

[0078] This is shown here:

[0079] Figure 1 A first embodiment of the device for automating the establishment of plug-in connections according to the present invention is shown;

[0080] Figure 2 A first embodiment of the clamp according to the invention is shown;

[0081] Figure 3 Shown in Figure 2 The three-dimensional view and cross-sectional view of the fixture shown;

[0082] Figure 4 A second embodiment of the clamp according to the invention is shown;

[0083] Figure 5 Shown in Figure 4 A perspective view of the second embodiment shown;

[0084] Figure 6a and 6b Show Figure 4 and 5 The sectional view and front view of the second embodiment shown;

[0085] Figure 7 A second embodiment of the device according to the invention for automating the establishment of plug-in connections is shown;

[0086] Figure 8 Shown in Figure 7 A detailed view of the operating unit used in the second embodiment of the device shown;

[0087] Figure 9A third embodiment of the device according to the invention is shown;

[0088] Figure 10 A fourth embodiment of the device according to the invention is shown;

[0089] Figure 11 shows the cable positioning process. Figure 10 A detailed view of the device shown;

[0090] Figure 12 A third embodiment of the clamp according to the invention is shown, as in the embodiment according to Figure 10 and 11 As used in embodiments of the device;

[0091] Figure 13 It has been shown that Figure 1 Detailed views of a first embodiment of the device according to the present invention are shown below;

[0092] Figure 14 A fourth embodiment of the clamp according to the invention is shown;

[0093] Figure 15 A fifth embodiment of the clamp according to the invention is shown; and

[0094] Figure 16 A third alternative embodiment of the clamp according to the invention is shown, as in its application to the device. Figure 10 and 11 As used in the embodiments. Detailed Implementation

[0095] Embodiments of the invention are described in more detail below, which partially combine various aspects of the invention. However, the aspects shown in combination in these embodiments can also be used individually.

[0096] Figure 1 A first embodiment of the device according to the invention is shown, which is used to automatically establish a plug-in connection between the plug 10 and the plug mating element 15.

[0097] Figure 1 The embodiment of the device according to the invention shown is used for wiring of battery module 1, particularly in the manufacture of vehicles with hybrid drive and / or electric drive. In this case, multiple battery modules are typically mounted on a carrier structure 2 and each has a plug-fitting element, for example in the form of a power strip or plug socket, via which the battery modules are connected to each other and / or to a controller. The carrier structure 2 may be, for example, part of the chassis of the corresponding vehicle, or a carrier device mounted on such a chassis.

[0098] Until now, the wiring of such battery modules has been done manually because no equipment is available for automating the establishment of plug-in connections. The present invention now provides such a device, by which plug-in connections, particularly in battery modules, can be established automatically.

[0099] In particular, the use of the present invention is within the scope of manufacturing vehicles with hybrid drive and / or electric drive. The carrier device 2 on which the module 1 is mounted can be transported via a transport device 3 to the device according to the invention to establish a plug-in connection. The device according to the invention can be part of a production line for manufacturing vehicles.

[0100] The device according to the invention can be used in possible applications of installing cables, wherein plugs are provided at both ends of the cable, and the plugs are connected to plug mating elements by means of the device according to the invention.

[0101] However, in alternative designs, one end of the cable may already be electrically connected.

[0102] In one possible design, the device according to the invention is configured such that its controller is programmed to sequentially install multiple cables onto the battery cell of the same vehicle. Preferably, cables of different lengths and / or with different cable routes can be installed.

[0103] In one possible design of the invention, multiple devices according to the invention can be sequentially arranged in a production line, wherein in one possible design, the cable installed on the first device is shorter than that of the second device.

[0104] The above-mentioned uses for wiring battery modules are not only in Figure 1 The first embodiment of the device according to the invention shown is possible; conversely, all embodiments of the invention can be configured and used for this purpose. However, the device according to the invention can also be used in other areas of industrial production, particularly as part of a production line, to establish electrical connections by means of plug-in connections.

[0105] The device according to the invention is as follows: Figure 1 The device shown has at least one clamp 30 for holding the plug 10, an operating unit 20 to 23 with multiple axes for moving at least one clamp 30, and a controller 50 for manipulating the clamp 30 and the operating units 20 to 23.

[0106] exist Figure 1In the illustrated embodiments, the operating units used are multi-axis robots with multiple rotational axes, particularly six-axis industrial robots. In alternative designs also described below, area gantry cranes with multiple linear axes can be used instead of or additionally applied to such multi-axis robots. Operating units 20 to 23 can be mounted on the support frame 5, such as... Figure 1 As shown.

[0107] The controller 50 of the device according to the invention is programmed such that the methods described within the scope of this application for establishing plug-to-plug mating connections are all executed in an automated manner. In particular, the entire installation of the cable and plug is performed automatically.

[0108] Only Figure 1 The controller schematically shown may have a microprocessor and program code stored in memory, wherein the program code running on the microprocessor accordingly manipulates the operating unit and the fixture. For the purposes of describing how the operating unit and / or fixture are used in the context of this application, this is always done by the corresponding manipulation of the controller 50—unless otherwise stated—by programming the controller 50 accordingly for this purpose.

[0109] The following describes it in more detail. Figure 1 The device shown is characterized according to the invention. However, an embodiment of a clamp for holding a plug according to the invention will be described first: Figure 2 and 3 A first embodiment of a clamp for holding a plug according to the present invention is shown here. Figures 4 to 6b The second embodiment is shown.

[0110] The clamps are used to hold the plug 10, which is pushed into the plug mating element 15 in the form of a power strip. The plug 10 is mounted on the cable 11 and establishes an electrical connection between the cable 11 and the plug mating element 15.

[0111] In one embodiment, the plug 10 has a locking element 13 that is mechanically operable and locks the plug in the plugged position. For this purpose, the locking element 13 can cooperate with a mating element 16 of the plug mating element, which may be, for example, a locking protrusion. However, the clamp according to the invention can also be used to insert the plug without the aid of a locking element.

[0112] In a first aspect of the invention, the movement of pushing the plug into the insertion position with the plug mating element 15 is performed not only by the operating unit 20, but also at least in part by the insertion actuator 36 of the corresponding clamp. Using this insertion actuator 36, which can also be referred to as an engagement actuator, allows the clamp according to the invention to establish a mating connection between the plug and the plug mating element more efficiently and with less load.

[0113] The plug actuator, particularly a linear actuator, moves the plug into a plug-in position with the plug mating element 15. In particular, the plug actuator 36 can press the plug 10 against the end stop of the plug mating element 15 to engage the plug connection.

[0114] In this embodiment, the axis of motion of the plug actuator 36 extends perpendicular to the axis of motion of the gripper 33. Furthermore, the axis of motion of the plug actuator 36 is perpendicular to the plane defined by the upper side of the plug 10 or the contact surface of the push element 37. Additionally, the axis of motion of the plug actuator 36 extends in the plug insertion direction.

[0115] In this embodiment, the actuators 36 are pneumatic cylinders. However, any other actuators, especially any other linear actuators, such as electromechanical or hydraulic actuators, are also conceivable.

[0116] To hold the plug 10, the clamp has one or more clamping elements 33 via which the plug 10 is held. The clamp can be, for example, mechanical, pneumatic, and / or magnetic. In one possible embodiment of the invention, the clamp is a suction clamp and / or an adaptive forming clamp. In the illustrated embodiment, the clamp is a mechanical clamp. Accordingly, mechanical clamping elements are used, particularly two jaws that can be moved toward each other by means of an actuator to hold the plug. However, in an alternative design, other clamps, such as pneumatic clamps, can also be used.

[0117] In this embodiment, the plug actuator 36 for moving the plug is not acted on the plug 10 by the clamping element 33, but rather by moving the pushing element 37, which presses against the upper side of the plug 10 and pushes the plug into the plugged position.

[0118] In one embodiment, the clamp is manipulated such that the clamping element 33 releases or loosens its grip on the plug before the plug actuator has moved the plug into the plug position.

[0119] exist Figure 2 and 3 In the first embodiment shown, the plug actuator 36 causes the push element 37 to move relative to the clamping element 33 of the fixture. In this embodiment, the plug actuator acts between the base of the fixture and the push element 37 such that movement of the plug actuator 36 does not cause any movement of the clamping element 33, which is also disposed on the base.

[0120] And in Figures 4 to 6bIn the second embodiment shown, the insertion actuator 36 moves the clamping element 33 and the pushing element 37 of the clamp. However, the plug is pushed into the final insertion position by the pushing element 37, while the clamping element 33 moves only with the plug.

[0121] However, in an alternative design, it is conceivable that the plug actuator moves the clamping element so as to move the plug housed in the clamping element into the plugging position by means of the clamping element.

[0122] In this embodiment, the controller 50 is configured to operate an operating unit to move the plug to an engagement position with the plug mating element 15. The operating unit then stops moving and instead operates a plug actuator to move the plug to its final insertion position with the plug mating element 15 while the operating unit remains stationary. Therefore, the operating unit is only used to engage the plug with the plug mating element; the actual insertion process is then performed via the plug actuator 36.

[0123] As shown above, after the plug enters the engagement position, the clamp is released or released, and then the pusher pushes the plug into the final engagement position.

[0124] In one embodiment, each clamp has a mounting element 31, by means of which the clamp is mounted on the end member of the operating unit. Figure 4 As can be seen from this, this could be a flange plate.

[0125] The plug-in actuator 36 is disposed on the fixture such that it can move the components of the fixture, particularly the pushing element 37 and / or the clamping element 33 of the fixture, relative to the mounting element 31, thereby moving them relative to the end member of the operating unit.

[0126] In another aspect of the invention, which is also part of the invention regardless of the use of a plug-in actuator, an embodiment of the clamp according to the invention includes a compensation unit 32 that, in at least one operating state, allows offset movement of the clamp relative to the mounting element 31, thereby operating the end member of the unit.

[0127] In both embodiments, the plug is inserted into the final insertion position with the compensation unit in a state in which the compensation unit can perform compensating movement. This removes stress that would otherwise be transmitted to the plug by the operating unit.

[0128] In one possible design, the compensation unit 32 can be switchable, and particularly switchable from a first operating state to a second operating state, in which the compensation unit allows compensating movement of the clamp relative to the operating unit, and in the second operating state the clamp is rigidly mounted on the operating unit. In an alternative design of the invention, the compensation unit can also always be in the first operating state, which allows compensating movement.

[0129] The compensation unit 32 may have one or more springs, and the clamp may deflect laterally or axially against the preload of the springs.

[0130] The compensation unit may be configured, for example, as referenced in the same applicant's publication document EP 2 679 354 A2. Figures 16 to 2 As described in 2.

[0131] Switchability can be provided pneumatically, for example, by pneumatically generating a holding force to secure the switching unit, thereby fixing the clamp relative to the mounting element 31.

[0132] In another aspect of the invention, it can also be used independently of the aspects described herein, wherein the clamp includes a locking device for locking the locking element 13 for locking the plug 10.

[0133] In this embodiment, a contact element 38 is provided for this purpose, which contacts the locking element 13 in the plug-in position of the plug 10 and moves the locking element into the locking position.

[0134] In both embodiments, the contact element 38 can be moved via the actuator of the clamp. Linear actuators are involved in both cases. Here, a plug-in actuator 36 or a separate additional actuator 35 can be used as the actuator.

[0135] In either of these two embodiments, the means for moving the contact element 38 is configured such that the contact element can be moved relative to the push element 37, by means of which the plug is pushed into the insertion position to manipulate the locking element 13 of the plug.

[0136] Because the two implementations of the clamp are used in the industrial assembly of cables and plugs respectively, the position of the plug mating element is predetermined by the geometry of the device into which the plug is to be inserted, i.e., known for example by the position and arrangement of the battery module. However, in industrial production, tolerances result in a certain deviation between the actual position and the predetermined position.

[0137] To compensate for these deviations, both embodiments have an orientation device that can orient the plug relative to the plug mating element to the correct position so that plug insertion can still be achieved, even though the actual position of the plug mating element deviates from the preset position.

[0138] Independent of the foregoing, these directional devices are also independent subjects of the present invention.

[0139] exist Figure 2 and Figure 3 In the illustrated embodiment, the clamp is mechanically oriented via a clamping element 34, which abuts against the plug mating element and, in particular, at least one side of the plug mating element, in order to orient the plug toward the plug mating element.

[0140] In this embodiment, two directional elements 34 movable relative to each other via actuators are provided, and in this embodiment, these directional elements are configured as directional claws. The directional elements 34 here form a clamping element surrounding the plug mating element 15.

[0141] The orientation of the clamp relative to the plug mating element 15 is performed in the operating state of the compensation unit 32, which allows for compensating movement of the clamp. The clamp is thus oriented relative to the plug mating element 15 by closing the orientation element around it. This is performed directly by the actuator of the orientation element 34 in the direction of movement, and perpendicularly by the stop ramp 34' of the orientation element 34, which surrounds the edge of the plug on both sides and centers it relative to the orientation element 34.

[0142] Both the orientation element 34 and the clamping element 33 are mounted on the base 39 of the fixture. The axes of motion of the orientation element 34 and the clamping element 33 extend parallel to each other.

[0143] In one embodiment, the orientation element 34 extends at least partially below the clamping element 33 for clamping the plug 10 in the insertion direction.

[0144] Thus, in the embodiment, the directional element 34 extends beyond the front side of the plug mating element 15, such that when the directional element 34 is closed in a position where the plug mating element 15 is actually positioned further forward than intended, the stop slope 34' contacts the corner of the plug.

[0145] The pushing element 37 is also mounted on the base 39 of the clamp via the plug-in actuator 36, so that it can move independently of the clamping element 33 and the orientation element 34.

[0146] Here, the pushing element 37 is positioned between the clamping element 33 and the orienting element 34 above the plug receiving area formed by the clamping element 33, which surrounds the side of the plug or the plug mating element, thereby pressing against the upper side of the plug to push the plug into the plug mating element 15.

[0147] The connection is made as follows:

[0148] The operating device first moves the clamp with the plug 10 held by the clamping element 33 to a directional position in front of the plug mating element, in which the plug 10 has not yet contacted the plug mating element, but the directional element 34 has already positioned the side of the plug mating element 15. This is based on a preset position of the end element of the operating unit, which is determined based on a preset position of the plug mating element 15. If the compensation unit is switchable, this is preferably performed when the compensation unit is rigidly connected.

[0149] When the compensation unit is activated, the clamp is subsequently oriented. The orientation element 34 thereby centers the clamp with plug 10 in the correct position above the plug mating element 15.

[0150] The operating unit 20 now moves the plug 10 into the plug mating element 15, so that the plug engages with it.

[0151] The clamping element 33 is now open. The plug actuator 35 pushes the plug 10 onto the end stop. The plug is now in the final plugged position.

[0152] In one embodiment, the clamp also includes a locking device for locking the locking element 13 of the plug once the plug is in the final plugged position.

[0153] For this purpose, a contact element 38 is provided, which moves against the locking element 13. In an embodiment, the contact element 38 moves the locking element 13 in the insertion direction.

[0154] A locking actuator 35 is provided for moving the contact element 38, which is mounted on the base 39 of the clamp via the locking actuator. Therefore, the contact element can move independently of the clamping element 33, the orienting element 34, and the pushing element 37.

[0155] In an embodiment, the locking actuator 35 is a linear actuator, such as a pneumatic cylinder.

[0156] The locking actuator operates the locking element, specifically the locking pin of the plug, after the plug is in the final plugged position.

[0157] This completes the connection process.

[0158] exist Figures 4 to 6bIn the illustrated embodiment, the orientation of the clamp is performed via a camera 41, which is mounted on the clamp and detects the actual position of the plug mating element 15, and the operation unit 20 performs corresponding position corrections.

[0159] In this embodiment, position is detected via image recognition. However, in alternative designs, position detection can also be performed via more sophisticated camera-based sensors, such as laser scanners, to detect the actual position of the plug mating element 15 in two or three dimensions.

[0160] In one embodiment, the camera 41 is positioned next to the base 39 of the clamp and is recessed relative to the clamping element 33. In another embodiment, the optical axis of the camera 41 is parallel to the insertion direction of the plug or the movement axis of the insertion actuator 36.

[0161] In this embodiment, the camera is fixed to the mounting element 31, thereby connecting to the operation unit without the compensation unit 32 being connected in between, and the compensation unit 32 is also fixed to the mounting element.

[0162] The actual position of the plug-fitting element 15 is determined by moving the camera 41 above the plug-fitting element 15 using the operation unit. This is based on a preset position of the plug-fitting element 15. The actual position of the plug-fitting element 15 is detected by image recognition and its offset from the preset position is determined.

[0163] The operating unit now moves the clamp with plug 10 to the insertion position in front of plug mating element 15, taking into account the offset determined by the camera. The operating unit then moves plug 10 into plug mating element 15, such that the plug and the plug mating element engage with each other.

[0164] When the compensation unit is switchable, the movement to the insertion position before the plug mating element 15 is performed when the compensation unit is rigidly connected.

[0165] In order to move the plug 10 into the plug mating element 15, it is preferable to activate the compensation unit. Alternatively, the compensation unit may also be activated after the plug has been engaged with the plug mating element 15 via the operating unit.

[0166] Now manipulate the plug actuator to press the plug onto the end stop. This is done with the compensation unit activated.

[0167] exist Figures 4 to 6b In the second embodiment shown, the plug is pressed into its final insertion position not via the clamping element 33 but via the pushing element 37. The pushing element is also positioned between the clamping elements 33 above the receiving area for the plug formed by these clamping elements, thereby pressing against the upper side of the plug.

[0168] However, in Figures 4 to 6b In the second embodiment shown, both the clamping element and the pushing element 37 are disposed on the base element 46, which is movable in the insertion direction relative to the base 30 of the clamp via the insertion actuator 36.

[0169] A plug-in actuator 36 is mounted on the base 39 of the clamp, which is connected to the end member of the operating unit via a compensation unit 32. Furthermore, a rod 42 is provided to guide the base element 46 axially relative to the base 39.

[0170] In the second embodiment, the clamping element 33 thus moves together with the pushing element 37, which pushes the plug into its final insertion position. However, during this pushing motion, the clamping element no longer clamps the plug 10, so that no stress is transmitted from the clamp 40 to the plug 10.

[0171] A second embodiment of the clamp also includes a locking device for locking the locking element 13 of the plug 10. A contact element 38 is provided here, which is pressed against the locking element 13 by the clamp's actuator to manipulate the locking element.

[0172] In the second embodiment, the contact element 38 is operated via the plug actuator 36 and is disposed on the base element 46 for this purpose.

[0173] To allow further movement of the base element 46 and contact element 38 after the push element 37 has pushed the plug into its final mating position, the push element 37 is movably disposed on the base element 46. The push element 37 is preloaded relative to the base element 46 in the mating direction via a spring 44. The preload of the spring 44 is greater than the insertion force required to insert the plug into its final mating position. However, after the plug is pushed against the end stop, the base element 46 can overcome the force of the spring 44 to approach the push element 37, thereby actuating the locking element together with the contact element 38.

[0174] If the base element 46 moves toward the push element 37 and the plug against the force of the spring 44, then the clamping element 33, which is rigidly disposed on the base element 46 in the axial direction, continues to move with the base element in the insertion direction or in the axial direction.

[0175] The clamping element 33 is provided with an undercut 43 that surrounds the upper edge of the plug to prevent the plug from falling out of the clamp when it is clamped. However, the plug can move upward within the clamping element 33 against the prestress of the spring 44, wherein the upper edge surrounded by the undercut 43 moves upward in a gap in the inner wall of the clamping element.

[0176] In one embodiment, the actuating element 37 is configured as an elongated plate that is guided in a recess 45 of the base element 46 via two rods 43, wherein a spring 44 surrounds the rods 43 and preloads the actuating element 37 relative to the base element 46.

[0177] Furthermore, a sensor 48 is provided on the base element 46, which detects when the base element 46 has moved to a position where the contact element has been manipulated. In an embodiment, the sensor 48 is mounted on the base 46 in a protrusion 47 and configured as a proximity sensor, which recognizes the approach of the pushing element 47 to the underside of the sensor 48.

[0178] Contact element 38 is movably disposed on base element 46 in the insertion direction and preloaded in the insertion direction by a spring. The preload of the spring is greater than the force required to actuate the locking element. If the locking element is actuated, the movable mounting of the contact element protects the locking element from damage as the base element 46 moves further toward the plug.

[0179] The clamps described to date are used to hold the plug for connection to the plug mating element.

[0180] According to another independent aspect of the invention, the device according to the invention includes, in addition to a first clamp for clamping a plug, a second clamp for clamping a cable or a second plug disposed at the other end of the cable. If the second clamp is used to clamp another plug, then the cable with plugs at both ends can be connected to the corresponding plug mating element by means of the device according to the invention. If the second clamp is used to clamp the cable, then the invention enables the cable to be positioned according to the desired route of the cable. This is particularly advantageous when installing longer cables, because the flexible design of the cable makes it difficult to position longer cables using only positioning plugs.

[0181] The first and second clamps can be respectively mounted on the first and second operating units having multiple axes of motion so that they can move at least partially independently of each other.

[0182] Figure 7 and Figure 8 A second embodiment of the device according to the invention, having two clamps 40, is shown, wherein the two clamps are movable via separate operating units 24, 25, which are also disposed on a common support element, which is movable via a third operating unit 26.

[0183] The movement space of operating units 24 and 25 is smaller than that of the third operating unit 26. Operating unit 26 is used for coarse positioning of the double clamp formed by the two clamps 40. On the other hand, the two operating units 24 and 25 are used for fine positioning of the clamp, especially for positioning the plugs housed in the two clamps relative to the corresponding plug mating elements.

[0184] In this embodiment, the two operating units 24 and 25 are configured as a small area gantry crane, wherein the load-bearing element 27 is a moving track on which the slider of the corresponding operating unit can move. Another slider of the corresponding operating unit forms another axis extending perpendicularly thereto.

[0185] The other axis of the operating units 24 and 25 in the insertion direction is not necessary, because if needed, the insertion actuator of the corresponding fixture can perform position compensation in the insertion direction.

[0186] The third operating unit 26 is a space gantry crane, which is positioned above the transport line 3 via a carrying device 5, on which the carrying device 2 for the battery module is transported to the device according to the invention.

[0187] exist Figure 7 and Figure 8 In the illustrated embodiment, both clamps 40 are clamps according to the second embodiment of the present invention. However, clamps according to the first embodiment can also be used in the same manner.

[0188] Figure 7 and Figure 8 The device shown is particularly useful for inserting short cables that do not require support cables, but the cables can be positioned using appropriate positioning plugs.

[0189] exist Figure 9 In the third embodiment of the device according to the invention shown, two clamps 40 are also provided for holding the plugs on the operating units 24 and 25. However, the operating units 24 and 25 are configured completely separately and mounted on a rigid support device.

[0190] In this embodiment, the two operating units are multi-axis robots with rotational axes, particularly 6-axis industrial robots. This allows the two grippers to move independently of each other.

[0191] In this embodiment, the clamps are mounted on the corresponding end elements of the operating units 24 and 25 via the extension of the gripper arm to avoid collisions between the operating units.

[0192] This embodiment is also preferably used for inserting short cables, wherein the cables themselves do not need to be supported or clamped.

[0193] Instead of the clamp according to the second embodiment, the clamp according to the first embodiment can also be used.

[0194] exist Figure 10 and 11 The diagram illustrates a fourth embodiment of the device according to the invention, which includes a clamp 70 for clamping a cable in addition to a clamp 40 for clamping a plug. In this embodiment, two clamps 40 are provided for clamping the plug located at both ends of the cable, and two clamps 70 are also provided for clamping the cable. However, according to the design, only one such clamp 70 may be used to clamp the cable and / or only one clamp 40 may be used to clamp the plug.

[0195] Longer cables can also be positioned using the additional clamps 70 used to hold the cables, or non-linear cable guidance can be achieved.

[0196] exist Figure 10 and 11 In the embodiment shown, a combined bending fixture is used, such as Figure 12 As shown. An alternative design scheme for this fixture is... Figure 16 As shown in the figure. Unless otherwise described in detail, the following description refers to two design options. In both embodiments, a clamp 70 for holding the cable is combined with a clamp 40 for holding the plug, wherein the two clamps are disposed on a common operating unit 24, 25.

[0197] In this embodiment, the operating units 24 and 25 are multi-axis robots with rotational axes, particularly 6-axis industrial robots. However, alternatively, area gantry cranes or the solutions shown in Figures 7 and 8 can also be used.

[0198] Furthermore, in the embodiments, the clamp according to the second embodiment of the present invention is used as a clamp 40 for holding the plug. However, alternatively, another clamp, such as the clamp according to the first embodiment, may also be used.

[0199] The clamp 70 for holding the cable is a mechanical clamp having two clamping elements 72, which can be moved toward each other via an actuator to accommodate and mechanically hold the cable between the clamping elements. Figure 12 In some embodiments, the gripping element is a gripping finger or a gripper. Figure 16 In one embodiment, a roller is used as a clamping element.

[0200] The clamp 70 is combined with the clamp 40 such that when the plug and cable are clamped by the respective clamps, the cable is guided to the clamp 70 in a straight direction away from the plug. In particular, the respective grippers 33 and 72 of the clamps 40 and 70 extend in parallel, and the respective axes of motion of the actuators for moving the clamping elements also extend in parallel.

[0201] In this embodiment, a clamp 70 for holding the cable is connected to a clamp 40 for holding the plug via a linear axis 71. The distance between the clamp 70 holding the cable and the plug can be set via this linear axis.

[0202] The task of the clamp 70 is to stabilize the prefabricated cable, especially to prevent the cable from sagging and to maintain its shape, and / or, if the cable is not prefabricated, to twist it at a defined point.

[0203] As from Figure 11 As can be seen from the image, clamp 70 is used to bend the cable in the embodiment.

[0204] For this purpose, Figure 12 The front edge 75 of the jaw 72 of the clamp 70 has a radius of curvature around which the cable can be bent.

[0205] The jaws 72 are preferably configured to be relatively wide to keep the bending torque of the cable away from the plug 10, or two jaws 70 are used, which engage the cable in sequence. The jaws 72 may preferably have a length of more than two centimeters, especially more than five centimeters.

[0206] exist Figure 16 In one embodiment, the radius of curvature around which the cable can be bent is obtained by designing the clamping element 72 as a roller.

[0207] In this embodiment, the axis of roller 72 extends perpendicular to the plane of cable extension and / or perpendicular to the direction of movement of linear axis 71 and / or in the insertion direction of first clamp 40.

[0208] The roller is preferably rotatably mounted. In one possible design, the roller may be fixed in at least one rotational position, for example by an actuator that moves the roller axially against a braking element.

[0209] Therefore, the roller 72 clamps the cable circumferentially. In an embodiment, a lower engagement portion in the form of a circumferential groove is provided on the circumference of the roller 72, by means of which the cable is clamped and thus secured to the clamp.

[0210] The clamp 70 can move along the cable during clamping in order to position the cable and bend it at the end of the travel path.

[0211] like Figure 16 As shown, the second clamp can also be used independently of the first clamp in an alternative design to guide the cable. The following also relates to... Figure 14 and 15 Describe this design scheme. The description there also applies to... Figure 16 The second clamp 70 shown.

[0212] In one embodiment, a first clamp 40 is disposed on a support element 76, which includes a linear shaft 71 on which the clamp 70 is disposed. The support element 76, which is fixed by the two clamps, is itself disposed on the end member of the operating unit.

[0213] An additional actuator 74 is provided on the clamp 70 for holding the cable. This actuator can be pressed onto the cable via a contact element 73 to, for example, press the cable into the clamp or cable channel. The axis of the actuator or the axis of motion of the contact element 73 preferably extends perpendicular to the path of the cable through the clamp and perpendicular to the closing direction of the clamping element 72, and / or parallel to the insertion direction for inserting a plug. Figure 16 The roller 72 in the embodiment can also be used as a contact element. In this case, an additional actuator moves the second clamp 40. The additional actuator moves the second clamp preferably perpendicular to the path of the cable passing through the clamp and perpendicular to the closing direction of the clamping element 72 and / or parallel to the insertion direction of the plug, so as to press the cable held on the second clamp 40 into the clamp or cable channel.

[0214] Figure 10 and 11 The device shown can also be used to insert cables with only one kink or no kink. In this case, the additional clamp 70 is also used to stabilize the cable.

[0215] One possible alternative design solution would be to... Figure 12 and 16 The combined bending fixture shown is combined with a standard fixture for holding the plug, which is mounted on another operating unit.

[0216] exist Figure 13 In the middle, now shown again in a magnified view, it has already been... Figure 1 The first embodiment of the device according to the present invention is shown in the figure.

[0217] In this embodiment, in addition to the clamp 30 for clamping the plug, a clamp 60 for clamping the cable is also used, wherein the clamp 60 for clamping the cable is disposed on separate operating units 22 and 23. The clamp for clamping the plug is also disposed on separate operating units 20 and 21.

[0218] This design is specifically for inserting long cables with or without kinks, or, as in this embodiment, with two kinks. Two clamps 60 allow the cable to be bent or laid at a defined location. Two independent operating units insert the plug into the cable end, and at least one additional operating unit positions, bends, and reguides and lays the cable.

[0219] In this embodiment, the operating units are multi-axis robots with rotational axes, particularly 6-axis industrial robots. Alternatively, area gantry cranes can also be used.

[0220] In addition, one could also think of things such as Figure 7 and Figure 8 The solution shown is as described.

[0221] For example, two or more clamps can be individually mounted on a carrier via smaller operating units, which are then roughly positioned via larger operating units. In particular, it is conceivable to mount all clamps on a common carrier element via smaller operating units, which is then positioned via larger operating units.

[0222] The clamp 60 can be configured as a simple mechanical clamp. However, the clamp can also be configured as already referenced. Figure 12 and 16 The clamp 70 is described in more detail. In particular, the clamp 70 may have an additional actuator 74 with contact elements 73 for pressing the cable into the receiving portion. If the clamp is used to bend the cable, then the clamp preferably has a radius of curvature at the respective ends of the jaws.

[0223] Within the scope of this invention, other methods may also be used, such as... Figure 14 and 15 The cable laying clamps shown are preferably mounted on a separate operating unit and are used to position the cable along a desired path. In particular, the cable laying clamps can be used to push the cable into a guide channel.

[0224] Clamps 80 and 90 have clamping elements 81 and 91, which serve as guiding elements and are applied to the cable 11. The clamping elements 81 and 91 are preferably rotatably mounted so that they can roll along the cable. The shape of the clamping elements 81 and 92 is preferably tapering downwards so that the cable can be pushed downwards out of the clamping elements.

[0225] The clamp also has pressing elements 82, 92, which press down on the cable from above to press it, for example, into the corresponding receiving channel.

[0226] exist Figure 14 In the illustrated embodiment, the pressing element is positioned between the clamping elements 81 at the height of the clamping elements 81. Preferably, an actuator 83 is provided here, via which the pressing element 82 can move between the clamping elements 81, for example, to press a cable into the clamping receptacle.

[0227] On the other hand, Figure 15In the illustrated embodiment, the pressing element 92 is mounted behind the clamping element 91 above the cable in the direction of movement, and presses the clamping element into the cable channel, for example, after the cable leaves the guiding element 91. Here, in Figure 15 In one embodiment, the press-in element 92 is elastically mounted on the clamp via a spring 93.

[0228] In both embodiments, the press-in elements 81 and 92 are rotatably mounted and roll on the cable. Figure 14 In the embodiment, the pressing element 82 is a narrow roller. Figure 15 In one embodiment, the pressing element is a roller wider than the cable.

[0229] Figure 14 and 15 The cable laying clamp shown moves along the cable via the operating unit on which it is located in order to orient the cable along a desired path and / or press it into the corresponding receiving portion.

[0230] After the plug at the end of the cable has been connected to the corresponding plug mating element by other clamps, the cable laying clamp preferably moves along the cable.

[0231] In one possible embodiment of the invention, the cable laying clamp is combined with a combination clamp, such as... Figure 12 As shown, the additional clamp 70 applied to the cable keeps the load away from the plug, which would otherwise be subject to a load by applying the cable laying clamp to the plug.

[0232] The laying clamp moves along the cable preferably along a predetermined path stored in the controller. In one possible design, a camera can also be mounted on the laying clamp to detect where the cable should be pressed into the receiving portion for positional correction.

[0233] The cable laying clamp can be combined with all the above-described devices according to the invention.

Claims

1. An apparatus for automating the establishment of plug-in connections between plugs and plug mating elements disposed on cables in the manufacture of vehicles having hybrid drive and / or electric drive, for wiring of battery modules, said apparatus comprising: A first clamp for holding the plug; An operating unit with multiple axes is used to move the first clamp; The operating unit is a multi-axis robot and / or a regional gantry crane; as well as A controller for operating the first clamp and the operating unit. Its features are, The device includes at least one separate second clamp for holding the cable. The controller is configured such that the second clamp holds the cable to position the cable during and / or after plugging in the connector, wherein the second clamp is disposed on a second operating unit having multiple axes, wherein the second operating unit is a multi-axis robot and / or a gantry crane.

2. The device according to claim 1, wherein the first clamp and the second clamp are movable together via one or more motion axes of the operating unit.

3. The device according to claim 2, wherein the first clamp is mounted on a common support element via a first operating unit and the second clamp via a second operating unit, the support element being movable via a third operating unit, wherein the movement space of the first operating unit and the second operating unit is smaller than the movement space of the third operating unit, wherein these operating units are area gantry cranes and / or space gantry cranes.

4. The device of claim 2, wherein the device includes at least one third clamp for clamping the cable, wherein the first clamp and the second clamp are movable together via one or more motion axes of the operating unit, and the third clamp is connected to the first clamp via at least one motion axis, wherein the motion axis is a linear axis oriented in a plane perpendicular to the insertion direction and / or parallel to the direction of the cable guided away from the plug in a straight line.

5. The device according to claim 1, wherein the cable is bent at the point where it exits the second clamp, wherein, The cable is provided with two first clamps for holding two plugs on the cable, and two second clamps for holding the cable and bending the cable by means of the second clamps.

6. The device of claim 5, wherein the second clamp has two clamping elements clamping the cable between the clamping elements, wherein at least one of the clamping elements has a curved side edge, the cable extends on the clamping element, and / or wherein the second clamp has two rollers as clamping elements clamping the cable between the clamping elements, wherein the rollers are rotatably mounted and / or have a lower engagement portion for the cable on their outer circumference.

7. The device according to claim 1, wherein the second clamp has a pressing element for pressing the cable into the receiving portion.

8. The device of claim 7, wherein the pressing element is movably disposed on the second clamp via an actuator.

9. The device of claim 1, wherein the clamping element of the second clamp is configured as a guiding element by means of which the second clamp can be moved along the cable to guide the cable along a defined path, wherein the second clamp has a pressing element rotatably mounted on the clamp and rolling on the cable.

10. The device according to claim 1, wherein the device has two clamps for holding and inserting plugs disposed at both ends of a cable.

11. The device of claim 1, wherein the first clamp has a plug actuator for moving the plug to a plug-in position with the plug mating element and / or has a compensation unit that allows compensated movement of the clamp relative to the operating unit in at least one operating state, and / or has an orientation element that can abut against at least one side of the plug mating element to orient the plug relative to the plug mating element, and / or wherein the device includes a camera for detecting the position of the plug mating element.

12. The device of claim 11, wherein the camera is mounted on the clamp.

13. A method for automating the establishment of a plug-in connection between a plug and a plug mating element disposed on a cable by means of the device according to claim 1 in the manufacture of a vehicle having a hybrid drive and / or an electric drive, for wiring a battery module, wherein the plug is held and plugged in by a first clamp and the cable is held and positioned by a second clamp.

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