Tool for manufacturing a device, method of manufacturing a device using the tool, and device

Abstract

The invention relates to a tool, a method for manufacturing a device using the tool and a device, wherein the tool has at least one first crimping jaw unit and a guide unit, wherein the first crimping jaw unit internally delimits a tool receiving portion extending along a straight line for receiving a crimp sleeve and an electrical wire, wherein the first crimping jaw unit has a first crimping jaw having a first pressing surface arranged on a side facing the tool receiving portion, a second crimping jaw having a second pressing surface arranged on a side facing the tool receiving portion, wherein the first pressing surface of the first crimping jaw is arranged axially offset with respect to the straight line relative to the second pressing surface of the second crimping jaw, wherein the first crimping jaw is mechanically connected to the second crimping jaw by a first setting device, wherein the second pressing surface is adjustable between a first pressing position and a second pressing position by the first setting device.

Description

TECHNICAL FIELD

[0001] The invention relates to a tool for manufacturing a device, a method for producing a device using the tool and a device produced using the tool. BACKGROUND

[0002] German patent application DE 102020101236.5 discloses a device having a contact device, a cable and a sheath. The contact device has a crimp sleeve and a contact element, wherein the crimp sleeve connects a shield conductor of the cable to the contact element. SUMMARY

[0003] It is an object of the invention to provide an improved tool for producing a device, an improved method for producing the device and a device produced using the tool.

[0004] It has been recognized that by means of a tool having at least one first crimping jaw unit and one guiding unit, an improved method for manufacturing a device can be provided, the device comprising an electrical wire and a contact device having a crimp sleeve, wherein the first crimping jaw unit defines a tool receiving portion inside, which extends along a straight line and serves for receiving the crimp sleeve and the electrical wire. The first crimping jaw unit has a first crimping jaw having a first pressing surface arranged on a side facing the tool receiving portion and a second crimping jaw having a second pressing surface arranged on a side facing the tool receiving portion. The first pressing surface of the first crimping jaw is arranged offset in axial direction with respect to the second pressing surface of the second crimping jaw with respect to the straight line. The first crimping jaw is mechanically connected with the second crimping jaw by means of a first setting device. The first pressing surface is adjustable by means of the first setting device between a first radially inner pressing position and a second pressing position, which is located radially outer with respect to the first pressing position. A first portion of a first pressing force, which can be provided by the guiding unit, can be transmitted via the first crimping jaw into the first pressing surface. The first setting device is configured to transmit a second portion of the first pressing force from the first crimping jaw to the second crimping jaw. The first pressing surface is configured to punch a first punch mark in the crimp sleeve and the second pressing surface is configured to punch a second punch mark in the crimp sleeve for crimping the crimp sleeve onto the electrical wire.

[0005] An advantage of this embodiment is that using the tool, the crimp sleeve can be connected both to the contact element and to the sheath of the electrical wire in one crimping step. In this way, a particularly high cycle rate can be achieved using the tool.

[0006] In another embodiment, the tool has a second crimping jaw unit, wherein the second crimping jaw unit is arranged offset in a circumferential direction relative to the straight line with respect to the first crimping jaw unit, and the tool has a third crimping jaw having a third pressing surface facing the tool receiving portion and a fourth crimping jaw having a fourth pressing surface facing the tool receiving portion, wherein the third pressing surface is arranged offset in an axial direction relative to the fourth pressing surface, wherein the second setting device connects the third crimping jaw to the fourth crimping jaw, wherein the fourth pressing surface is adjustable between a third radially inner pressing position and a fourth pressing position radially outside relative to the third pressing position by means of the second setting device, wherein the third pressing surface is configured to punch a third punch mark into the crimp sleeve, and the fourth pressing surface is configured to punch a fourth punch mark into the crimp sleeve for crimping the crimp sleeve onto the electrical wire. The embodiment has the advantage that due to the movability of the fourth crimping jaw relative to the third crimping jaw, and likewise in combination with the movability of the second crimping jaw relative to the first crimping jaw, the tool receiving portion can be flexibly adapted to the crimp sleeve and to the geometric embodiment of the sheath. In particular, the adjustability of the second and fourth pressing surfaces ensures a reliable crimping of the crimp sleeve onto the electrical wire sheath. It can thus be ensured that the electrical wire is released from tension in a particularly efficient manner.

[0007] In another embodiment, the first pressing surface and the third pressing surface are arranged in a common fourth plane relative to the straight line. Furthermore, the first pressing surface and the third pressing surface extend in a circumferential direction on a common first circular path around the straight line. The third pressing surface and the fourth pressing surface are arranged on a common fifth plane, which is arranged offset in an axial direction relative to the fourth plane relative to the straight line, and the third pressing surface and the fourth pressing surface extend in a circumferential direction on a common second circular path around the straight line. The embodiment has the advantage of ensuring that the crimp sleeve rests particularly tightly against the contact element and the electrical wire sheath.

[0008] In another embodiment, the first crimping jaw has a pressing portion and a support portion, both of which adjoin the pressing portion and are connected to the pressing portion in an axial direction. The first pressing surface is arranged radially inside the pressing portion. The second crimping jaw is arranged radially inside relative to the support portion. The first setting device is arranged radially between the support portion and the second crimping jaw. The first setting device is configured to transmit the second portion of the first pressing force from the support portion to the second crimping jaw. The embodiment has the advantage that the number of components can be kept particularly low. Furthermore, the second crimping jaw can be arranged particularly close to the first crimping jaw, so that the first pressing surface can be arranged particularly close to the second pressing surface in the axial direction. If the pressing portion and the support portion are a single piece and are of unitary form in terms of material, the first crimping jaw is particularly mechanically rigid.

[0009] In another embodiment, the setting device has at least one spring unit and a guide, wherein the guide is configured to guide the second pressing jaw in its movement between the first pressing position and the second pressing position. The spring unit is arranged at least partially between the first pressing jaw and the second pressing jaw in the radial direction and is configured to push the second pressing jaw radially inwards from the second pressing position into the first pressing position. In this way, the second pressing jaw is positioned in a self-aligning manner relative to the first pressing jaw by means of the spring unit.

[0010] In another embodiment, the guide has at least one guide element and a guide receptacle configured accordingly. The guide element is arranged radially on the inside of the support part and is mechanically connected to the support part. The guide element extends radially inwards from the support part. The guide receptacle is arranged in the second pressing jaw. Alternatively, the guide element is arranged radially on the outside of the pressing jaw and is mechanically connected to the second pressing jaw. The guide element extends radially outwards from the pressing jaw, wherein the guide receptacle is arranged in the support part. The guide element engages into the guide receptacle. In this way, reliable guidance of the movement of the second pressing jaw between the first pressing position and the second pressing position can be ensured.

[0011] In another embodiment, the guide has a slotted guide receptacle arranged in the second pressing jaw. Furthermore, the guide has a stop element which is connected to the first pressing jaw and has a stop surface. In the first pressing position, the stop surface abuts against an end of the slotted guide receptacle and limits the movement of the second pressing jaw relative to the first pressing jaw. An undesired detachment or separation of the second pressing jaw from the first pressing jaw is thus prevented.

[0012] In another embodiment, the stop element is configured in the manner of a pin and is oriented parallel to the straight line. In this way, the stop element can be produced and connected to the first pressing jaw in a particularly simple and inexpensive manner.

[0013] In another embodiment, in the first pressing position, the spring unit is prestressed. The advantage of this embodiment is that it ensures that the second stamping indentation can be reliably stamped into the crimp sleeve by the second pressing jaw.

[0014] In another embodiment, the setting device has an adjustment unit, wherein the adjustment unit is coupled to the support part. The adjustment unit has a first threaded hole which is arranged in the support part and extends in the radial direction. A first screw is screwed into the first threaded hole, wherein the prestress of the spring unit in the first pressing position can be defined depending on the depth to which the first screw is screwed into the threaded hole. In this way, the stamping behavior of the second pressing jaw can be purposefully adjusted during the stamping of the second stamping indentation together with the first stamping indentation into the crimp sleeve.

[0015] In another embodiment, the first pressing jaw has a first bevel on a side facing the second pressing jaw, which first bevel extends obliquely with respect to the straight line. The first setting device has a fastening means, an adjustment unit and a wedge element. The wedge element is arranged radially within the support portion and the second pressing jaw abuts against the wedge element. On a side of the wedge element facing the first bevel, the wedge element has a second bevel, which second bevel extends obliquely with respect to the straight line. The fastening means holds the second pressing jaw against the support portion and presses the wedge element between the support portion and the second pressing jaw. By means of the adjustment unit, the axial spacing between the wedge element and the pressing portion is adjustable in order to adjust the second pressing jaw between the first pressing position and the second pressing position.

[0016] The device manufactured using the tool has a contact device and an electrical wire having a first electrical conductor and a sheath. The contact device has a crimp sleeve and a contact element mechanically and electrically connected to the crimp sleeve. The crimp sleeve is pressed against the first electrical conductor in a first sub-portion. A first inner peripheral side forms an electrical contact. The crimp sleeve has a second sub-portion, wherein the second sub-portion is arranged offset with respect to the first sub-portion about an axis. A second stamping indentation and a fourth stamping indentation are stamped into the crimp sleeve at least in the second sub-portion, the fourth stamping indentation being arranged offset with respect to the second stamping indentation in a circumferential direction with respect to the axis. In the second sub-portion, the crimp sleeve circumferentially surrounds the sheath of the electrical wire, which sheath circumferentially surrounds the first electrical conductor and electrically insulates it. A second inner peripheral side of the crimp sleeve is shaped by the second stamping indentation and the fourth stamping indentation such that the second inner peripheral side presses against the sheath and produces a frictional engagement.

[0017] In a method of manufacturing the device using the tool described above, a contact device and an electrical wire having a first electrical conductor and a sheath surrounding the first electrical conductor are provided. The sheath is removed from the first electrical conductor in a stripped portion, and the sheath remains on the first electrical conductor in a sheathed portion adjoining the stripped portion. The crimp sleeve is pushed onto the stripped portion and the sheathed portion of the electrical wire, and these portions are jointly positioned in the tool receiving portion. The first pressing jaw unit is moved radially inwardly from a first position to a second position, and a first pressing force is introduced into the first pressing jaw unit. By a first portion of the first pressing force, the first pressing jaw stamps a first stamping indentation into the crimp sleeve at a first pressing surface, and a first inner peripheral side of the crimp sleeve is pressed against the first electrical conductor. By a second portion of the first pressing force, the second pressing jaw stamps a second stamping indentation into the crimp sleeve at a second pressing surface, the second stamping indentation being arranged offset in an axial direction with respect to the first stamping indentation. A second inner peripheral surface of the crimp sleeve is pressed against the sheath in order to produce a frictional engagement. BRIEF DESCRIPTION OF DRAWINGS

[0018] The application is explained in greater detail below with reference to the drawings, in which:

[0019] Figure 1A side view of the device is shown;

[0020] Figure 2 It shows along Figure 1 The section AA shown passes through Figure 1 A cross-sectional view of the device shown;

[0021] Figure 3 It shows along Figure 1 The sectional view shown is a section AA, which passes through Figure 1 and 2 The apparatus shown and the tool according to the first embodiment;

[0022] Figure 4 It shows Figure 3 Side view of the first clamping unit of the tool shown;

[0023] Figure 5 It is in an uncrimped state. Figures 1 to 3 A perspective view of the crimped sleeve structure shown;

[0024] Figure 6 yes Figures 1 to 3 The perspective view of the device shown with the contact elements in an unpressed state;

[0025] Figure 7 It shows the manufacturing process. Figures 1 to 3 A flowchart of the method using the apparatus shown;

[0026] Figure 8 This is a perspective view of the wires after the second method step;

[0027] Figure 9 This is a perspective view of the apparatus after the fifth method step;

[0028] Figure 10 This is a perspective view of the apparatus after the sixth method step;

[0029] Figure 11 A second embodiment is shown. Figure 3 A detailed side view of the tool shown.

[0030] Figure 1 A side view of the device 10 is shown. Detailed Implementation

[0031] The device 10 has a contact device 15 and an electric line 20. The electric line 20 is, for example, configured as a shielded cable, in particular a shielded high-voltage cable for transmitting electric power in a motor vehicle, in particular for transmitting charging power or drive power in a motor vehicle. The electric line 20 has a first electric conductor 25. The first electric conductor 25 can be configured as a shielded and / or outer conductor. The first electric conductor 25 extends along an axis 30. Here, the first electric conductor 25 has an approximately hollow-cylindrical form with respect to the axis 30. The first electric conductor 25 can, for example, have a wire mesh, which is formed, for example, from thin wires or ultra-thin wires. The wire mesh can be braided or have individual wires extending parallel to the axis 30.

[0032] In the following, for ease of understanding, the device 10 will be described based on a cylindrical coordinate system with respect to the axis 30.

[0033] The first electric conductor 25 is radially surrounded on the outside by a sheath 35. The sheath 35 has an electrically insulating first material and electrically insulates the first electric conductor 25 with respect to an environment 40. Here, the sheath 35 preferably completely surrounds the first electric conductor 25 in the circumferential direction. In Figure 1 In the present embodiment, the sheath 35 has, for example, an outer substantially cylindrical form. Here, the sheath 35 extends in the circumferential direction around the axis 30.

[0034] On the radially inner side with respect to the first electric conductor 25, the electric line 20 has, for example, an electrically insulating intermediate layer 45. In this embodiment, the electrically insulating intermediate layer 45 is surrounded in the circumferential direction by the first electric conductor 25.

[0035] On the radially inner side with respect to the intermediate layer 45, the electric line 20 has, for example, a second electric conductor 50. The second electric conductor 50 can be formed by a single wire. The second electric conductor 50 can also be formed by a bundle of wires, which is, for example, in the form of thin wires or ultra-thin wires. The second electric conductor 50 can also be referred to as an inner conductor. The second electric conductor 50 can, for example, be used for transmitting data signals. Here, the current to be transmitted is less than 1 ampere. As is preferably shown in the present embodiment by the geometric configuration of the second electric conductor 50, the second electric conductor 50 can also be configured for transmitting electric power, for example for supplying an electric motor. The electric motor can, for example, be a drive motor or a traction motor of a motor vehicle. Charging power can also be transmitted via the device 10 and the second electric conductor 50. Preferably, for this purpose, the second electric conductor 50 has a cross-sectional area of at least 2 mm2, preferably 5 mm2, in particular 10 mm2, preferably at least 25 mm2. The second electric conductor 50 can, for example, be configured such that the cross-sectional area of the second electric conductor 50 is less than or equal to 200 mm2, less than or equal to 100 mm2, or less than or equal to 50 mm2. Figure 1

[0036] ​The second electrical conductor 50 has a conductive second material, preferably copper and / or aluminum and / or gold and / or silver. The first material and / or the second material may be the same or different. The first material may also be, for example, copper and / or aluminum and / or gold and / or silver.

[0037] The intermediate layer 45 can be configured to extend around axis 30 in the form of a hollow cylinder and is radially disposed between the first electrical conductor 25 and the second electrical conductor 50. The intermediate layer 45 insulates the second electrical conductor 50 relative to the first electrical conductor 25. In this embodiment, the first electrical conductor 25 is configured to electromagnetically shield the second electrical conductor 50 relative to the surrounding environment 40. In particular, by means of the first electrical conductor 25, it is sought to prevent high currents (e.g., 100 amperes) transmitted by the second electrical conductor 50 from generating electromagnetic fields that interfere with other electrical appliances in the surrounding environment 40 of the wire 20. Therefore, the electromagnetic compatibility of the device 10 is improved by means of the first electrical conductor 25.

[0038] The contact device 15 has a crimping sleeve 60 and a contact element 65 connected to the crimping sleeve 60. The contact element 65 may, for example, be configured to extend about an axis 30 in the form of a hollow cylinder, at least in certain regions. The contact element 65 extends along the axis 30. The contact element 65 is conductive and is used relative to another contact device (in... Figure 1 Electrical contact is formed (invisible to the naked eye).

[0039] The crimp sleeve 60 has a third material, which is conductive and mechanically deformable. Particularly advantageously, the contact element 65 also has a third material.

[0040] The crimping sleeve 60 has a first sub-part 70, a second sub-part 75 and a transition part 80, the transition part 80 being axially arranged between the first sub-part 70 and the second sub-part 75.

[0041] In the axial direction, a first sub-part 70 abuts a first end side 85, which is arranged on the side facing the contact element 65. The first sub-part 70 has a first radial extent. On the side axially away from the first end side 85, a transition portion 80 directly abuts the first sub-part 70. The transition portion 80 is substantially conical about axis 30 and mechanically and electrically connects the first sub-part 70 to the second sub-part 75. The second sub-part 75 is arranged to axially abut the transition portion 80 on the side away from the first end side 85. The second sub-part 75 has a second radial extent, which is smaller than the first radial extent of the first sub-part 70. The second sub-part 75 terminates at a second end side 90 axially opposite the first end side 85.

[0042] The first end side 85 and the second end side 90 are configured to extend substantially perpendicular to the axis 30 and have a substantially annular basic shape in a side view. Here, due to the smaller radial extent of the second sub-portion 75, the second end side 90 has a smaller radial extent than the first end side 85.

[0043] In the state in which the contact device 15 has been mounted on the electrical line 20, the crimp sleeve 60 has at least one first stamped indentation 140 in the first sub-portion 70. Furthermore, in the second sub-portion 75, the crimp sleeve has a second stamped indentation 190, which extends circumferentially on substantially the same angular section as the first stamped indentation 190.

[0044] By the first inner peripheral side 95 in the first sub-portion 70, the crimp sleeve 60 delimits a first crimp receiving portion 100. Furthermore, by the second inner peripheral side 105 of the crimp sleeve 60 in the second sub-portion 75, the crimp sleeve 60 delimits a second crimp receiving portion 110. The second crimp receiving portion 110 is arranged axially offset with respect to the first crimp receiving portion 100 about the axis 30. In this embodiment, both the first inner peripheral side 95 and the second inner peripheral side 105 are configured without a gap. This means that, in this embodiment, over the entire range along the axis 30, the crimp sleeve 60 does not extend radially outward from the inner peripheral side 95, 105 of the respective sub-portion 70, 75 of the crimp sleeve 60 to the outer peripheral side 115, 120 without a slot or a gap.

[0045] The electrical line 20 has a sheath portion 125 and a stripped portion 130. In the sheath portion 125, the electrical line 20 is configured as described above. In the stripped portion 130, the sheath 35 has been removed radially outward from the first electrical conductor 25, so that radially outward, the first electrical conductor 25 is not protected by the first sheath 35. The first electrical conductor 25 has a third outer peripheral side 135, which can be contacted freely in the stripped portion 130.

[0046] Furthermore, the crimp sleeve 60 has a third stamped indentation 145 in the first sub-portion 70. The third stamped indentation 145 is arranged offset in the circumferential direction with respect to the first stamped indentation 140. The first stamped indentation 140 and the third stamped indentation 145 have substantially the same extent in the circumferential direction, but also, for example, in the direction of the axis 30. Here, in the first sub-portion 70, the third stamped indentation 145 is arranged radially inward of the first stamped indentation 140. Figure 1In this case, for example, the first stamping indentations 140 and / or the third stamping indentations 145 extend substantially over the entire extent of the first sub-portion 70 in a direction parallel to the axis 30. The first and / or third stamping indentations 140, 145 are axially directly adjoined on the side facing away from the first end side 85 by the transition portion 80. The first thickening 150 is arranged in the circumferential direction between the first stamping indentations 140 and the third stamping indentations 145. The first thickening 150 is configured in the form of a web and protrudes in the radial direction outward beyond the first stamping indentations 140 and the third stamping indentations 145. The first thickening 150 is configured to be substantially narrower in the circumferential direction than the first stamping indentations 140 and / or the third stamping indentations 145.

[0047] As shown in Figure 1 the first stamping indentations 140 and / or the third stamping indentations 145 each extend over a first angular section of approximately 20° to 60°, preferably 30° to 45°. The first thickening 150 is configured to be substantially narrower in the circumferential direction than the first stamping indentations 140 and / or the third stamping indentations 145. The first thickening 150 can extend in the circumferential direction with respect to the axis 30 over an angular section of approximately 0.5° to 2°, in particular 0.7° to 1.5°.

[0048] In this embodiment, the plurality of first and third stamping indentations 140, 145 are stamped into the first outer peripheral side 115 of the first sub-portion 70, which are configured substantially identically to one another. Here, the first and third stamping indentations 140, 145 have the same spacing in the circumferential direction.

[0049] Furthermore, in the state in which the contact device 15 has been mounted on the electrical line 20, the crimp sleeve 60 has at least a second stamping indentation 190 and a fourth stamping indentation 195 in the second sub-portion 75. The second and fourth stamping indentations 190, 195 are arranged offset with respect to one another in the circumferential direction. Here, a second thickening 200 is arranged in the circumferential direction between the second stamping indentation 190 and the fourth stamping indentation 195. The second thickening 200 is configured to be substantially narrower in the circumferential direction than the second and / or fourth stamping indentations 190, 195.

[0050] The second stamping indentation 190 and the fourth stamping indentation 195 have substantially the same extent in the circumferential direction and preferably in the axial direction with respect to the axis 30. Here, the second stamping indentation 190 and the fourth stamping indentation 195 preferably extend axially between the transition portion 80 and the second end side 90.

[0051] The second thickened portion 200 arranged between the third and fourth press marks 190, 195 is configured in the form of a web and protrudes in the radial direction beyond the second and fourth press marks 190, 195.

[0052] It is preferred that, in the second sub-portion 75, a plurality of second and fourth press marks 190, 195 are pressed into the second sub-portion 75 on the second outer circumferential side 120, which are arranged alternatingly in the circumferential direction. Here, it is particularly advantageous if the second press marks 190 and / or the fourth press marks 195 each extend over a second angular section of approximately 20° to 60°, preferably 30° to 45°.

[0053] The second thickened portion 200 can extend in the circumferential direction with respect to the axis 30 over a fourth angular section of approximately 0.5° to 2°, in particular 0.7° to 1.5°. The spacing between the second and fourth press marks 190, 195 in the circumferential direction is preferably identical.

[0054] It is particularly advantageous if the second press marks 190 and the first press marks 140 extend over identical angular sections and are arranged to overlap in the circumferential direction. Here, the angular overlap in the circumferential direction is understood to mean that the first press marks 140 and the second press marks 190 extend over identical angular sections, even in a three-dimensional arrangement of the angular sections. Thus, if the first press marks 140 are located radially outward with respect to the second press marks 190 in a common first plane arranged perpendicular to the axis 30, then the first press marks 140 and the second press marks 190 will overlap in a direction radially inward on a second plane into which the first press marks 140 and the second press marks 190 are projected, in which the axis 30 extends. In other words, the first press marks 140 and the second press marks 190 can be said to be arranged coaxially with respect to the axis 30.

[0055] Similar to the first press marks 140 and the second press marks 190, the third press marks 145 and the fourth press marks 195 are likewise arranged to overlap at an angle with respect to one another in the circumferential direction. This arrangement has the effect that the first and second thickened portions 150, 200 extend in a common third plane 205, in which the axis 30 also extends. A particularly mechanically stable crimp sleeve can thus be provided.

[0056] Figure 2 A cross-sectional view along the line Figure 1 The cross-sectional view A-A shown passes through Figure 1 A cross-sectional view of the device 10 shown.

[0057] The contact element 65 has a connecting portion 155 and a contact portion 160 axially adjoining the connecting portion 155. The contact portion 160 has a third end side 165 on a side facing the connecting portion 155, which third end side is oriented perpendicular to the axis 30 and forms a shoulder on the contact element 65. The contact portion 160 can extend radially outward beyond the connecting portion 155 and protrude radially beyond the connecting portion 155.

[0058] By way of example, the connecting portion 155 is hollow-cylindrical about the axis 30. Internally, the contact element 65 has an opening 170, which extends through the entire contact element 65 along the axis 30. Here, by way of example, the axis 30 is arranged centrally with respect to the opening 170. The contact portion 160 is only present on the side facing the connecting portion 155. Figure 2 The contact portion 160 is shown symbolically here and serves to establish contact with a further contact device (not shown).

[0059] In this embodiment, the connecting portion 155 and the contact portion 160 are mechanically and electrically connected to one another. The connecting portion 155 and the contact portion 160 are preferably of one piece and of integral form in terms of material. Here, in particular, the contact element 65 can be configured rotationally symmetrical with respect to the axis 30.

[0060] On the radially outer side, the connecting portion 155 has a third outer peripheral side 175. The third outer peripheral side 175 can be configured, for example, to extend in cylindrical form about the axis 30. The connecting portion 155 can be configured, for example, to be longer in an axial direction parallel to the axis 30 than the first sub-portion 70 of the crimp sleeve 60.

[0061] The first electrical conductor 25 is arranged radially between the third outer peripheral side 175 of the connecting portion 155 and the first inner peripheral side 95 of the first sub-portion 70. Radially inward with respect to the connecting portion 155, the stripped portion 130 of the electrical wire 20 passes through the opening 170 together with the second electrical conductor 50 and the intermediate layer 45. Here, the stripped portion 130 can extend through the connecting portion 155 all the way and into the contact portion 160.

[0062] The crimp sleeve 60 forms, by way of its first inner peripheral side 95 in the first sub-portion 70 together with the third outer peripheral side 175 of the connecting portion 155, an annular gap 180, in which the first electrical conductor 25 is arranged. Here, the first electrical conductor 25 is expanded with respect to the sheathed portion 125 of the electrical wire 20. The first inner peripheral side in the first sub-portion 70 lies tightly against the fourth outer peripheral side 185 of the first electrical conductor 25 and presses against the fourth outer peripheral side 185. Here, the fourth outer peripheral side 185 produces a first frictional engagement with the first inner peripheral side.

[0063] Radially inward with respect to the conical transition portion 80, the first electrical conductor 25 likewise has a conical configuration and is expanded with respect to the sheathed portion 125.

[0064] By the second inner circumferential side 105, the second sub-portion 75 abuts against and presses against the fifth outer circumferential side 210 of the jacket 35 in the jacketed portion 125. In particular, here, the second inner circumferential side 105 creates a second frictional engagement with the fifth outer circumferential side 210, such that a release of the tension between the crimp sleeve 60 and the jacket 35 can be achieved in this way. Due to the second inner circumferential side 105 abutting against the jacket 35 and due to the second frictional engagement and the resulting release of the tension, a situation in which the first electrical conductor 25 is subjected to a tensile load at the connection portion 155 and the crimp sleeve 60 is prevented. By the first and the second frictional engagement, the tension can be transmitted to the contact element 65 along the axis 30.

[0065] Figure 3 A cross-sectional view along the section A-A is shown, through Figure 1 A cross-sectional view along the section A-A is shown, through Figure 1 and 2 The device 10 shown as well as a tool 300 for manufacturing the device 10 according to the first embodiment.

[0066] In Figure 3 , the tool 300 is merely in a schematic and highly simplified form. The tool 300 has at least one first crimping jaw unit 305 and one guiding unit 310. The tool 300 can additionally have at least one second crimping jaw unit 315. The first crimping jaw unit 305 is arranged offset in a circumferential direction with respect to the second crimping jaw unit 315. In particular, it is conceivable to provide a plurality of crimping jaw units 305, 315. The guiding unit 310 is connected to the first crimping jaw unit 305 and to the second crimping jaw unit 315 and is configured to move and guide the first crimping jaw unit 305 and the second crimping jaw unit 315 between a first position and a second position which is located radially inwards with respect to the first position.

[0067] The first crimping jaw unit 305 and the second crimping jaw unit 315 internally delimit a tool receiving portion 325 which extends along a straight line 320. In Figure 3 , the straight line 320 and the axis 30 overlap. The crimp sleeve 60, the connection portion 155 of the contact element 65 and the electrical wire 20 are arranged in the tool receiving portion 325.

[0068] The first crimping jaw unit 305 has a first crimping jaw 330 and a second crimping jaw 335 as well as a first setting device 340. The first crimping jaw 330 has a first pressing surface 345 on an inner side facing the tool receiving portion 325. The second crimping jaw 335 has a second pressing surface 350 on an inner side facing the tool receiving portion 325. By way of example, the second pressing surface 350 is arranged radially inwards with respect to the first pressing surface 345. Furthermore, the second pressing surface 350 is arranged axially offset with respect to the first pressing surface 345 with respect to the straight line 320.

[0069] The first setting device 340 mechanically connects the first pressing jaw 330 to the second pressing jaw 335. Here, the second pressing jaw 335 is adjustable in a radial direction by means of the first setting device 340, such that the second pressing surface 350 is adjustable between a first radially inner pressing position and a second radially outer pressing position relative to the first pressing surface 345, even though the first pressing jaw 330 remains in the same position. The adjustment of the second pressing surface 350 relative to the first pressing surface 345 can take place independently of the actuation of the first pressing unit 305 by the guide unit 310 and allows an adaptation / alignment of the first radial spacing between the first pressing surface 345 and the second pressing surface 350.

[0070] The second pressing unit 315 is configured similar to the first pressing unit 305. The second pressing unit 315 has a third pressing jaw 355, a fourth pressing jaw 360 and a second setting device 365. The second setting device 365 mechanically connects the fourth pressing jaw 360 to the third pressing jaw 355. The third pressing jaw 355 is mechanically connected on the radially outer side to the guide unit 310. Relative to the third pressing jaw 355 radially inward, the third pressing jaw 355 has a third pressing surface 370 on the inner side facing towards the tool receptacle 325. The fourth pressing jaw 360 is arranged axially offset relative to the third pressing surface 370.

[0071] On the radially side facing towards the tool receptacle 325, the fourth pressing jaw 360 has a fourth pressing surface 375. The fourth pressing surface 375 is arranged radially inward relative to the third pressing surface 370. In this embodiment, the first pressing surface 345 and the third pressing surface 370 are arranged in a common fourth plane 380 relative to the straight line 320, for example, so as to extend on a common first circular path around the straight line 320. Likewise, the second pressing surface 350 and the fourth pressing surface 375 are arranged in a common fifth plane 385 axially offset relative to the fourth plane 380. The second and fourth pressing surfaces 350, 375 are configured to extend on a common second circular path around the straight line 320.

[0072] The second setting device 365 is arranged radially between the third pressing jaw 355 and the fourth pressing jaw 360. The second setting device 365 mechanically connects the third pressing jaw 355 to the fourth pressing jaw 360. By means of the second setting device 365, the fourth pressing surface 375 is adjustable relative to the third pressing surface 370 independently of the guide unit 310 between a third radially inner pressing position and a fourth radially outer pressing position different from the third pressing position.

[0073] Figure 4 A side view of the first pressing jaw unit 305 of the tool 300 shown is shown. In Figure 3 A side view of the first pressing jaw unit 305 of the tool 300 shown is shown. In Figure 4In the middle, the first pressing jaw unit 305 is partly shown in cross-section for the purpose of providing a better illustration.

[0074] In this embodiment, the first pressing jaw unit 305 and the second pressing jaw unit 315 are configured to be identical to each other, so that in the following the first pressing jaw unit 305 will be discussed as an example of both pressing jaw units. The following explanations apply equally to the second pressing jaw unit 315 and are modified accordingly in terms.

[0075] The first pressing jaw 330 has a pressing portion 500 and a support portion 505, wherein the support portion 505 axially adjoins the pressing portion 500 in the axial direction. The support portion 505 is configured to be narrower than the pressing portion 500 in the radial direction. Furthermore, the first outer side 506 of the first pressing jaw 330 is configured to be stepless, for example.

[0076] The first pressing surface 345 is arranged radially inside the pressing portion 500. Axially adjoining the support portion 505 and radially inside the support portion 505, a pressing jaw receiving portion 510 is arranged. The pressing jaw receiving portion 510 is axially delimited by the pressing portion 500 and radially outwardly by the support portion 505. The pressing jaw receiving portion 510 is configured to be open in the direction radially inwards. The second pressing jaw 335 is arranged in the pressing jaw receiving portion 510 in some sections. Here, the second pressing jaw 335 together with the second pressing surface 350 protrudes in the radial direction beyond the first pressing surface 345 and out of the pressing jaw receiving portion 510.

[0077] The first setting device 340 has at least one spring unit 515, one adjustment unit 520 and one guide 525. The spring unit 515 can have a spring 530, wherein the spring 530 is configured as a coil spring, for example. It goes without saying that some other embodiments of the spring 530 are possible as well. The spring 530 is oriented to extend in the radial direction. The spring 530 is supported on the second pressing jaw 335 radially inwards. For this purpose, a spring receiving portion 535 can be provided in the second pressing jaw 335, which is configured as a blind hole, for example. A first spring end 540 of the spring 530 engages into the spring receiving portion 535.

[0078] The adjustment unit 520 is arranged radially outside with respect to the second pressing jaw 335. The adjustment unit 520 has, for example, a first threaded hole 545 which is arranged in the support portion 505 in a radial direction from inside to outside. A first screw 550, for example a grub screw, is screwed into the first threaded hole 545. A second outer end 555 of the spring 530 is supported on the first screw 550 radially inside of the first screw 550. The first screw 550 can have a tool contour 560 radially outside, into which another tool can engage in order to rotate the first screw 550. The prestress FS1 of the spring 530 can be adjusted by screwing in or out of the screw 550 by the respective screwing-in depth of the first screw 550 in the first threaded hole 545.

[0079] The guide 525 serves to guide the second pressing jaw 335 in a circumferential direction and in an axial direction between the first pressing position and the second pressing position. By way of example, the guide 525 has at least one guide element 565 which is, for example, pin-like and / or cylindrical in configuration and engages into a guide element receptacle 570 of the second pressing jaw 335. The guide element 565 can be, for example, pressed into the guide element receptacle 570. The guide element 565 preferably extends in a radial direction.

[0080] The guide element 565 engages with a radially outer portion into a guide receptacle 575, wherein the guide receptacle 575 is configured in correspondence to the guide element 565. Here, the guide receptacle 575 can be selected to form a clearance fit system with the guide element 565. By way of example, the guide receptacle 575 is formed as a blind hole which leads in the support portion 505 from radially inside to radially outside. The guide receptacle 575 can be, for example, arranged in the axial direction between the first threaded hole 545 and a third end side of the first pressing jaw 330, which is arranged on a side of the support portion 505 which faces away from the pressing portion 500. As is shown in Figure 4 It goes without saying that further guide elements 565, guide element receptacles 570 and guide receptacles 575 can also be provided. For example, axially between the pressing portion 500 and the first threaded hole 545, a further guide element 565 can additionally be provided which is located in a further guide element receptacle 570 and engages into a further guide receptacle 575.

[0081] As an alternative to the arrangement of the guide 525 as shown in Figure 4 The guide element receptacle 570 can also be arranged in the support portion 505 and the guide receptacle 575 can be arranged in the second pressing jaw 335. However, it is also possible that the guide element 565 is arranged in the second pressing jaw 335 and the guide element receptacle 570 is arranged in the support portion 505. Figure 4The illustrated embodiment has the advantage of being particularly easy to assemble, since in this way the guide element 565 can be particularly easily pressed into a guide element receptacle provided in the second pressure jaw 335. In this case, the guide element 565 extends from radially outside to radially inside and is mechanically connected to the support portion 505.

[0082] The guide 525 also has a slotted guide receptacle 580, which is arranged on the end side on the side of the second pressure jaw 335 facing the pressing portion 500. The slotted guide receptacle 580 can be configured in the form of an elongated hole. The guide 525 also has a stop element 585. The stop element 585 can be configured in the form of a pin and / or in the form of a cylinder, wherein the stop element 585 extends parallel to the straight line 320 in its main extension direction. The stop element 585 has a stop surface 590 on the circumference. The stop element 585 is pressed into the pressing portion 500, for example. It is particularly advantageous that, in the first pressing position, the stop surface 590 abuts against the end of the slotted guide receptacle 580 and prevents an undesired relaxation of the prestressed spring 530. Furthermore, a movement of the second pressure jaw 335 beyond the second pressing position is limited by the stop element 585 abutting against the slotted guide receptacle 580.

[0083] The protrusion length e of the second pressing surface 350 in the radial direction relative to the first pressing surface 345 is greater than the maximum movement travel f of the second pressure jaw 335 between the first pressing position and the second pressing position. In the first pressing position, a movement of the second pressure jaw 335 is prevented by the second pressure jaw 335 abutting against the support portion 505 radially on the outside. It is likewise possible that a movement of the second pressure jaw 335 radially outward beyond the first pressing position is prevented by the slotted guide receptacle 580 further abutting against the stop element 585.

[0084] Due to the fact that the second pressure jaw unit 315 is configured identically to the first pressure jaw unit 305, the fourth pressing surface 375 can be adjusted between the third pressing position and the fourth pressing position by means of the second setting device 365. The guide 525 of the second pressure jaw unit 315 serves to guide the fourth pressure jaw 360 in the circumferential direction and in the axial direction between the third pressing position and the fourth pressing position. The spring 530 prestresses the fourth pressure jaw 360.

[0085] Figure 5 is Figures 1 to 3 Perspective view of the crimping sleeve 60 of the illustrated device 10 in the uncrimped state

[0086] In the uncrimped state, the crimping sleeve 60 is essentially configured as a hollow cylinder. Here, the crimping sleeve 60 has an essentially constant material thickness in the radial direction relative to the axis 30. The crimping sleeve can be formed, for example, from a thin-walled material, for example a sheet metal.

[0087] Figure 6 is Figures 1 to 3 Perspective view of the device 10 shown in Fig. 1 in the uncrimped state of the contact element 65.

[0088] In this embodiment, as an example, the inner diameter d of the crimp sleeve 60 has been chosen to be larger than the maximum outer diameter dMAX of the connection portion 155 of the contact element 65.

[0089] The connection portion 155 is mechanically more rigid than the crimp sleeve 60. This is achieved, for example, by the connection portion 155 having a further wall thickness which is much thicker, preferably 1.5 to 10 times, than the wall thickness of the crimp sleeve 60.

[0090] Figure 7 is for producing Figures 1 to 3 Flow chart of the method for producing the device 10 shown in Fig. 1. Figure 8 is a perspective view of the electrical wire after the second method step 410. Figure 9 is a perspective view of the device 10 after the fifth method step 425. Figure 10 is a perspective view of the device 10 after the sixth method step 430.

[0091] In the first method step 405, furthermore, the first and second crimping jaw units are calibrated before the other method steps are carried out. To this end, in the second position of the first and second crimping jaw units 305, 315, the opening width of the tool receiving portion 325 between the first and third pressing surfaces 345, 370 is determined, and based on a setpoint value of the opening width, the first and second crimping jaw units 305, 315 are positioned and set in the second position.

[0092] Furthermore, using the first screw 550, a one-time setting of the prestress FS1 of the spring 530 is carried out based on a desired crimping force, and the first screw 550 is fixed against unwanted rotation, optionally using screw fixing means, for example a screw fixing lacquer.

[0093] Thereafter, by means of the guide unit 310, the crimping jaw units 305, 315 are moved radially outward to the first position. After reaching the radially outer first position, the crimping jaw units 305, 315 are held by the guide unit 310 such that the tool receiving portion 325 is opened in the radial direction to a particularly large extent. Furthermore, the respective prestressed spring causes the second crimping jaw 335 to be in the first pressing position and the fourth crimping jaw 360 to be in the third pressing position.

[0094] First, after the first method step 405, a second method step 410 (see Figure 8In this process, the wire 20 is cut from a roll, for example, and then, at the cut point 390, the sheath 35 is removed from the conductor 25 to form a stripped portion 130 between the cut point 390 and the sheathed portion 125.

[0095] In step 415 of the third method, the crimp sleeve 60 (see...) Figure 5 ) and contact element 65 (see Figure 6 It is provided in an uncrimped state.

[0096] In the fourth method step 420, the crimp sleeve 60 is pushed onto the wire 20 such that the crimp sleeve 60 completely surrounds the sheathed portion 125.

[0097] The fifth method step 425 (see step 425 of the fourth method) follows step 420 of the fourth method. Figure 9 In this process, the first electrical conductor 25 is expanded, for example. This can be done, for example, using a (hollow) mandrel.

[0098] Furthermore, the intermediate layer 45 and the second electrical conductor 50 are inserted through the opening 170 of the contact element 65, such that the second electrical conductor 50 and the intermediate layer 45 protrude beyond the contact element 65 on the side of the contact element 65 opposite to the connection portion 155.

[0099] Here, the contact element 65 is positioned relative to the first electrical conductor 25 such that the connection portion 155 is radially arranged between the intermediate layer 45 and the first electrical conductor 25. The first electrical conductor 25 radially surrounds the connection portion 155 and abuts against the third outer peripheral side 135 of the connection portion 155.

[0100] The sixth method step 430 (see step 425 of the fifth method) is followed by the fifth method step 425. Figure 10 In this process, the crimp sleeve 60 is pushed onto the connecting portion 155 and the first electrical conductor 25 on the connecting portion 155. Here, the crimp sleeve 60 forms an annular gap 180 with the third outer peripheral side 135. The expanded first electrical conductor 25 is arranged in the annular gap 180.

[0101] After the sixth method step 430, in the seventh method step 435, the device 10 is placed into the tool receiving unit 325 (see...). Figure 3 Here, the device 10 is positioned such that the pressing surfaces 345, 350, 370, 375 are positioned to radially overlap the crimping sleeve 60. Here, radial overlap is understood to mean that, in the radial projection of the axis 30 and the straight line 320 into a plane in which they extend, the two components, such as the pressing surfaces 345, 350, 370, 375 and the crimping sleeve 60, overlap. Similarly, the first pressing surface 345 and the third pressing surface 370 radially overlap the extended first electrical conductor 25 in the connecting portion 155 and the peeling portion 130.

[0102] In this embodiment, the crimping sleeve 60 and the first and / or second crimping jaw units 305, 315 have substantially the same axial extent along the axis 30 or straight line 320. Here, the device 10 is positioned in the tool receiving portion 325 such that the crimping sleeve 60 preferably completely radially overlaps the first and second crimping jaw units 305, 315.

[0103] In an eighth method step 440 following the seventh method step 435, the guiding unit 310 moves the first and second crimping jaw units 305, 315 radially inwardly from the radially outer first position to a second position (see Figure 3 ). Each of the crimping jaws 330, 335, 355, 360 abuts with the respective associated pressing surface 345, 350, 370, 375 against the outer peripheral side 115, 120 of the crimping sleeve 60.

[0104] When the crimping jaw units 305, 315 are moved inwardly from the first radially outer position to the radially inner second position, first the second and fourth pressing surfaces 350, 375 come into contact with the second outer peripheral side 120 of the second sub-portion 75 of the crimping sleeve 60.

[0105] The guiding unit 310 provides a first pressing force Fl at the first crimping jaw unit 305 and a second pressing force F2 at the second crimping jaw unit 315. The first and second pressing forces Fl, F2 each point from the radially outer side to the radially inner side and preferably have substantially the same magnitude.

[0106] During crimping and moving from the radially outer first position to the radially inner second position, the first pressing force Fl is only transmitted from the first crimping jaw 330 via the first setting device 340 to the second crimping jaw 335 and from the second crimping jaw 335 to the second pressing surface 350 as long as the first and third crimping jaws 330, 355 are spaced apart from the first outer peripheral side at the first and third pressing surfaces 345, 370. Similarly, the second pressing force F2 introduced by the guiding unit 310 into the second crimping jaw unit 315 is transmitted from the third crimping jaw 355 via the second setting device 365 to the fourth crimping jaw 260 as long as the third pressing surface 370 is still arranged spaced apart from the first outer peripheral side.

[0107] The crimping sleeve 60 provides respective counter forces FG1, FG2 which are opposite to the first and second pressing forces Fl, F2. With increasing pressing forces Fl, F2, the springs 530 of the crimping jaw units 305, 315 can be compressed, respectively, and ensure that the second and fourth pressing surfaces 350, 375 reliably abut against the second sub-portion of the crimping sleeve 60. Here, the second crimping jaw 335 is moved radially outwardly from the first pressing position to the second pressing position and the fourth crimping jaw 360 is moved from the third pressing position to the fourth pressing position.

[0108] Due to the flexible form of the crimping sleeve 60, the first pressing force F1 is introduced only from the first clamping unit 305 through the second pressing surface 350 into the second outer peripheral side 120 of the crimping sleeve 60.

[0109] By means of a first pressing force F1 transmitted from the first clamp 330 to the second clamp 335 via the first setting device 340 within the first clamp unit 305, the second clamp 335 forms a second stamping indentation 190 into the periphery of the crimping sleeve 60 in the second sub-part 75. A fourth stamping indentation 195, offset circumferentially relative to the second stamping indentation 190, is stamped circumferentially into the second sub-part 75 by means of a second pressing force F2 from the fourth pressing surface 375. Here, a second thickened portion 200 is formed between the second stamping indentation 190 and the fourth stamping indentation 195.

[0110] The first and second pressing forces F1 and F2 continue to be applied, and the guide unit 310 guides the first clamping unit 305 and the second clamping unit 315 further radially away from the first position in the direction of the second position. During this process, the magnitude of the pressing forces F1 and F2 increases. The spring 530 is also compressed. Shortly before reaching the second position, the first pressing surface 345 of the first clamping unit 330 also contacts the first outer peripheral side 115 of the contact element 65. Similarly, the third pressing surface 370 contacts the first outer peripheral side 115 of the crimping sleeve 60 in the first sub-part 70.

[0111] Here, the first clamp 330 directly transmits a first portion of the first pressing force F1 to the first pressing surface 345, and the first pressing surface 345 presses the first stamping indentation 140 into the first sub-part 70. Here, due to the first portion of the first pressing force F1, the first inner circumferential side of the first sub-part 70 is tightly pressed against the third outer circumferential side 135 of the first electrical conductor 25. Furthermore, a second portion of the first pressing force F1 is transmitted to the second clamp 335 via the first setting device 340, and the second clamp 335 further presses the second stamping indentation 145 into the second outer circumferential side 120 of the crimping sleeve 60. Here, the second clamp 335 can be pushed radially outward into the second pressing position.

[0112] During the pressing and crimping process of the crimping sleeve 60, the second inner circumferential side 105 closely abuts against the fifth outer circumferential side 210 of the sheath 35, and a second frictional engagement is generated. Here, the second clamping clamp 335 may abut against the support portion 505, or the second part of the first pressing force F1 may be transmitted essentially solely through the spring 530.

[0113] In this embodiment, a second portion of the first pressing force Fl can be transmitted to the second pressure jaws 335 via the support portion 505 and the spring 530, even without abutment of the second pressure jaws 335, by adjusting the prestress FS1 of the spring 530, which is mounted so as to be flexible in the radial direction, can particularly effectively abut against the crimp sleeve 60 in the second sub-portion 75. To this end, the spring 530 must be selected in accordance with the pressing forces Fl, F2 and prestressed with the prestress FS1 accordingly.

[0114] In an alternative embodiment, the second pressure jaws 335 abut against the support portion 505 on the radially outer side, so that a particularly high second portion of the first pressing force Fl can be transmitted from the first pressure jaws 330 to the second pressure jaws 335 via the support portion 505.

[0115] The introduction of the force for stamping the third and fourth stamping indentations 145, 195 by the second pressure jaw unit 315 also takes place analogously. Here, a first portion of the second pressing force F2 is transmitted directly from the third pressure jaws 355 to the third pressing surface 370 when the third pressing surface 370 comes into contact with the first sub-portion 70 of the crimp sleeve 60 as the second pressure jaw unit 315 is moved into the second position. Here, by means of the first portion of the second pressing force F2, the third pressing surface 370 forms the third stamping indentation 145 in the crimp sleeve, so that at the third stamping indentation 145 the first inner circumferential side 95 of the crimp sleeve 60 lies tightly against the first electrical conductor 25 and a first frictional engagement connection is produced between the first inner circumferential side 95 and the electrical conductor 25 on the one hand and also between the first electrical conductor 25 and the connecting portion 155. In addition, the third pressure jaws 355 transmit a second portion of the second pressing force F2 to the second setting device 365. The second setting device 365 transmits the second portion of the second pressing force F2 to the fourth pressure jaws 360, which further stamp the fourth stamping indentation 195 into the second outer circumferential side 120 of the crimp sleeve 60.

[0116] During the stamping of the stamping indentations 140, 190, 145, 195, a portion of the material of the crimp sleeve 60 flows into the respective gap between the first pressure jaw unit 305 and the second pressure jaw unit 315 and forms the first and second thickened portions 150, 200 accordingly. The crimp sleeve 60 thus has a different material thickness in the circumferential direction, so that the material thickness on the radially inner side of the first to fourth stamping indentations 140, 190, 145, 195 is smaller than the material thickness at the first and second thickened portions 150, 200.

[0117] In a ninth method step 445, following the crimping in the eighth method step 440, after the crimping in the eighth method step 440 is completed, the crimping jaw unit 305, 315 is moved by the guiding unit 310 from the second position again radially outward into the first position, so that the tool receptacle 325 is opened again and the crimped contact arrangement 15 together with the electrical wire 20 can be removed from the tool receptacle 325.

[0118] The stamping of the stamping indentations 140, 190, 145, 195 and the forming of the thickened portions 150, 200 have the advantage that the crimping sleeve 60 is thus reinforced and an undesired expansion of the crimping sleeve 60 upon removal of the crimping jaw unit 305, 315 is thus avoided. Thus, a particularly good first crimping connection is provided between the first electrical conductor 25 and the crimping sleeve 60 and a particularly good second crimping connection is provided between the sheath 35 and the same crimping sleeve 60.

[0119] Furthermore, at the same time, due to the connection of the crimping sleeve 60 with the sheath 35 and also due to the crimping of the crimping sleeve 60 with the first electrical conductor 25 and with the connection portion 155 in a single crimping / pressing step in the tool 300, a release of the tension occurs.

[0120] Due to the stamping of the stamping indentations 140, 190, 145, 195 and the associated reduction of the inner diameter of the crimping sleeve 60 at the connection portion 155 and the sheath 35, the crimping sleeve 60 at least partially maintains the first and second pressing forces F1, F2 even after the tool 300 has been removed and presses the first electrical conductor 25 on the radially inner side against the connection portion 155, so that a first frictional engagement connection between the first electrical conductor 25 and the first inner peripheral side 95 of the first sub-portion 70 of the crimping sleeve 60 and a second frictional engagement connection between the second inner peripheral side 105 of the second sub-portion 75 of the crimping sleeve 60 and the fifth outer peripheral side 210 of the sheath 35 are maintained.

[0121] Due to the first inner peripheral side 95 lying tightly against the first electrical conductor 25 and the second inner peripheral side 105 lying tightly against the fifth outer peripheral side 210 of the sheath 35, it is avoided that parts of the crimping sleeve 60 are chiseled into the first electrical conductor 25 and the sheath 35 during the stamping and crimping of the stamping indentations 140, 190, 145, 195. Rather, after the stamping of the stamping indentations 140, 190, 145, 195, the crimping sleeve 60 has a substantially cylindrical form at each of the first inner peripheral side 95 and the second inner peripheral side 105, but with a respectively different reduced inner diameter. The embodiment has the advantage that damage to the first electrical conductor 25 and the sheath 35 due to the crimping of the crimping sleeve 60 is avoided.

[0122] Figure 11 A crimping tool 300 according to a second embodiment is shown.Figure 3 a detailed side view of the tool 300.

[0123] The tool 300 is essentially the same as Figure 3 and 4 the tool 300 according to the first embodiment as shown. In the following, only the differences of the tool 300 according to the second embodiment as shown in Figure 11 Figure 3 and 4 the first embodiment as shown will be discussed.

[0124] It is again pointed out that in the following only the first pressing jaw unit 305 will be discussed. By way of example, the second pressing jaw unit 315 is configured identically to the first pressing jaw unit 305, so that the explanations given in the following with respect to the first pressing jaw unit 305 apply equally to the second pressing jaw unit 315, except that a second pressing force F2 instead of a first pressing force Fl is introduced into the second pressing jaw unit 315.

[0125] In this embodiment, the spring unit 515 is omitted. Instead of the spring unit 515, the first pressing jaw unit 305 has a fastening device 595 and a wedge element 605. The fastening device 595 can for example have a second screw 610. Figure 11 The second screw 610 is inserted into a screw opening 615, wherein the screw opening 615 is arranged in the support portion 505 so as to extend in the radial direction. On the support portion 505, the first pressing jaw 330 has a first bevel 620, wherein the first bevel 620 is arranged so as to be inclined with respect to the straight line 320. Here, the first bevel 620 can be arranged such that a radial spacing between the straight line 320 and the first bevel 620 increases with an increase of an axial spacing between the first bevel 620 and the pressing portion 500. The first bevel 620 can also be in the form of a flat surface and extend in the flat surface. The first bevel 620 can also be configured in the form of a partial cone with respect to the straight line 320.

[0126] In this embodiment, the guide element receiving portion 570, the guide element 565 and the guide receiving portion 575 are omitted. Instead, the guide 525 has a guide portion 625 extending inwardly in the radial direction, wherein the guide portion 625 is oriented so as to extend in a sixth plane perpendicularly with respect to the straight line 320. Here, the guide portion 625 is connected to the support portion 505 radially outwardly. In particular, the pressing portion 500, the support portion 505 and the guide portion 625 can be in the form of a single piece and of a material entirety.

[0127]

[0128] ​​On the first axial side facing the pressing portion 500, the guiding portion 625 has a first guiding surface 630 which is planar. On the axial side facing the guiding portion 625, the pressing portion 500 has a second guiding surface 635 which is arranged, for example, parallel to the first guiding surface 630. By way of example, the first and second guiding surfaces 630, 635 are oriented to extend perpendicularly with respect to the straight line 320. The first guiding surface 630 and the second guiding surface 635 together with the first bevel 620 delimit a pressure tongs receiving portion 510 in which both the second pressure tongs 335 and the wedge element 605 are arranged. Here, the wedge element 605 is arranged between the second pressure tongs 335 and the first bevel 620 in a radial direction.

[0129] On the radially outer side, the wedge element 605 has a second bevel 645 which is oriented parallel to the first bevel 620. In the assembled state, the second bevel 645 abuts against the first bevel 620 on the radially inner side. In the axial direction, the wedge element 605 is arranged between the first guiding surface 630 and the second guiding surface 635, wherein the axial extent of the wedge element 605 is smaller than the maximum axial width of the pressure tongs receiving portion 510 between the first guiding surface 630 and the second guiding surface 635.

[0130] On the radially inner side of the second bevel 645 and opposite the second bevel 645 in the radial direction, the wedge element 605 has a first contact surface 650. The first contact surface 650 is configured to extend parallel to the straight line 320. Opposite the first contact surface 650 in the radial direction, the second pressure tongs 335 have a second contact surface 655 which is configured correspondingly to the first contact surface 650. The first contact surface 650 and the second contact surface 655 can be configured to extend in a circumferential direction on a circular path about the straight line 320.

[0131] The wedge element 605 has a first channel opening 660 in the radial direction, wherein the first channel opening 660 is configured, for example, to be open on the side facing the second guiding surface 635. The first channel opening 660 extends in the radial direction from the second bevel 645 radially inwards to the first contact surface 650. The first channel opening 660 can be configured in the form of a groove.

[0132] The configuration of the adjustment unit 520 differs from Figure 4The first threaded hole 545 of the adjustment unit 520 is arranged in the wedge-shaped element 605 and preferably extends parallel to the straight line 320, contrary to the latter. Here, the first threaded hole 545 is arranged on the side of the wedge-shaped element 605 facing the first guide surface 630 and thus on the side of the wedge-shaped element 605 facing away from the pressing portion 500. The first threaded hole 545 can be configured as a blind hole. The first threaded hole 545 can also open into the first passage opening 660. Alternatively, the first passage opening 660 and the first threaded hole 545 can be arranged offset relative to each other in the circumferential direction.

[0133] Furthermore, in addition to the first screw 550, which is configured as an inner hexagon screw with a shank in this embodiment, for example, the adjustment unit 520 has a second passage opening 670, wherein the second passage opening 670 is arranged in the guide portion 625 and extends substantially in the axial direction parallel to the straight line 320 through the guide portion 625. The first screw 550 is inserted through the second passage opening 670 and screwed into the first threaded hole 545. The axial position of the wedge-shaped element 605 relative to the pressing portion 500 is set in accordance with the extent to which the first screw 550 is screwed into the first threaded hole 545.

[0134] Furthermore, on the side facing away from the pressing portion 500, a holder 675 can be arranged on the support portion 505, wherein the holder 675 is fastened to the support portion 505 in a reversible, non-destructive detachable manner at the guide portion 625, for example by a screw connection. The holder 675 protrudes in the radial direction beyond the screw head 676 of the first screw 550 and prevents the screw head 676 from being able to be pulled away from the guide portion 625 in the axial direction or pushed away by an axial deflection of the wedge-shaped element 605.

[0135] Furthermore, a third passage opening 680 can be arranged in the holder 675 for inserting an assembly tool into the screw head 676 in order to rotate the first screw 550 by means of the screw head 676. The third passage opening 680 is thus arranged to overlap the first screw 550 in the axial direction. In this way, the wedge-shaped element 605 can be displaced in the axial direction by the screw 550.

[0136] The axial movement clearance of the screw head 676 of the first screw 550, for example in the axial direction between the holder 675 and the guide portion 625, is selected such that on the one hand jamming of the screw head 676 of the first screw 550 is prevented, but at the same time the axial movement clearance of the first screw 550 between the holder 675 and the guide portion 625 is minimized.

[0137] The second pressing jaw 335 has a second threaded hole 665, wherein the second threaded hole 665 extends from the radial outer side in the direction of the second pressing surface 350, but ends at a distance from the second pressing surface 350. The second screw 610 is inserted through the screw opening 615 and is screwed into the second threaded hole 665. Here, the screw 610 engages through the first passage opening 660.

[0138] The positioning of the second pressing surface 350 and the fourth pressing surface 375 will be discussed below.

[0139] The screw 610 provides a clamping force FS2 which acts in the radial direction and presses the second pressing jaw 335 against the first contact surface 650 of the clamping element with the second contact surface 655. In addition, the clamping force FS2 presses the second ramp 645 against the first ramp 620.

[0140] In order to move the second pressing surface 350 in the radial direction between the first pressing position and the second pressing position and the fourth pressing surface 375 between the third pressing position and the fourth pressing position, the wedge element 605 can be axially displaced between the first guide surface 630 and the second guide surface 635 by means of the first screw 550. To this end, the second screw 610 is loosened.

[0141] After the axial position of the wedge element 605 between the first guide surface 630 and the second guide surface 635 has been set by means of the first screw 550, the second screw 610 is tightened so that the first and second ramps 620, 645 and the first and second contact surfaces 650, 655 abut against one another. Here, the first guide surface 630 and the second guide surface 635 guide the second pressing jaw 335 between the first pressing position and the second pressing position and the fourth pressing jaw 360 between the third pressing position and the fourth pressing position by the axial abutment of the second pressing jaw 335 and the fourth pressing jaw 360 against the guide surfaces 630, 635.

[0142] When the second screw 610 is tightened and the clamping force FS2 is provided, the holder 675 ensures that the obliquely extending ramps 645, 620 and the clamping force FS2 do not cause the wedge element 605 to be pushed in the direction of the holder 675, the axial position of the wedge element 605 between the first guide surface 630 and the second guide surface 635 being defined by the screw head 676 of the first screw 550 abutting against the holder 675.

[0143] Figure 11An advantage of the embodiment shown is that the radial position of the second pressing surface 350 relative to the first pressing surface 345 can be adjusted in a defined manner by the setting device 340, 365. In the case of the further (multiple) crimping jaw unit 305 and the second crimping jaw unit 315, the second crimping jaw 335 and the fourth crimping jaw 360 can also each be adjusted by the setting device 340, 365 in a defined manner. Figure 11 The setting device 340, 365 shown is adjusted relative to the first pressing surface 345 and relative to the third pressing surface 370. Thus, it is ensured that, during production of the device 10, reliable crimping of the sheath 35 by the second sub-section 75 of the crimping sleeve 60 is ensured.

[0144] The production method for producing the device 10 using the tool 300 shown in Figure 11 is essentially the same as the method described in Figure 7 Contrary thereto, during the seventh method step 435, no adjustment of the second and fourth crimping jaws 335, 360 takes place, but rather, in the first method step 405, the respective pressing positions of the second and fourth crimping jaws 335, 360 are pre-calibrated, together with the adjustment of the first and third crimping jaws 330, 355, and thus the pressing positions of the second and fourth pressing surfaces 350, 375 are pre-calibrated.

[0145] List of reference signs

[0146] 10 device

[0147] 15 contact device

[0148] 20 electrical line

[0149] 25 first electrical conductor

[0150] 30 axis

[0151] 35 sheath

[0152] 40 ambient environment

[0153] 45 intermediate layer

[0154] 50 second electrical conductor

[0155] 60 crimping sleeve

[0156] 65 contact element

[0157] 70 first sub-section

[0158] 75 second sub-section

[0159] 80 transition section

[0160] 85 first end side

[0161] 90 second end side

[0162] 95 first inner circumferential side

[0163] 100 first crimp receiving portion

[0164] 105 second inner circumferential side

[0165] 110 second crimp receiving portion

[0166] 115 first outer circumferential side

[0167] 120 second outer circumferential side

[0168] 125 sheath portion

[0169] 130 peel portion

[0170] 135 third outer circumferential side

[0171] 140 first punch indentation

[0172] 145 third punch indentation

[0173] 150 first thickened portion

[0174] 155 connecting portion

[0175] 160 contact portion

[0176] 165 third end side

[0177] 170 opening

[0178] 175 third outer circumferential side

[0179] 180 annular gap

[0180] 185 fourth outer circumferential side

[0181] 190 second punch indentation

[0182] 195 fourth punch indentation

[0183] 200 second thickened portion

[0184] 205 third plane

[0185] 210 fifth outer circumferential side

[0186] 300 tool

[0187] 305 first plier unit

[0188] 310 guide unit

[0189] 315 second plier unit

[0190] 320 straight line

[0191] 325 tool receiving portion

[0192] 330 first pressing jaw

[0193] 335 second pressing jaw

[0194] 340 first setting device

[0195] 345 first pressing surface

[0196] 350 second pressing surface

[0197] 355 third pressing jaw

[0198] 360 fourth pressing jaw

[0199] 365 second setting device

[0200] 370 third pressing surface

[0201] 375 fourth pressing surface

[0202] 380 fourth plane

[0203] 385 fifth plane

[0204] 390 cut-off point

[0205] 405 first method step

[0206] 410 second method step

[0207] 415 third method step

[0208] 420 fourth method step

[0209] 425 fifth method step

[0210] 430 sixth method step

[0211] 435 seventh method step

[0212] 440 eighth method step

[0213] 445 ninth method step

[0214] 450 tenth method step

[0215] 500 pressing portion

[0216] 505 support portion

[0217] 506 first outer side

[0218] 510 jaw receiving portion

[0219] 515 spring unit

[0220] 520 adjustment unit

[0221] 525 guide

[0222] 530 spring

[0223] 535 spring receiving portion

[0224] 540 first end

[0225] 545 first threaded hole

[0226] 550 first screw

[0227] 555 second end

[0228] 560 tool profile

[0229] 565 guide element

[0230] 570 guide element receiving portion

[0231] 575 guide receiving portion

[0232] 580 slotted guide receiving portion

[0233] 585 stop element

[0234] 590 stop surface

[0235] 595 fastening means

[0236] 605 wedge element

[0237] 610 second screw

[0238] 615 screw opening

[0239] 620 first ramp

[0240] 625 guide portion

[0241] 630 first guide surface

[0242] 635 second guide surface

[0243] 640 pliers receiving portion

[0244] 645 second ramp

[0245] 650 first contact surface

[0246] 655 second contact surface

[0247] 660 first passage opening

[0248] 665 second threaded hole

[0249] 670 second passage opening

[0250] 675 retainer

[0251] 676 screw head

[0252] 680 third passage opening

Claims

1. A tool (300) for manufacturing an apparatus (10), the apparatus (10) comprising an electrical wire (20) and a contact device (15) having a crimping sleeve (60). in, The tool (300) has at least one first clamping unit (305) and a guide unit (310). The first crimping unit (305) defines a tool receiving section (325) on its inner side, which extends along a straight line (320) and is used to receive the crimping sleeve (60) and the wire (20). The first clamping unit (305) includes a first clamp (330), a second clamp (335), and a first setting device (340). The first clamp has a first pressing surface (345) disposed on the side facing the tool receiving part (325), and the second clamp has a second pressing surface (350) disposed on the side facing the tool receiving part (325). The first pressing surface (345) of the first clamp (330) is offset in the axial direction relative to the second pressing surface (350) of the second clamp (335) relative to the straight line (320). The first setting device (340) mechanically connects the first clamp (330) to the second clamp (335). The second pressing surface (350) can be adjusted by the first setting device (340) between a first pressing position radially inward and a second pressing position radially outward relative to the first pressing position. A first portion of the first pressing force (F1) provided by the guide unit (310) can be transmitted to the first pressing surface (345) via the first clamp (330), and the first setting device (340) is configured to transmit a second portion of the first pressing force (F1) from the first clamp (330) to the second clamp (335). The first pressing surface (345) is configured to press a first stamping indentation (140) into the crimping sleeve (60), and the second pressing surface (350) is configured to press a second stamping indentation (145) into the crimping sleeve (60) to crimp the crimping sleeve (60) onto the wire (20). The first clamp (330) has a pressing portion (500) and a supporting portion (505), the supporting portion (505) being adjacent to the pressing portion (500) and connected to the pressing portion (500) in the axial direction. The first pressing surface (345) is radially arranged inside the pressing portion. The second clamp (335) is arranged radially inside the support portion (505). The first setting device (340) is radially arranged between the support portion (505) and the second clamp (335) and is configured to transfer a second portion of the first pressing force (F1) from the support portion (505) to the second clamp (335).

2. The tool (300) according to claim 1. Includes a second clamping unit (315). in, The second clamping unit (315) is offset in the circumferential direction relative to the first clamping unit (305) relative to the straight line (320), and has a third clamping unit (355), a fourth clamping unit (360), and a second setting device (365). The third clamping unit has a third pressing surface (370) facing the tool receiving part (325), and the fourth clamping unit has a fourth pressing surface (375) facing the tool receiving part (325). The third pressing surface (370) is offset relative to the fourth pressing surface (375) in the axial direction. The second setting device (365) mechanically connects the third clamp (355) and the fourth clamp (360). The fourth pressing surface (375) can be adjusted by the second setting device (365) between a third pressing position located radially inward and a fourth pressing position located radially outward relative to the third pressing position. The third pressing surface (370) is configured to press a third stamping indentation (190) into the crimping sleeve (60), and the fourth pressing surface (375) is configured to press a fourth stamping indentation (195) into the crimping sleeve (60) for crimping the crimping sleeve (60) onto the wire (20).

3. The tool (300) according to claim 2. in, The first pressing surface (345) and the third pressing surface (370) are arranged in a common plane (380) relative to the straight line (320) and extend in the circumferential direction, thereby extending around the straight line (320) on a common first circular path. The third pressing surface (370) and the fourth pressing surface (375) are arranged in a common third plane (385), which is offset in the axial direction relative to another plane (380) about a second straight line (320), and the third pressing surface (370) and the fourth pressing surface (375) extend in the circumferential direction so as to extend around the straight line (320) on a common second circular path.

4. The tool (300) according to any one of claims 1 to 3. in, The pressing part (500) and the supporting part (505) are single pieces and are made of one material.

5. The tool (300) according to any one of claims 1 to 3. in, The first setting device (340) has at least one spring unit (515) and a guide (525). The guide (525) is configured to guide the movement of the second clamp (335) between the first pressing position and the second pressing position. The spring unit (515) is at least partially arranged between the first clamp (330) and the second clamp (335), and is configured to push the second clamp (335) radially inward from the second pressing position into the first pressing position.

6. The tool (300) according to claim 5. in, The guide (525) has at least one guide element (565) and a guide receiving part (575) constructed corresponding to the guide element (565). The guide element (565) is radially arranged inside the support portion (505) and mechanically connected to the support portion (505). The guide element (565) extends radially inward from the support portion (505). The guide receiving part (575) is arranged in the second clamp (335). or The guide element (565) is radially disposed on the outside of the second clamp (335) and mechanically connected to the second clamp (335). The guide element (565) extends radially outward from the second clamp (335). The guide receiving part (575) is arranged in the support part (505). The guide element (565) is engaged in the guide receiving part (575).

7. The tool (300) according to claim 5. in, The guide (525) has a slotted guide receiving portion (580) arranged in the second clamp (335). The guide (525) has a stop element (585), which is connected to the first clamp (330) and has a stop surface (590). In the first pressing position, the stop surface (590) abuts against the end of the slotted guide receiving part (580) and restricts the movement of the second clamp (335) relative to the first clamp (330).

8. The tool (300) according to claim 7. in, The stop element (585) is constructed as a pin and oriented parallel to the straight line (320).

9. The tool (300) according to claim 5. in, At the first pressing position, the spring unit (515) is prestressed.

10. The tool (300) according to claim 5. in, The first setting device (340) has an adjustment unit (520). The adjustment unit (520) is connected to the support portion (505). The adjustment unit (520) has a first threaded hole (545) arranged in the support portion (505) and extending in the radial direction, and has a first screw (550). The first screw (550) is screwed into the first threaded hole (545). The prestress (FS1) of the spring unit (515) at the first pressing position can be limited according to the depth of the first screw (550) screwed into the first threaded hole (545).

11. The tool (300) according to any one of claims 1 to 3. in, The first clamp (330) has a first ramp (620) on the side facing the second clamp (335), the first ramp extending obliquely relative to the straight line (320). The first setting device (340) includes a fastening device (595), an adjustment unit (520), and a wedge element (605). The wedge-shaped element (605) is radially arranged between the support portion (505) and the second clamping clamp (335). The second clamp (335) abuts against the wedge-shaped element (605). On the side of the wedge element (605) facing the first inclined surface (620), the wedge element (605) has a second inclined surface (645) that extends obliquely relative to the straight line (320). The fastening device (595) holds the second clamp (335) against the support portion (505) and presses the wedge element (605) between the support portion (505) and the second clamp (335). The axial distance between the wedge element (605) and the pressing part (500) can be adjusted by the adjustment unit (520).

12. An apparatus (10) produced using the tool (300) according to any one of claims 1 to 11. It includes a contact device (15) and a wire (20) having a first electrical conductor (25) and a sheath (35). in, The contact device (15) has a crimping sleeve (60) and a contact element (65) mechanically and electrically connected to the crimping sleeve (60). The crimping sleeve (60) extends along the axis (30). In at least one of the first sub-parts (70) of the crimp sleeve (60), the first inner circumferential side (95) is pressed against the first electrical conductor (25), and the first inner circumferential side (95) is in electrical contact with the first electrical conductor (25). Its features are, The crimping sleeve (60) has a second sub-part (75). The second sub-part (75) is offset relative to the first sub-part (70) about the axis (30). In this process, at least in the second sub-part (75), a second stamping indentation (145) and a fourth stamping indentation (195) offset in the circumferential direction relative to the second stamping indentation (145) about the axis (30) are stamped into the crimping sleeve (60). In the second sub-part (75), the crimp sleeve (60) circumferentially surrounds the sheath (35) of the wire (20), and the sheath (35) circumferentially surrounds and electrically insulates the first electrical conductor (25). The second inner circumferential side (105) of the crimping sleeve (60) is formed by the second stamping indentation (145) and the fourth stamping indentation (195), such that the second inner circumferential side (105) is pressed against the sheath (35) and a frictional engagement is formed.

13. A method for producing an apparatus using a tool (300) according to any one of claims 1 to 11, in, A contact device (15) and a wire (20) are provided, the wire having a first electrical conductor (25) and a sheath (35) surrounding the first electrical conductor (25). In this process, the sheath (35) is removed from the first electrical conductor (25) in the stripping portion (130), and the sheath (35) remains on the first electrical conductor (25) in the sheathed portion (125) adjacent to the stripping portion (130). The crimping sleeve (60) is pushed onto the stripped portion (130) and the sheathed portion (125) of the wire (20), and the stripped portion (130) and the sheathed portion (125) are jointly positioned in the tool receiving portion (325). In this process, the first clamping unit (305) moves radially inward from the first position to the second position, and a first pressing force (F1) is introduced into the first clamping unit (305). In this process, by applying the first part of the first pressing force (F1), the first clamp (330) presses the first stamping indentation (140) into the crimping sleeve (60) at the first pressing surface (345), and causes the first inner circumferential side (95) of the crimping sleeve (60) to press against the first electrical conductor (25). In this process, using the second part of the first pressing force (F1), the second clamp (335) presses the second stamping indentation (145) which is offset in the axial direction relative to the first stamping indentation (140) into the crimping sleeve (60) at the second pressing surface (350), and causes the second inner circumferential side (105) of the crimping sleeve (60) to press against the sheath (35).

Images