Method and device for electrically connecting several individual electrical conductors to a common electrical contact element

Abstract

The invention relates to a method for electrically connecting several individual electrical conductors (3, 4) to a common electrical contact element (1), wherein the individual conductors (3, 4) are provided with insulation (3.1, 4.1) and the insulation (3.1, 4.1) is removed section by section at at least one conductor end and / or an intermediate section located between the two conductor ends. According to the invention, the individual conductors (3, 4) are attached with one of their conductor ends to a support element (2), or several individual conductors (3, 4) are attached with their conductor ends to a common support element (2), or several groups of individual conductors (3, 4) are attached to a support element (2).The at least one support element (2) with at least one individual conductor (3, 4) attached to it is positively and / or force-fitted to a complementary mechanical contact coupling device (1.1, 1.2) formed on the contact element (1) by means of a mechanical support coupling device formed on the support element (2). Subsequently, the individual conductors (3, 4) are welded to the contact element (1) at least in a section of their stripped area. The invention further relates to a device for electrically connecting several individual electrical conductors (3, 4) to a common electrical contact element (1).

Description

[0001] The invention relates to a method for electrically connecting several individual electrical lines to a common electrical contact element according to the preamble of claim 1.

[0002] The invention further relates to a device for electrically connecting several individual electrical lines to a common electrical contact element according to the preamble of claim 5.

[0003] DE 10 2016 107 270 A1 discloses a device and a method for bundling individual wires of a cable harness comprising a plurality of insulated wires. The device comprises a holding device for a connector, a receiving device with receiving chambers, wherein the receiving chambers have a clamping device with respect to an insulation of the wires. Furthermore, the device comprises a gripper for moving the wires and a control device for controlling the gripper, wherein a first set of wires is inserted into the connector and a second set of wires is inserted into the receiving chambers of the receiving device. The wires for the receiving device are stripped at an end on the receiving device side or near this end at an intermediate section.

[0004] The invention is based on the object of providing a novel method and a novel device for electrically connecting several individual electrical lines to a common electrical contact element.

[0005] The object is achieved according to the invention by a method which has the features specified in claim 1 and by a device which has the features specified in claim 5.

[0006] Advantageous embodiments of the invention are the subject of the subclaims.

[0007] In a method for electrically connecting a plurality of individual electrical lines to a common electrical contact element, wherein the individual lines are provided with insulation, the insulation is removed in sections at at least one line end and / or an intermediate region located between the two line ends.

[0008] According to the invention, the individual lines are fastened by one of their line ends to a carrier element, or several individual lines are fastened by their line ends to a common carrier element, or several groups of individual lines are each fastened to a carrier element, for example pinned into the respective carrier element. The common carrier element, with the individual lines fastened thereto, is fastened in a form-fitting and / or force-fitting manner to a complementary mechanical contact coupling device formed on the contact element by means of a mechanical carrier coupling device formed on the common carrier element, or several carrier elements, with the individual lines fastened thereto, are fastened in a form-fitting and / or force-fitting manner to the contact element by means of mechanical carrier coupling devices formed on the carrier elements or complementary mechanical contact coupling devices formed on the contact element.The individual wires are then welded to the contact element at least in a section of their stripped area.

[0009] In order to combine or distribute several individual wires in a vehicle to a ground bolt, ground bar, or potential distributor, forming a so-called splice, the individual wires are attached to a common contact element and electrically connected. The present method enables automated assembly of the carrier elements with the individual wires and automated attachment of these to the contact element. By welding the individual wires to the common contact element, an electrical ground offset is avoided, particularly compared to bridges known from the prior art with contact carriers and crimped individual wires inserted into them.

[0010] According to one possible embodiment of the method, the individual wires are attached to the at least one carrier element in such a way that the section of their stripped area intended for welding to the contact element is located outside the carrier element. This enables a secure and easy-to-carry welding of the individual wires to the contact element.

[0011] According to a further possible embodiment of the method, the individual wires are attached to the at least one carrier element in such a way that the section of their stripped area intended for welding to the contact element is arranged in a material recess of the carrier element, with the area being welded to the contact element through the material recess. This also enables a secure and easy-to-carry welding of the individual wires to the contact element in a defined area within the material recess.

[0012] According to another possible embodiment of the method, the at least one carrier element is removed from the carrier element and the individual lines after the individual lines have been welded. This allows for the realization of a particularly compact contact element with individual lines attached to it.

[0013] In a device for electrically connecting a plurality of individual electrical lines to a common electrical contact element, the individual lines are provided with insulation and the insulation is partially removed at at least one line end and / or an intermediate region located between the two line ends.

[0014] According to the invention, the individual lines are each fastened by one of their line ends to a support element, or several individual lines are fastened by their line ends to a common support element, or several groups of individual lines are each fastened to a support element. The common support element, with the individual lines fastened thereto, is fastened to the contact element in a form-fitting and / or force-fitting manner by means of a mechanical support coupling device formed on the common support element to a complementary mechanical contact coupling device formed on the contact element, or several support elements, with the individual lines fastened to them, are fastened to the contact element in a form-fitting and / or force-fitting manner by means of mechanical support coupling devices formed on the support elements to complementary mechanical contact coupling devices formed on the contact element.Furthermore, a welding device is provided which is designed to weld the individual lines to the contact element at least in a section of their stripped area.

[0015] The device enables automated loading of the carrier elements with the individual wires and automated attachment of these to the contact element, which is designed, for example, as a cable lug. By welding the individual wires to the common contact element, an electrical ground offset is avoided, particularly compared to bridges known from the prior art with contact carriers and crimped individual wires inserted into them.

[0016] According to another possible embodiment of the device, the at least one contact coupling device is a tab formed from the contact element. Such a tab is easy to manufacture and enables simple and secure attachment of the carrier element to the contact element. The tab, in particular, forms a so-called measuring contact.

[0017] According to a further possible embodiment of the device, the at least one contact coupling device is a pin element arranged on the contact element. Such a pin element is easy to manufacture and enables simple and secure attachment of the carrier element to the contact element.

[0018] According to a further possible embodiment of the device, the at least one carrier element has a material recess, wherein the material recess is designed to accommodate the section of the stripped area of ​​the corresponding individual wire intended for welding to the contact element and to accommodate at least a section of a sonotrode of the welding device. This enables particularly precise welding of the individual wires to the contact element in a defined, delimited area. Thus, a welded connection of particularly high quality can be created.

[0019] According to another possible embodiment of the device, the welding device is an ultrasonic welding device. Such an ultrasonic welding device allows for particularly short process times with low energy consumption and low heat input into the components.

[0020] According to a further possible embodiment of the device, it comprises a handling device designed for automatic handling of the individual lines and / or the at least one carrier element and / or the contact element. Such automatic handling can significantly simplify and accelerate the establishment of the electrical connection between the individual lines and the contact element. Furthermore, the reliability of the created connection can be reproducibly increased.

[0021] Embodiments of the invention are explained in more detail below with reference to drawings.

[0022] Showing: Fig. 1 schematically shows a perspective view of a first embodiment of a contact element and of individual lines attached to a first embodiment of a carrier element, Fig. 2 schematically shows a perspective view of the contact element and the individual lines attached to the carrier element according to Fig. 1 in a first relative position to each other, Fig. 3 schematically shows a perspective view of the contact element and the individual lines attached to the carrier element according to Fig. 1 in a second relative position to each other, Fig. 4 schematically shows a perspective view of the contact element and the individual lines attached to the carrier element according to Fig. 3 during a welding process, Fig. 5 schematically shows a perspective view of the contact element and the individual lines attached to the carrier element according to Fig. 4 after the welding process, Fig. 6 schematically shows a perspective view of the first embodiment of the contact element and of individual lines attached to support elements according to a second embodiment, Fig. 7 schematically shows a perspective view of the contact element and the individual lines attached to the support elements according to Fig. 6 in a first relative position to each other, Fig. 8 schematically shows a perspective view of the contact element and the individual lines attached to the support elements according to Fig. 6 in a second relative position to each other, Fig. 9 schematically shows a perspective view of the contact element and the individual lines attached to the support elements according to Fig. 6 in a third relative position to each other, Fig. 10 schematically shows a perspective view of the contact element and the individual lines attached to the support elements according to Fig. 9 during a welding process, Fig. 11 schematically shows a perspective view of the contact element and the individual lines attached to the support elements according to Fig. 10 after the welding process, Fig. 12 schematically shows a perspective view of a second embodiment of a contact element and of individual lines attached to a third embodiment of a carrier element, Fig. 13 schematically shows a perspective view of the contact element and the individual lines attached to the carrier element according to Fig. 12 in a first relative position to each other, Fig. 14 schematically shows a perspective view of the contact element and the individual lines attached to the carrier element according to Fig. 12 in a second relative position to each other, Fig. 15 schematically shows a perspective view of the contact element and the individual lines attached to the carrier element according to Fig. 14 during a welding process, Fig. 16 schematically shows a perspective view of the contact element and the individual lines attached to the carrier element according to Fig. 15 after the welding process, Fig. 17 schematically shows a perspective view of the first embodiment of the contact element and of individual lines attached to a fourth embodiment of a carrier element, Fig. 18 schematically shows a perspective view of the contact element and the individual lines attached to the carrier element according to Fig. 17 in a first relative position to each other and Fig. 19 schematically shows a perspective view of the contact element and the individual lines attached to the carrier element according to Fig. 18 during a welding process.

[0023] Corresponding parts are provided with the same reference numerals in all figures.

[0024] In Fig. 1 is a perspective view of a first embodiment of a contact element 1 and of individual lines 3, 4 attached to a first embodiment of a carrier element 2.

[0025] The individual lines 3, 4 each comprise an electrical conductor 3.2, 4.2, which is surrounded by electrical insulation 3.1, 4.1. At the respective line end shown, the individual lines 3, 4 are stripped, i.e. the insulation 3.1, 4.1 is removed in sections at the line end. With the stripped line ends, the individual lines 3, 4 are pinned or plugged into the carrier element 2 in such a way that at least a stripped section of the individual lines 3, 4 protrudes from the carrier element 2. The pinning or plugging of the individual lines 3, 4 into the carrier element 2 can, for example, be carried out automatically. The carrier element 2 can be designed as a so-called contact carrier, as is installed, for example, in electrical plugs.

[0026] The contact element 1 is designed, for example, as a cable lug and comprises two contact coupling devices 1.1, 1.2, each formed as a tab formed from the contact element 1. The tabs are, for example, punched out of the contact element 1 and bent upwards at least in sections, forming so-called blade contacts.

[0027] As in the Fig. 2 and Fig. As shown in Figure 3, the individual lines 3, 4 are attached to the carrier element 2 on the contact coupling devices 1.1, 1.2 of the contact element 1. For this purpose, the carrier element 2 comprises carrier coupling devices (not shown in detail), which are designed to complement or correspond to the contact coupling devices 1.1, 1.2. For example, the carrier coupling devices are slot-shaped. Furthermore, the carrier coupling devices can comprise clamping devices and / or locking devices for clamping and / or locking the contact coupling devices 1.1, 1.2 in the carrier element 2.

[0028] The fastening of the individual cables 3, 4 with the carrier element 2 to the contact element 1 can be carried out automatically.

[0029] After this fixing, the Fig. 4 a welding of the conductors 3.2, 4.2 to the contact element 1 in stripped areas of the individual conductors 3, 4 protruding from the carrier element 2.

[0030] The welding is carried out by means of a welding device 5, which is designed, for example, as an ultrasonic welding device and comprises a sonotrode 5.1 and an anvil 5.2.

[0031] Welding, for example, is also automated.

[0032] A welded joint 6 produced during welding is in Fig. 5 is shown in more detail.

[0033] In one possible embodiment, the carrier element 2 remains attached to the contact element 1 after welding. In an alternative embodiment, the carrier element 2 is removed from the individual lines 3, 4 and the contact element 1 after welding. This removal can also be automated.

[0034] In Fig. 6 is a perspective view of the first embodiment of the contact element 1 according to Fig. 1 and of individual lines 3, 4 attached to support elements 2 according to a second embodiment.

[0035] In contrast to the Fig. In the first embodiment of the carrier element 2 shown in Figure 1, the carrier elements 2 are designed as so-called terminals, wherein each individual line 3, 4 is pinned or plugged into a separate carrier element 2 with its stripped line end.

[0036] On an underside of the support elements 2, a locking element 2.1, designed, for example, as a so-called locking lance, is arranged.

[0037] As in the Fig. As shown in Figures 7 to 9, the carrier elements 2 with the individual lines 3, 4 are fastened to the contact coupling devices 1.1, 1.2 of the contact element 1. For this purpose, the carrier elements 2 comprise carrier coupling devices (not shown in detail), which are designed to be complementary or corresponding to the contact coupling devices 1.1, 1.2. For example, the carrier coupling devices are slot-shaped. When the carrier elements 2 reach a target position on the contact element 1, the locking elements 2.1 arranged on the underside of the carrier elements 2 each lock into a material recess formed by the shape and bending of the tab-shaped contact coupling devices 1.1, 1.2. Alternatively or additionally, other locking structures for locking the locking elements 2.1 in the contact element 1 can also be provided.Furthermore, the carrier coupling devices can comprise clamping devices and / or locking devices for clamping and / or locking the contact coupling devices 1.1, 1.2 in the carrier element 2.

[0038] After this fixing, the Fig. 10 a welding of the conductors 3.2, 4.2 with the contact element 1 in stripped areas of the individual conductors 3, 4 projecting from the carrier element 2, analogous to the Fig. 4 shown welding.

[0039] The welded joint 6 produced during welding is in Fig. 11 is shown in more detail.

[0040] In one possible embodiment, the carrier elements 2 remain attached to the contact element 1 after welding. In an alternative embodiment, the carrier elements 2 are removed from the individual lines 3, 4 and the contact element 1 after welding. This removal can also be automated.

[0041] In Fig. 12 is a perspective view of a second embodiment of the contact element 1 and of a third embodiment of the carrier element 2 according to Fig. 1 attached individual lines 3, 4 are shown.

[0042] In contrast to the Fig. In the first embodiment of the contact element 1 shown in Figure 1, the contact coupling devices 1.1, 1.2 are each designed as pin elements, wherein the pin elements are part of a so-called pin strip. The pin elements can also form so-called blade contacts. The carrier element 2 differs from the one shown in Figure 1. Fig. 1 only in that it is designed to correspond to the pin elements.

[0043] As in the Fig. 13 and Fig. 14, the individual lines 3, 4 are fastened to the carrier element 2 on the contact coupling devices 1.1, 1.2 of the contact element 1. For this purpose, the carrier element 2 comprises carrier coupling devices (not shown in detail), which are designed to be complementary or corresponding to the contact coupling devices 1.1, 1.2. For example, the carrier coupling devices are designed as openings in the carrier element 2 that are complementary to the pin elements. Furthermore, the carrier coupling devices can comprise clamping devices and / or locking devices for clamping and / or locking the contact coupling devices 1.1, 1.2 in the carrier element 2.

[0044] The fastening of the individual cables 3, 4 with the carrier element 2 to the contact element 1 can be carried out automatically.

[0045] As an alternative to the common carrier element 2, separate carrier elements 2 designed as terminals according to the second embodiment (as shown in the Fig. 6 to 11 shown in more detail).

[0046] After this fixing, the Fig. 15 the welding of the conductors 3.2, 4.2 with the contact element 1 in stripped areas of the individual conductors 3, 4 projecting from the carrier element 2 analogous to the Fig. 4 shown welding.

[0047] The welded joint 6 produced during welding is in Fig. 16 is shown in more detail.

[0048] In one possible embodiment, the carrier element 2 remains attached to the contact element 1 after welding. In an alternative embodiment, the carrier element 2 is removed from the individual lines 3, 4 and the contact element 1 after welding. This removal can also be automated.

[0049] In Fig. 17 is a perspective view of the first embodiment of the contact element 1 according to Fig. 1 and of individual lines 3, 4 attached to a fourth embodiment of a support element 2.

[0050] In contrast to the Fig. In the first embodiment of the carrier element 2 shown in Figure 1, this has a material recess 2.2 through which the stripped cable ends of the individual cables 3, 4 run.

[0051] After a Fig. 18, the fastening of the individual lines 3, 4 with the carrier element 2 to the contact coupling devices 1.1, 1.2 of the contact element 1, which is analogous to the fastening shown in the Fig. 2 and Fig. 3 shown fastening is carried out, the welding is carried out.

[0052] As in Fig.19, in order to carry out the welding, the sonotrode 5.1 of the welding device 5 is inserted into the material recess 2.2 of the carrier element 2.

[0053] The welding is then performed through the material recess 2.2. This welding can also be performed automatically. List of reference symbols 1 contact element 1.1 Contact coupling device 1.2 Contact coupling device 2 support element 2.1 Locking element 2.2 Material recess 3 single lines 3.1 Insulation 3.2 Ladder 4 single lines 4.1 Insulation 4.2 Ladder 5 Welding device 5.1 Sonotrode 5.2 Anvil 6 Welded joint QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] DE 10 2016 107 270 A1

[0003]

Claims

[1] Method for electrically connecting several individual electrical lines (3, 4) to a common electrical contact element (1), wherein the individual lines (3, 4) are provided with insulation (3.1, 4.1) and the insulation (3.1, 4.1) is removed in sections at at least one line end and / or an intermediate region located between both line ends, characterized by , that - the individual lines (3, 4) are fastened with one of their line ends to a respective support element (2) or several individual lines (3, 4) are fastened with their line ends to a common support element (2) or several groups of individual lines (3, 4) are each fastened to a respective support element (2), - the common carrier element (2) with the individual lines (3, 4) attached thereto is fastened in a form-fitting and / or force-fitting manner to a complementary mechanical contact coupling device (1.1, 1.2) formed on the contact element (1) by means of a mechanical carrier coupling device formed on the common carrier element (2), or several carrier elements (2) with the individual lines (3, 4) attached thereto are fastened in a form-fitting and / or force-fitting manner to the contact element (1) by means of mechanical carrier coupling devices formed on the carrier elements (2) or complementary mechanical contact coupling devices (1.1, 1.2) formed on the contact element (1), and - the individual lines (3, 4) are welded to the contact element (1) at least in a section of their stripped area. [2] Method according to claim 1, characterized bythat the individual lines (3, 4) are fastened to the at least one carrier element (2) in such a way that the section of their stripped area intended for welding to the contact element (1) is arranged outside the carrier element (2). [3] Method according to claim 1, characterized by that the individual lines (3, 4) are fastened to the at least one carrier element (2) in such a way that the section of their stripped area intended for welding to the contact element (1) is arranged in a material recess (2.2) of the carrier element (2), wherein the welding of the area to the contact element (1) is carried out through the material recess (2.2). [4] Method according to one of the preceding claims, characterized by that the at least one support element (2) is removed from the support element (2) and the individual lines (3, 4) after the welding of the individual lines (3, 4). [5] Device for electrically connecting a plurality of individual electrical lines (3, 4) to a common electrical contact element (1), wherein the individual lines (3, 4) are provided with insulation (3.1, 4.1) and the insulation (3.1, 4.1) is partially removed at at least one line end and / or an intermediate region located between the two line ends, characterized by , that - the individual lines (3, 4) are fastened with one of their line ends to a respective support element (2) or several individual lines (3, 4) are fastened with their line ends to a common support element (2) or several groups of individual lines (3, 4) are each fastened to a respective support element (2), - the common carrier element (2) with the individual lines (3, 4) attached thereto is fastened to the contact element (1) in a form-fitting and / or force-fitting manner by means of a mechanical carrier coupling device formed on the common carrier element (2) to a complementary mechanical contact coupling device (1.1, 1.2) formed on the contact element (1), or several carrier elements (2) with the individual lines (3, 4) attached thereto are fastened to the contact element (1) in a form-fitting and / or force-fitting manner by means of mechanical carrier coupling devices formed on the carrier elements (2) to a complementary mechanical contact coupling device (1.1, 1.2) formed on the contact element (1), and - a welding device (5) is provided which is designed to weld the individual lines (3, 4) to the contact element (1) at least in a section of their stripped area. [6] Device according to claim 5, characterized by that the contact element (1) is a cable lug. [7] Device according to claim 5 or 6, characterized by that the at least one contact coupling device (1.1, 1.2) is a tab formed from the contact element (1). [8] Device according to claim 5 or 6, characterized by that the at least one contact coupling device (1.1, 1.2) is a pin element arranged on the contact element (1). [9] Device according to one of claims 5 to 8, characterized by that the at least one carrier element (2) has a material recess (2.2), wherein the material recess (2.2) is formed, - to receive the section of the stripped area of ​​the corresponding individual cable (3, 4) intended for welding to the contact element (1) and - to accommodate at least a section of a sonotrode (5.1) of the welding device (5). [10] Device according to one of claims 5 to 9, characterized bya handling device which is designed for automatic handling of the individual lines (3, 4) and / or the at least one carrier element (2) and / or the contact element (1).

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