Method and device for combined leak and electrical testing.

Abstract

2.1 Common leak and electrical testing methods rely on contact adapters that are plugged into the test object's plug or socket. This results in scratches on the contact surfaces or on the contact pins of the test object's plug or socket. In high-current applications, 4-wire measurements are performed in separate process steps, which is time-consuming. 2.2 The invention is a floating, combined contact adapter for electrical and pneumatic adaptation of high-voltage and high-current tests. The method is individually adapted to the geometry of the test object's connector. 2.3 The entire adapter unit is delivered, with the centering and guidance on the connector contour being carried out by the mask until the contact element rests on the connector base. As the feed motion continues, the contact pliers enclose the plug contact, and the pliers actuator is compressed. As the feed motion continues with a defined force, the sealing element between the inner and outer elements is deformed, contacting the plug contour and sealing.

Description

[0001] The invention defined in claim 1 addresses the following problems: Depending on their intended application, electrical control units must be tested for fluid tightness and electrical functionality.

[0002] For modules with high-voltage power supplies, such as the 800 V charging voltage in electric vehicles, an insulation test and a high-voltage test must also be performed. Four-wire measurements are often required in high-current applications.

[0003] In electromobility applications, connectors with increasingly high compactness, current-carrying capacity, and voltage insulation strength are being used. These connectors, especially the contact surfaces or contact pins, must not show any damage or scratches due to the electrical or pneumatic adaptations after testing. The tests described above are typically performed in individual test processes, each with specific contact adaptations.

[0004] Problem 1: Risk of damage to the contact surfaces or contact pins (scratches due to mechanical stress) on the test object-side connector.

[0005] Problem 2: Insufficient insulation distance between the contact elements for high-voltage tests with an exemplary test voltage of 3 kV.

[0006] Problem 3: Power transmission for high-current applications with an exemplary current flow of 50 A.

[0007] Problem 4: Insufficient space for a 4-wire measurement.

[0008] Problem 5: Missing sealing adapter of the plug connection for leak testing.

[0009] Problem 6: Insufficient stability of the contact adaptation for several 10,000 contacting operations.

[0010] Problem 7: No tolerance compensation possible due to fixed housing of the contact adaptation.

[0011] Problem 8: The above-mentioned problems 1 to 7 should be treated with a joint contact adaptation.

[0012] These problems are solved by the features mentioned in patent claim 1.

[0013] The invention is a combined multiple contact adaptation ( Fig. 3) For electrical and pneumatic adaptation of high-voltage and high-current tests. The floating bearing compensates for manufacturing tolerances.

[0014] The procedure is individually adapted to the geometry of the test plug.

[0015] The entire adaptation unit ( Fig. 3) is fed, whereby the centering and guidance on the connector contour (1) is carried out by the mask (2) until the contact element (3) rests on the connector base.

[0016] By continuing the feed movement of the contact adapter ( Fig. 1), the contact pliers (4) enclose the plug contact (5) and the pliers actuator (6) is compressed ( Fig. 2)

[0017] Through further feed movement by a pneumatic cylinder with a defined force, the elastomer ring (7) between the inner element (3) (insulator) and the outer element (2) is deformed, whereby it contacts and seals the outer connector contour (or, in the inverted configuration, the inner connector contour). Overpressure can be generated in the inner chamber (9) using compressed air via the compressed air connection (8) and the outer housing.

[0018] A leak test is performed, for example, using a differential pressure method or a flow measurement. Electrical energy, for example, 1 kV / 100 A, and electrical signals, such as an interlock, can be transmitted and measured simultaneously.

[0019] The advantages achieved by the process are characterized by the fact that - No risk of damage to the contact surfaces or contact pins (scratches due to mechanical stress) on the plug connection on the test object side due to the targeted actuation of the contact clamp. - Insulating housing between the contact elements for high-voltage tests with an exemplary test voltage of 3 kV. - Power transmission for high-current applications with an exemplary current flow of 50 A. - Sufficient installation space for a 4-wire measurement through separate contacts. - Sealing adapter of the plug connection for leak testing realized by elastomer ring. - High stability of the contact adaptation for several 10,000 contacting operations realized by actuated contact pliers.

Claims

[1] Method and device for combined leak and electrical testing, consisting of: a) a floating housing b) an insertion mask on the inner or outer contour of the plug / socket to be tested c) a sealing element d) an insulator between the electrical energy supply and the sealing element e) a contact element for transmitting electrical energy f) an actuator for contacting and sealing in a common stroke

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