ARRANGEMENT FOR SHAPED A POWER BUSBAR

Abstract

The disclosure relates to an arrangement (100) for forming a busbar (110) extending along a first spatial axis (101), the arrangement (100) comprising: a first forming element (120) into which a first section (111) of the busbar (110) can be inserted, the first forming element (120) being configured to form the first section (111) of the busbar (110) in the direction of a second spatial axis (102); and a second forming element (130) into which a second section (112) of the busbar (110) can be inserted, the second forming element (130) being configured to form the second section (112) of the busbar (110) in the direction of a third spatial axis (103); wherein the two forming elements (120, 130) are designed for simultaneous or sequential forming of the two sections (111, 112) of the busbar (110), so that a three-dimensional shaping of the busbar (110) takes place.

Description

Technical field

[0001] The present invention relates to the field of forming processes and equipment for the forming of metal parts, such as die bending processes. The invention relates to an arrangement and a method for forming a busbar or a rigid conductor. The invention relates in particular to the three-dimensional die bending of high-voltage busbars, especially high-voltage (HV) busbars, which are used, for example, in battery-electric vehicles. State of the art

[0002] In battery-electric vehicles, rigid high-voltage conductors or busbars are used in the charging circuit and other electrical circuits. To enable routing from one point to another within the vehicle, these busbars must first be bent into shape to conform to the available space and the specific conditions at the installation location. Appropriate shaping of the busbars is necessary to ensure ease of installation and stress-free mounting within the vehicle. Die bending processes are used to shape these busbars, but these processes only allow shaping in two dimensions and are limited to bending busbars with a maximum cross-section of 150 mm². 2 do not permit this. Furthermore, busbars with insulating layers cannot be processed with this method.

[0003] German patent applications DE 10 2021 201 194 A1 and DE 10 2018 217 785 A1 disclose a method for manufacturing a two- or three-dimensionally shaped flat conductor made of metal. German patent application DE 10 2013 017 748 A1 discloses an electrical connecting element for the low-loss conduction of electric current. German patent application JP 2010 176 893 A discloses a method for manufacturing a conductive component for an electrical installation device. Description of the invention

[0004] One object of the invention is therefore to create a concept for the efficient shaping of busbars or rigid conductors in which the aforementioned disadvantages do not occur, i.e., in which the forming of insulated and non-insulated busbars in three-dimensional die bending is possible and which is also feasible for busbars with a larger cross-section.

[0005] The problem is solved by the subject matter of the independent claims. Advantageous embodiments of the invention are specified in the dependent claims, the description, and the accompanying figures.

[0006] The inventive solution is based on the idea of ​​equipping a die with a corresponding negative mold and a straight (insulated), pre-cut rail. The high-voltage rail is formed when the die is closed using sequence control. Additionally, the rail can be cut to its final length.

[0007] The solution presented here can be used in current and future projects involving busbars. It ensures ease of assembly and prevents mechanical stress within a charging path. This allows for simple, efficient, and rapid shaping of the busbars in three-dimensional space. The solution offers high reproducibility with consistent quality. Furthermore, high cycle times are achievable.

[0008] The solution presented here offers the following technical advantages. Compared to currently available technologies, tolerances are significantly reduced and reproducibility is substantially improved. Cycle times are greatly reduced compared to currently available forming methods. The solution according to the invention also allows the forming of high-voltage busbars in an insulated state. Bending is possible in all spatial axes. The solution according to the invention allows the bending of busbars with a large cross-section, i.e., cross-sections larger than 150 mm². 2 .

[0009] The solution presented here allows the bending of (insulated) busbars with a large cross-section greater than 150 mm. 2 in the three-dimensional die bending process.

[0010] According to a first aspect, the problem described above is solved by an arrangement for shaping a busbar extending along a first spatial axis, the arrangement comprising: a first forming element into which a first section of the busbar can be inserted, the first forming element being configured to shape the first section of the busbar in the direction of a second spatial axis; and a second forming element into which a second section of the busbar can be inserted, the second forming element being configured to shape the second section of the busbar in the direction of a third spatial axis; the two forming elements being configured for simultaneous or sequential shaping of the two sections of the busbar, resulting in a three-dimensional shaping of the busbar.

[0011] Such an arrangement allows for the efficient shaping of busbars or rigid conductors, enabling the forming of both insulated and uninsulated busbars using three-dimensional die bending. This arrangement also allows for the forming of busbars with larger cross-sections, such as those exceeding 150 square millimeters.

[0012] According to an exemplary embodiment of the arrangement, the arrangement comprises a support on which the two forming elements are mounted along the first spatial axis.

[0013] The support provides a stable and robust reference surface on which the two forming operations can be performed sequentially or simultaneously.

[0014] According to an exemplary embodiment of the arrangement, the distance between the two forming elements can be adjusted manually or mechanically.

[0015] This offers the advantage that the bends can be made at different points along the busbar. Depending on the available space in the vehicle, the busbar can therefore be custom-made to fit perfectly.

[0016] According to an exemplary embodiment of the arrangement, at least one of the two forming elements comprises a forming cavity which is shaped according to a negative form of the forming by the forming element.

[0017] This allows the busbar to be easily pressed into the mold cavity to obtain the desired positive, i.e., inverse, shape of the mold cavity.

[0018] According to an exemplary embodiment of the arrangement, at least one of the two forming elements comprises a guide which is designed to guide the corresponding section of the busbar into the second spatial axis during the forming process.

[0019] Such a guide creates an efficient execution of the forming process, in which the busbar has no discontinuities.

[0020] According to an exemplary embodiment of the arrangement, the guide comprises a first forming jaw and a second forming jaw; wherein the first forming jaw is pivotably arranged between the first spatial axis and the second spatial axis and is configured to reshape the first section of the busbar from the first spatial axis towards the second spatial axis and to align it along the second spatial axis; and wherein the second forming jaw has a curvature from the first spatial axis towards the second spatial axis and is configured to guide the busbar during the reshaping process from the first spatial axis to the second spatial axis.

[0021] These two forming jaws allow for efficient bending. This results in a flat, even bending of the busbar, preventing damage to the component or insulation.

[0022] According to an exemplary embodiment of the arrangement, the guide is designed to engage the corresponding section of the busbar over a flat area during the forming process.

[0023] Such a large-scale intervention does not cause any damage to the component or the insulation.

[0024] According to an exemplary embodiment of the arrangement, the first forming element is designed to bend the first section of the busbar in a range from 0° to 90°.

[0025] This allows the busbar to be reshaped according to the requirements of the installation location, so that it can be installed with a precise fit.

[0026] According to an exemplary embodiment of the arrangement, the arrangement comprises a cover element configured to cover the first section of the busbar after it has been inserted into the first forming element; wherein the cover element is configured to leave a space between the first section of the busbar and the cover element into which the busbar can expand during forming.

[0027] Such a cover element prevents the busbar from buckling in the inner radius.

[0028] According to an exemplary embodiment of the arrangement, the arrangement comprises a hold-down element configured to hold down the busbar during forming, so that the busbar remains in position during forming; wherein the hold-down element is arranged between the first forming element and the second forming element.

[0029] Such a hold-down element prevents the rail from twisting during the forming process.

[0030] According to an exemplary embodiment of the arrangement, the arrangement is designed to form a busbar encased in an insulating layer.

[0031] This allows already insulated busbars to be reshaped without damaging the insulation, making the manufacturing process more efficient.

[0032] According to an exemplary embodiment of the arrangement, the arrangement comprises: one or more further forming elements configured to each form further sections of the busbar; and a sequence control configured to control a sequence of forming operations by the respective forming elements.

[0033] This allows more than two forming operations to be performed simultaneously or sequentially. A suitable forming machine can therefore produce a multiply formed busbar very quickly and efficiently.

[0034] According to an exemplary embodiment of the arrangement, the arrangement comprises: a cutting element designed to bring the busbar to a predetermined length dimension.

[0035] This allows the busbar to be brought to the required length after forming, so that it can be installed directly in the desired location in the vehicle.

[0036] According to an exemplary embodiment of the arrangement, the arrangement is designed to form a busbar with a cross-section larger than 150 square millimeters.

[0037] This arrangement is therefore particularly suitable for the transformation of busbars or rigid conductors with a large cross-section, which has not been possible with conventional transformation methods.

[0038] According to a second aspect, the problem described above is solved by a method for shaping a busbar extending along a first spatial axis, wherein the method comprises the following steps: inserting a first section of the busbar into a first forming element and shaping the first section of the busbar in the direction of a second spatial axis by the first forming element; inserting a second section of the busbar into a second forming element and shaping the second section of the busbar in the direction of a third spatial axis by the second forming element; wherein the shaping of the two sections of the busbar by the two forming elements is carried out simultaneously or sequentially, so that a three-dimensional shaping of the busbar is achieved.

[0039] This forming process allows for the efficient shaping of busbars or rigid conductors, enabling the three-dimensional die bending of both insulated and uninsulated busbars. The process also allows for the forming of busbars with larger cross-sections, such as those exceeding 150 square millimeters. Brief character description

[0040] The invention will now be described in more detail with reference to exemplary embodiments and the figures. The figures show: Fig. 1 a three-dimensional representation of an arrangement 100 for shaping a busbar according to an embodiment; Fig. 2 a top view of a first forming element 120 of the arrangement 100 Fig. 1 in the initial state, i.e. before the transformation; Fig. 3 a top view of the first forming element 120 of the arrangement 100 Fig. 1 after the forming process, i.e. with the profile fully bent; and Fig. 4 a schematic representation of a method 400 for shaping a busbar according to an embodiment.

[0041] The figures are merely schematic representations and serve only to illustrate the invention. Identical or equivalent elements are consistently identified by the same reference numerals.

[0042] The following detailed description refers to the accompanying drawings, which form part thereof and illustrate specific embodiments in which the invention can be implemented. It is understood that other embodiments can also be used and structural or logical modifications can be made without deviating from the concept of the present invention. Therefore, the following detailed description is not to be understood as limiting. Furthermore, it is understood that the features of the various embodiments described herein can be combined with one another, unless specifically stated otherwise.

[0043] The aspects and embodiments are described with reference to the drawings, where the same reference numerals generally refer to the same elements. For illustrative purposes, numerous specific details are presented in the following description to provide a thorough understanding of one or more aspects of the invention. However, it may be obvious to a person skilled in the art that one or more aspects or embodiments can be implemented with a lesser degree of specific detail. In other cases, known structures and elements are shown schematically to facilitate the description of one or more aspects or embodiments. It is understood that other embodiments may be used and structural or logical modifications may be made without departing from the concept of the present invention.

[0044] Fig. Figure 1 shows a three-dimensional representation of an arrangement 100 for shaping a busbar according to an embodiment.

[0045] The arrangement 100 serves to shape a conductor rail 110, which extends along a first spatial axis 101.

[0046] The arrangement 100 comprises a first forming element 120 into which a first section 111 of the busbar 110 can be inserted. The first forming element 120 is configured to form the first section 111 of the busbar 110 in the direction of a second spatial axis 102. "In the direction of the second spatial axis" here means that the first section is formed along a surface spanned by the first spatial axis 101 and the second spatial axis 102. It can be, but does not have to be, a 90° bend.

[0047] The arrangement 100 comprises a second forming element 130 into which a second section 112 of the busbar 110 can be inserted. The second forming element 130 is configured to form the second section 112 of the busbar 110 in the direction of a third spatial axis 103. Here, too, "in the direction of the third spatial axis 103" means that the second section is formed along a surface spanned by the first spatial axis 101 and the third spatial axis 103. It can be, but does not have to be, a 90° bend.

[0048] In the arrangement 100, the two forming elements 120, 130 are designed for simultaneous or sequential forming of the two sections 111, 112 of the busbar 110, so that a three-dimensional shaping of the busbar 110 takes place.

[0049] The arrangement 100 can have a support 150 on which the two forming elements 120, 130 are mounted along the first spatial axis 101. Mounting can be done manually or mechanically.

[0050] A distance of 151 between the two forming elements 120, 130 can therefore be adjusted manually or by machine.

[0051] At least one (here the second forming element) 130 of the two forming elements 120, 130 can comprise a forming cavity 131, which is formed according to a negative shape of the forming by the forming element 130.

[0052] At least one (here the first forming element) 120 of the two forming elements 120, 130 can include a guide 132 which is designed to guide the corresponding section 111, 112 of the busbar 110 into the second spatial axis during the forming process.

[0053] The guide 132 can comprise a first forming jaw 132a and a second forming jaw 132b, as shown in Fig. 1 shown.

[0054] The first forming jaw 132a can be pivotably arranged between the first spatial axis 101 and the second spatial axis 102 and can be designed to reshape the first section 111 of the busbar 110 from the first spatial axis 101 in the direction of the second spatial axis 102, e.g. bending it, and align it along the second spatial axis 102.

[0055] The second forming jaw 132b can have a curvature from the first spatial axis 101 towards the second spatial axis 102, and be designed to guide the busbar 110 from the first spatial axis 101 to the second spatial axis during forming.

[0056] The guide 132 can be designed to engage the corresponding section 111, 112 of the conductor rail 110 over a flat area during the forming process.

[0057] The first forming element 120 can be configured to bend the first section 111 of the busbar 110 in a range from 0° to 90°. Bends greater than 90° are also possible.

[0058] The arrangement 100 can include a cover element 160, as shown in Fig. Figure 1 shows a device designed to cover the first section 111 of the busbar 110 after it has been inserted into the first forming element 120. The cover element 160 can be designed to leave a space between the first section 111 of the busbar 110 and the cover element 160, into which the busbar 110 can expand during forming.

[0059] The arrangement 100 can include a hold-down element 140, as shown in Fig. Figure 1 shows a device designed to hold down the busbar 110 during the forming process, so that the busbar 110 remains in position during the forming process. The holding element 140 can, for example, be arranged between the first forming element 120 and the second forming element 130, or at other locations.

[0060] In particular, the arrangement 100 is also designed to form a busbar 110 encased in an insulating layer or an insulated rigid conductor.

[0061] The arrangement 100 can also include one or more further forming elements, each configured to form further sections of the busbar 110. The arrangement 100 can also include a sequence control (not shown) configured to control a sequence of forming operations by the respective forming elements.

[0062] The arrangement 100 can include a cutting element (not shown) designed to bring the busbar 110 to a predetermined length dimension.

[0063] The arrangement 100 is also specifically designed for shaping a busbar 110 with a cross-section larger than 150 square millimeters.

[0064] Fig. Figure 2 shows a top view of a first forming element 120 of the arrangement 100. Fig. 1 in the initial state, i.e. before the transformation.

[0065] The busbar 110, inserted into the first forming element 120, is visible here. During the forming process, in this case bending, the busbar 110 is engaged by the first forming jaw 132a and rotated upwards by approximately 90°. The second forming jaw 132b guides the other side of the busbar 110 during bending, ensuring a round bend.

[0066] A cover element 160 or a cover plate 160 is mounted above the busbar 110 and ensures that the busbar 110 has some room to expand when it bends upwards.

[0067] Fig. Figure 3 shows a top view of the first forming element 120 of the arrangement 100. Fig. 1 after the forming process, i.e. with the profile fully bent.

[0068] The busbar 110 is inserted into the first forming element 120 and is now in the bent state. The first forming jaw 132a has engaged the outer surface of the busbar 110 and rotated it upwards by approximately 90°, thus bending the busbar 110 accordingly. The second forming jaw 132b guided the inner surface of the busbar 110 during the bending process, resulting in a bend on the inner surface that is smaller than the bend on the outer surface of the busbar 110.

[0069] Especially when bending the parts into the Fig. 2 and Fig. In section 111 of the busbar 110 shown in Figure 3, it is important that the forming area is completely covered throughout the entire bending process. This prevents the busbar 110 from buckling on the inner radius. It should be noted that the gap between the busbar 110 and the cover unit or cover element 160, as shown in the figures, must be kept clear. Fig. 2 and Fig. Figure 3 shows that it should be precisely aligned. To accommodate variations in material thickness, a spring-loaded cover plate 160 is feasible. This can be rigidly designed. Holding down the rail 100, for example with a spring-loaded hold-down or hold-down element 140, as shown in the Fig. 2 and Fig. As shown in section 3, this should be ensured in the area before forming. These measures prevent the rail 110 from twisting during the bending process.

[0070] Another important point is that the attack in the bending process is not localized, but rather spread over a surface, as shown here in the Fig. 2 and Fig. Figure 3 shows that, due to the soft material of the rail, point attacks can cause 110 marks on the component, which can lead to damage to the insulation.

[0071] With the arrangement 100 presented here, bends from 0° to 90° can be produced "virtually steplessly". Bends greater than 90° are also possible.

[0072] Fig. Figure 4 shows a schematic representation of a method 400 for shaping a busbar according to one embodiment.

[0073] Method 400 is used to shape a busbar 110 which extends along a first spatial axis 101.

[0074] Procedure 400 comprises the following steps: Insertion 401 of a first section 111 of the busbar 110 into a first forming element 120 and forming 402 of the first section 111 of the busbar 110 in the direction of a second spatial axis (102) by the first forming element (120), as above to the Fig. 1, Fig. 2 to Fig. 3 described; Insertion 403 of a second section 112 of the busbar 110 into a second forming element 130 and forming 404 of the second section 111 of the busbar 110 in the direction of a third spatial axis 103 by the second forming element 130, as above to the Fig. 1, Fig. 2 to Fig. 3 described; wherein the forming 402, 404 of the two sections 111, 112 of the busbar 110 is carried out simultaneously or sequentially by the two forming elements 120, 130, so that a three-dimensional shaping of the busbar 110 takes place. REFERENCE MARK LIST 100 Arrangement according to the invention for shaping a busbar 101 first spatial axis 102 second spatial axis 103 third spatial axis 110 busbar or rigid conductor 111 first section of the power rail 112 second section of the power rail 120 first forming element 130 second forming element 131 Mold nest 132 Leadership 132a first mold jaw 132b second mold jaw 140 hold-down element 150 beams or support plates 151 Distance between the two forming elements 160 cover element 400 Inventive method for shaping a busbar 401 First step: Introducing 402 second step: Transformation 403 Third step: Introducing 404 fourth step: Transforming

Claims

[1] Arrangement (100) for shaping a busbar (110) extending along a first spatial axis (101), the arrangement (100) comprising the following: a first forming element (120) into which a first section (111) of the busbar (110) can be inserted, wherein the first forming element (120) is configured to form the first section (111) of the busbar (110) in the direction of a second spatial axis (102); and a second forming element (130) into which a second section (112) of the busbar (110) can be inserted, wherein the second forming element (130) is designed to form the second section (112) of the busbar (110) in the direction of a third spatial axis (103); wherein the two forming elements (120, 130) are designed for simultaneous or sequential forming of the two sections (111, 112) of the busbar (110), so that a three-dimensional shaping of the busbar (110) takes place characterized by, that at least one (120) of the two forming elements (120, 130) comprises a guide (132) which is designed to guide the corresponding section (111, 112) of the busbar (110) into the second spatial axis during the forming process, wherein the guide (132) comprises a first forming jaw (132a) and a second forming jaw (132b); wherein the first forming jaw (132a) is pivotably arranged between the first spatial axis (101) and the second spatial axis (102) and is configured to reshape the first section (111) of the busbar (110) from the first spatial axis (101) in the direction of the second spatial axis (102) and to align it along the second spatial axis (102); and wherein the second forming jaw (132b) has a curvature from the first spatial axis (101) towards the second spatial axis (102), and is designed to guide the busbar (110) from the first spatial axis (101) to the second spatial axis during forming. [2] Arrangement (100) according to claim 1, comprising: a support (150) on which the two forming elements (120, 130) are mounted along the first spatial axis (101). [3] Arrangement (100) according to claim 1 or 2, wherein a distance (151) between the two forming elements (120, 130) is adjustable manually or mechanically. [4] Arrangement (100) according to one of the preceding claims, wherein at least one (130) of the two forming elements (120, 130) comprises a forming cavity (131) which is formed according to a negative shape of the forming by the forming element (130). [5] Arrangement (100) according to one of the preceding claims, wherein the guide (132) is designed to engage the corresponding section (111, 112) of the busbar (110) over a flat area during the forming process. [6] Arrangement (100) according to one of the preceding claims, wherein the first forming element (120) is configured to bend the first section (111) of the busbar (110) in a range from 0° to 90°. [7] Arrangement (100) according to any one of the preceding claims, comprising: a cover element (160) which is designed to cover the first section (111) of the busbar (110) after it has been inserted into the first forming element (120); wherein the cover element (160) is designed to leave a space between the first section (111) of the busbar (110) and the cover element (160) into which the busbar (110) can expand during forming. [8] Arrangement (100) according to any one of the preceding claims, comprising: a holding element (140) which is designed to hold down the busbar (110) during the forming process, so that the busbar (110) remains in position during the forming process; wherein the hold-down element (140) is arranged between the first forming element (120) and the second forming element (130). [9] Arrangement (100) according to one of the preceding claims, which is designed to form a busbar (110) enclosed with an insulating layer. [10] Arrangement (100) according to any one of the preceding claims, comprising: one or more further forming elements, each designed to form further sections of the busbar (110); and a sequence control system designed to control a sequence of forming operations by the respective forming elements. [11] Arrangement (100) according to any one of the preceding claims, comprising: a cutting element designed to bring the busbar (110) to a predetermined length dimension. [12] Arrangement (100) according to one of the preceding claims, which is designed to form a busbar (110) with a cross-section greater than 150 square millimeters. [13] Method (400) for shaping a busbar (110) extending along a first spatial axis (101), wherein the method (400) comprises the following steps: Inserting (401) a first section (111) of the busbar (110) into a first forming element (120) and forming (402) the first section (111) of the busbar (110) in the direction of a second spatial axis (102) by the first forming element (120); Inserting (403) a second section (112) of the busbar (110) into a second forming element (130) and forming (404) the second section (111) of the busbar (110) in the direction of a third spatial axis (103) by the second forming element (130); wherein the forming (402, 404) of the two sections (111, 112) of the busbar (110) is carried out simultaneously or sequentially by the two forming elements (120, 130), so that a three-dimensional shaping of the busbar (110) takes place.

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