Joining process, joining connection, housing and current straightener housing made of joining connections and joining pliers

Abstract

The invention relates to a joining method for a profile to a node, comprising the steps of sliding (S10) the profile (10) onto one of at least one pin (22) of the node (20), such that the profile (10) and the pin (22) have an overlap area (50). The method also includes positioning (S20) a joining tool (40) in the overlap area (50). Finally, the method discloses actuating (S30) the joining tool (40), wherein the joining tool (40) applies a pressing force (F) to the overlap area (50) at least at two opposing points, such that the pin (22) of the node (20) and the profile (10) are joined.

Description

[0001] The invention relates to a joining method, joining connection and housing made of joining connections. Problem statement

[0002] Joining methods for modular housing or truss structures are known in the prior art. These methods utilize additional components to create a connection, as shown, for example, in EP2767459B1. EP1994617A1 describes a housing in which the individual elements are welded together.

[0003] Both of the aforementioned options have the disadvantage that additional elements are required for the joining process and / or a welding process is used, resulting in a high thermal input into the material and stresses being introduced into the material.

[0004] This application addresses the aforementioned problems of producing a reliable and efficient joining connection between a profile and a node. In particular, the application offers improvements with respect to the joining process and the joining tool to ensure a positive-locking connection and consistent positioning of the joining tool during the joining process. Furthermore, aspects such as the use of flat gaskets, sealants, and electrically conductive connections are also considered to achieve a joining connection optimized for housings of electrical and electronic devices. The application aims to improve the efficiency and reliability of joining connections, especially for housings and power converter enclosures containing electrical or electronic components.

[0005] A joining method for a profile to a node is shown, comprising the steps

[0006] Sliding the profile onto one of at least one pins of the node, such that the profile and the pin have an overlap area, positioning a joining tool in the overlap area, actuating the joining tool, wherein the joining tool applies a pressing force to the overlap area at least at two opposite areas, so that the pin of the profile and the node are joined.

[0007] By sliding the profile onto a pin of the joint with an overlap area and then joining it using a joining tool, a stable connection between the components is created, exhibiting high load-bearing capacity. Positioning a joining tool in the overlap area and subsequently actuating it ensures a uniform distribution of the pressing force, resulting in improved joining quality. Applying pressing force to opposite areas of the overlap contributes to the creation of a uniform joint that is less susceptible to material fatigue or breakage. Furthermore, the process does not require explicit heating of the individual components, thus preventing stresses caused by localized heat input and making the joining process more energy-efficient and less hazardous.

[0008] This invention offers the advantage that the joining method provides an efficient and precise way to join a profile to a node. The steps of sliding, positioning, and actuating the joining tool result in a reliable connection between the profile and the node's tenon. The method can be performed by a human operator or a machine, such as a robotic arm.

[0009] In one embodiment, the joining tool is a joining pliers that deforms the profile in such a way that a positive-locking joint is created with at least two recesses provided on the pin of the node, wherein the recesses are preferably arranged in pairs on opposite sides of the pin.

[0010] The use of a joining tool that deforms the profile enables a positive-locking connection, ensuring high mechanical strength and a durable bond. Creating a positive-locking connection with recesses on the tenon of the joint increases the reliability of the connection, as it is less susceptible to vibrations and dynamic loads. The positive-locking connection achieved with the joining tool allows for quick and easy assembly, resulting in reduced manufacturing time and costs. By strategically arranging at least two recesses on opposite sides of the tenon, the joining forces cancel each other out, making the joining process more reliable.

[0011] In one embodiment, when the profile is pushed onto the pin, the profile is pushed onto the pin up to at least one stop provided on the pin or at the node.

[0012] Sliding the profile up to a stop ensures precise positioning, contributing to consistent joining quality. Using a stop on the tenon or node simplifies assembly by reducing the need for external positioning measurements. A stop serves as a reference point for the joining tool, improving the reproducibility of joining processes and reducing the likelihood of errors.

[0013] In one embodiment, the joining tool has locking devices designed to engage in locking areas provided on the pin or node, which serve as at least one stop, so that the joining tool remains in a constant position with respect to the overlap area during actuation of the joining tool.

[0014] Snap-in mechanisms on the joining tool ensure stable positioning during the joining process, resulting in consistent joint quality. Furthermore, they reduce manual influence, enabling more efficient and safer operation. The use of snap-in mechanisms minimizes the risk of tool displacement during operation, increasing joining precision and preventing material damage.

[0015] In one embodiment, the joining pliers are designed such that the pressing force applied to the overlap area is applied to the profile by means of defined projecting geometries, wherein the defined projecting geometry is preferably spherical or partially spherical.

[0016] Applying the pressing force via defined, protruding geometries allows for targeted action on the profile, resulting in the desired deformation and an optimized joint. The use of spherical or semi-spherical geometries distributes the pressing force evenly and avoids peak loads, thus preserving the integrity of the profile. The specific design of the joining pliers with protruding geometries facilitates adaptation to different profile shapes and materials, increasing the flexibility of the joining process.

[0017] In one embodiment, the distance from the defined geometries of the joining pliers to the locking devices corresponds to the distance between the recesses of the pin from the locking areas, and wherein, when the joining tool is actuated, the profile is deformed by the pressing force in such a way that material of the profile is pressed into the at least two recesses.

[0018] The corresponding distance between the geometries of the joining tool and the locking mechanisms enables precise and reproducible positioning of the joining tool relative to the tenon, resulting in increased reliability through standardized joint spacing. Furthermore, it ensures that the profile material is deformed in such a way that it is pressed into the recesses on the tenon. This deformation of the profile and the pressing of the material into the recesses creates a positive-locking connection that exhibits high mechanical strength and reduces the need for additional fasteners. The specific arrangement of the recesses and locking areas helps to distribute the load across the joint points, increasing the service life of the connection and reducing the likelihood of material fatigue.

[0019] In one embodiment of the method, prior to the step of sliding the profile onto the pin, a step of sliding a flat gasket onto the pin is carried out, wherein the flat gasket is preferably pushed onto the pin so far that the flat gasket is in contact with an end face of the node.

[0020] Sliding a flat gasket onto the pin before joining the profile creates an additional barrier against the ingress of moisture and dirt, thus improving the corrosion resistance of the connection. Positioning the flat gasket in contact with the end face of the joint ensures optimal sealing and prevents the gasket from slipping during the assembly process. Using a flat gasket simplifies the assembly process because it can be easily positioned and adjusted, reducing installation time and increasing efficiency.

[0021] When designing the joining process, and in particular the thickness of the flat gasket and the stop, the flat gasket is designed so that, when the profile and the node are joined, the flat gasket experiences precisely the compression necessary for a tight seal. In other words, the flat gasket projects slightly further from the end face of the node than the stop. When the profile is then pushed onto the node, the gasket is compressed. This compression ensures optimal sealing of the node-profile joint.

[0022] In one embodiment, prior to the step of sliding the profile onto the pin, a step of applying a sealant to the node is carried out, wherein the sealant is applied to an end face of the node.

[0023] Applying a sealant to the end face of the joint before joining provides a tailored seal that conforms to the surface contours, ensuring a high level of tightness against liquids and gases. Using a sealant allows for flexible adaptation to varying tolerances and surface finishes, increasing the reliability of the connection under diverse operating conditions. The sealant can also act as additional corrosion protection by preventing direct contact between dissimilar metals, thus minimizing the risk of galvanic corrosion.

[0024] In one embodiment, the profile is made of aluminium or an aluminium alloy and is preferably manufactured by an extrusion process.

[0025] Manufacturing the profile from aluminum or an aluminum alloy through extrusion allows for the production of complex cross-sectional shapes while simultaneously maximizing material utilization and minimizing material costs. Aluminum profiles offer an excellent combination of low weight and high strength, which reduces the overall load on the structure and can contribute to energy savings. The use of aluminum alloys increases the corrosion resistance of the profiles, extending the service life of the structure and reducing maintenance costs.

[0026] In one embodiment, the node is made of aluminium or an aluminium alloy and is preferably manufactured by a rheocasting process.

[0027] Manufacturing the node from aluminum or an aluminum alloy using rheocasting enables a fine-grained microstructure, resulting in improved mechanical properties and higher strength of the castings. The rheocasting process offers high dimensional accuracy and surface quality, reducing post-processing steps and lowering production costs. Using aluminum alloys for the node contributes to a reduction in the overall weight of the structure and allows for easy recycling at the end of the product's life, thus improving environmental sustainability.

[0028] One aspect of the invention shows a joining connection of a profile and a node, which is produced using the joining method according to one of the preceding claims.

[0029] The joining process enables quick and efficient assembly of profiles and nodes, resulting in time and cost savings in production. This joining method ensures high stability and strength of the connection, increasing the durability and reliability of the structure. The standardized joining system allows for a modular design, enabling easy customization and expansion of the structure.

[0030] In one embodiment, the pin and the profile have a conductive connection.

[0031] The electrically conductive connection between the pin and the profile allows for the integration of a power supply, eliminating the need for additional wiring and simplifying the design. This power supply primarily serves EMC (electromagnetic compatibility) and housing grounding purposes, and can also be used for other applications.

[0032] In one embodiment, the profile is designed in such a way that cables can be guided in the side surfaces of the profile.

[0033] The ability to route cables within the profile's side surfaces contributes to a tidy and organized cable management system, simplifying maintenance and inspection. Integrating the cables into the profile protects them from mechanical damage and environmental influences, thus increasing operational reliability. The profile's cable routing design allows for flexible placement of electrical and electronic components within the structure, as power supplies can be supplied from various locations.

[0034] Housing, wherein the housing is made of several joining connections according to one of the claims to and including electrical or electronic components.

[0035] Manufacturing an enclosure from multiple joining connections enables a modular and flexible design that can be adapted to specific requirements. This modularity allows enclosures to be configured precisely as needed. For example, enclosures can be optimally adapted to electrical or electronic components and their wiring. Similarly, an enclosure can be optimized for heat dissipation. Furthermore, the use of standardized joining connections facilitates mass production of enclosures, as the same components can be used for different configurations, thus reducing manufacturing and transportation costs.

[0036] In one embodiment, the square-shaped side or inner surfaces formed by the joining connections can be provided with cover elements which are attached to the profiles or nodes of the joining connections by means of force-fit and / or form-fit joining methods.

[0037] The option of fitting rectangular side or interior surfaces with cover elements increases aesthetic flexibility and allows for attractive design of the visible surfaces. Similarly, such cover elements can protect devices or equipment mounted inside the enclosure from moisture, solids such as dust, and / or other environmental influences such as UV radiation or other types of radiation, as needed. Cover elements, which are attached using force-fit and / or form-fit joining methods, offer high mechanical strength and stability, thus reinforcing the enclosure structure.

[0038] Another aspect of the invention shows a power converter housing, wherein the power converter housing is made from several joining connections according to the above embodiments and comprises electrical or electronic components.

[0039] Manufacturing an enclosure from multiple joining points allows for a modular and flexible design that can be adapted to specific requirements. This modularity enables enclosures to be designed according to their intended use. For example, if the enclosure is intended for a simple inverter, it can be kept relatively small and simple. If the enclosure is for a battery or hybrid inverter, an additional module for a DC / DC converter can be incorporated.

[0040] Manufacturing the power converter housing from multiple joints can optimize heat dissipation, as the joints can act as heat conductors, thus increasing the reliability and lifespan of the electrical or electronic components. Furthermore, the use of standardized joints facilitates mass production of housings, since the same components can be used for different configurations, reducing manufacturing and transportation costs. The specific design of the joints can also achieve increased mechanical stability of the housing, resulting in improved protection of the integrated components against mechanical impacts.

[0041] Another advantage of a power converter enclosure manufactured using multiple joining connections is that such an enclosure can be assembled from the bottom up. For example, a base consisting of four nodes and four profiles can first be joined using the method described above. A top element is then inserted. Next, profiles are attached vertically to the existing nodes, thus building up the power converter enclosure vertically. After attaching further profiles and nodes, a lower section of the power converter enclosure is complete. Before attaching further top elements, electrical and / or electronic components can be mounted and wired in this lower section.Once these components are mounted, wired, and have undergone an optional functional test, the cover elements of the lower section are attached, and construction of the next section of the power converter housing begins using further nodes and profiles. These steps are continued until the power converter housing is equipped with all the intended components.

[0042] In this way, an enclosure can not only be modular in design, but also be modularly constructed, making the wiring and mounting of electrical and / or electronic components in the lower sections of the enclosure simple and easily accessible. Furthermore, if necessary or desired, intermediate shelves can be installed across a portion of the enclosure's width, ensuring that larger and smaller components have sufficient space and that no space is wasted.

[0043] Another aspect of the invention shows a joining pliers with two legs, wherein the leg ends are provided with defined geometries, preferably spherical or partially spherical geometries, locking devices which are designed to be able to engage in locking areas, wherein the joining pliers are designed such that when actuated the legs can approach each other and exert a force.

[0044] The defined, preferably spherical or semi-spherical geometries at the ends of the joining pliers' jaws enable precise and gentle handling of the joining elements, thus improving the quality of the joint. The locking mechanisms, which engage in designated areas, ensure secure positioning and holding of the joining pliers during the joining process, leading to increased process reliability and reproducibility of the joints. The joining pliers are designed so that, when actuated, a uniform force is applied through the jaws, resulting in consistent deformation of the joining elements and thus ensuring the integrity of the joint.

[0045] The invention is illustrated below with the aid of the figures, wherein Fig. 1 shows a profile, Fig. 2 shows an example knot with a cone, Fig. 3 shows a node with a partially pushed-on flat gasket, Fig. 4 shows a node with a fully pushed-on flat gasket, Fig. 5 shows a node with a partially pushed-up profile, Fig. 6 shows a node with a fully pushed-up profile, Fig. Figure 7 shows a joining pliers according to the invention, Fig. 8 shows a knot with flat gasket and profile and joining pliers, Fig. Figure 9 shows a sectional view of a profile, a node, a flat gasket and a joining pliers, and Fig. Figure 10 shows a housing according to the invention.

[0046] The characters are explained in detail below.

[0047] Fig. Figure 1 shows a profile 10. The profile 10 is shown with an exemplary shape. The profile 10 only requires a surface 12 on which a joining pliers according to the invention (which will be discussed later) can be applied and a joining force can act on the profile 10.

[0048] In Fig. Figure 2 shows a node 20 according to the invention. The node 20 shown here by way of example has three pins 22. The number of pins on the node 20 is exemplary and can be larger or smaller. Each pin 22 is provided with recesses 24. In this exemplary illustration, each pin 22 has three recesses 24 on the upper side and three recesses 24 on the lower side. The recesses 24 are opposite each other with respect to the pin 22. Since the recesses 24 serve to join a profile 10 to one of the pins 22, and this is to be carried out using a joining tool 40, it is advantageous for the recesses 24 to be opposite each other with respect to the pin 22, so that the forces exerted on the profile 10 by the joining tool 40 cancel each other out and no torques or similar forces are generated.Furthermore, the node 22 has locking areas 26 which are designed so that locking devices of a joining pliers or other joining tool can engage.

[0049] In Fig. 3 also shows a node 20 according to the invention. In the illustration of Fig. In section 3, two cones 22 of node 20 are visible. On one of the cones 22 in Fig. 3 is a flat gasket 30 that is partially pushed on. It is therefore not yet in its final position, which is reached when the flat gasket 30 is pushed all the way to the end face 28 of the node 20. This state, in which the flat gasket 30 is in its final position, i.e., in contact with the end face 28 of the node 20, is in Fig. Figure 4 shows that the locking areas 26 may be excluded from the flat seal 30 and may project from the node 20 towards the pin 22.

[0050] In Fig. 5 are profile 10 from Fig. 1, node 20 from the Fig. 2, Fig. 3 and Fig. Figure 4 shows the flat gasket 30. The profile 10 is positioned coaxially with respect to the pin 22 of the node 20, so that the profile 10 can be pushed onto the pin 22 of the node 20. The profile 10 is pushed onto the pin 22 of the node 20 until it rests against the flat gasket 30, as shown in Figure 4. Fig. Figure 6 shows that both the flat gasket 30 and the locking area 26 can serve as a stop, so that the profile 10 can be positioned in a standardized manner.

[0051] In Fig. Figure 7 shows a joining tool 40 according to the invention. Fig. 7 The joining tool 40 according to the invention is designed as a joining pliers. The illustrated joining pliers 40 have two arms 42, at the respective ends of which a locking device 44 and one or more defined geometries 46 are provided. In this, Fig. In the 7 examples shown, 3 defined geometries 46 are provided on each leg. These are exemplified as hemispheres and point towards each other. Not shown, but nevertheless provided on the joining tool 40, is a type of actuation, such as a switch, and a mechanical and / or electrical system that serves to move the legs of the joining tool 40 towards each other, so that a force is exerted by the legs 42.

[0052] In Fig. Figure 8 shows a profile 10 according to the invention, a node 20 according to the invention, and a joining tool 40. The profile 10 is already fully pushed onto a pin 22 of the node 20, with the joining tool 40 positioned such that the locking devices 44 engage with the locking areas 26 of the node. The defined geometry 46 of the joining tool 40 is positioned such that its position corresponds to the recesses 24 on the pin 22 of the node 20. When the joining tool 40 is actuated, a force F is exerted on the profile 10 by the legs 42 of the joining tool 40 and the defined geometry 46 attached thereto, so that the profile 10 is deformed in such a way that a positive-locking connection is formed between the profile 10 and the recesses 24 on the leg 22 of the node 20.

[0053] In Fig. Figure 9 shows a sectional view of a joint between a profile 10 and a node 20. The profile 10 is already deformed so that it projects into the recesses 24 of the node 20. The joining was carried out by the joining tool 40 such that the snap-in device 44 engages in the snap-in areas 26 of the node, so that the defined geometry 46 corresponds in position to the recesses 24 of the node 20. The overlap area 50 is also visible in this view.

[0054] Fig.Figure 10 shows a housing 60 according to the invention, which has several joining connections 1. The profiles, which are joined to the nodes to form joining connections 1, are present in large numbers and together form quadrilateral structures. These structures are open on the left side of the housing 60 in this view, while the structures on the right side of the housing 60 are provided with several cover elements 62. The cover elements 62 are joined to the profiles and the nodes. Reference symbol list 1 joining connection 10 Profile 12 area 20 knots 22 cones 24 recesses 26 Locking area 28 Front surface 30 flat gasket 40 joining tools 42 thighs 44 Locking device 46 Defined Geometry 50 overlap area 60 cases 62 Cover element F force QUOTES INCLUDED IN THE DESCRIPTION

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

[0000] EP 2767459B1

[0002] EP 1994617A1

[0002]

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