Method for electrically contacting a sensor, and valve assembly
Patent Information
- Application Number
- EP2024705072
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2023-03-02
- Filing Date
- 2024-02-09
- Publication Date
- 2026-01-07
AI Technical Summary
The electrical contacting of sensors integrated into valve assemblies, such as tank valves for fuel gas tanks, is time-consuming and costly, and prone to errors, especially in large-scale production, due to the complexity of using Molex connectors with angled orientations, which can lead to short circuits or line interruptions.
A method utilizing a fork-shaped insulation displacement terminal that makes a hidden electrical contact within the housing by inserting the connection cable into an intersection area, with a support structure to center and guide the cable, and using bronze or bronze alloy insulation displacement terminals for robustness, allowing for automated and reliable electrical contacting.
This method significantly reduces the time and cost of electrical contacting while increasing reliability, enabling efficient and robust electrical connections, even in large-scale production, by simplifying the process and minimizing the risk of errors.
Smart Images
Figure EP2024053295_06092024_PF_FP
Abstract
Description
[0001] Description
[0002] Method for electrically contacting a sensor, valve assembly
[0003] The invention relates to a method for electrically contacting a sensor, in particular a temperature sensor, which is integrated into a housing of a valve assembly. Furthermore, the invention relates to a valve assembly with a housing in which a sensor, in particular a temperature sensor, is integrated and electrically contacted.
[0004] The valve assembly can, in particular, be a tank valve for a fuel gas tank, for example, a hydrogen or natural gas tank. The preferred application of the invention is fuel cell and / or gas vehicles powered by a fuel gas.
[0005] State of the art
[0006] A tank valve for a fuel gas tank, such as a hydrogen tank, has a housing with multiple connections. This is because the tank valve must be connected to the fuel gas tank on the one hand, and to a gas line through which fuel gas can be drawn from the fuel gas tank and, if necessary, the fuel gas tank can be filled with fuel gas. Furthermore, the actuators of the controllable valves must be electrically connected. If a sensor, such as a temperature sensor, is also integrated into the housing, this must also be electrically connected.
[0007] The electrical connection of a sensor on a tank valve is usually made via a so-called Molex connector, which has a female plug contact and a male plug contact. The Molex connector is connected to the sensor or its connecting cables via the male plug contact, whereby the Molex connector and the temperature sensor are usually oriented at a 90° angle to each other within the housing. For this purpose, the housing of the tank valve has two housing holes located at right angles to each other, which are connected to each other via an intersection area. During assembly, the sensor's connecting cables are inserted into the housing hole for the sensor and pushed over the intersection area into the housing hole for the Molex connector. The connecting cables can then be pulled out via the housing hole for the Molex connector and connected to the male plug contact of the Molex connector.The male and female connectors are then connected and inserted into the housing hole for the Molex connector. The sensor's connecting cables must be pushed back into the housing hole for the sensor—again, over the intersection area. When inserting the Molex connector, care must be taken to ensure that the sensor's connecting cables are not trapped between the connector and the housing, as this could cause a short circuit or a cable break.
[0008] The electrical contacting of the sensor within the tank valve housing is therefore time-consuming and costly. Typically, it takes 40 to 300 seconds, which proves to be a disadvantage, especially for large-scale production. Furthermore, the required electrical contacting of the sensor may not be successful.
[0009] The present invention is concerned with simplifying the electrical contacting of a sensor integrated into the housing of a valve assembly, thus saving time and money. Furthermore, the process reliability of the electrical contacting is to be increased.
[0010] To achieve this objective, the method having the features of claim 1 is proposed. Advantageous further developments of the invention are set forth in the subclaims. Furthermore, a valve assembly, in particular a tank valve, is proposed.
[0011] Disclosure of the Invention: A method is proposed for electrically contacting a sensor, in particular a temperature sensor, within a housing of a valve assembly, wherein the housing comprises a first bore and a second bore arranged at an angle, in particular at right angles, to the first bore, and wherein the first and second bores are connected via an intersection region. The method comprises the steps:
[0012] Inserting at least one connecting cable of the sensor into the first bore and pushing the connecting cable into the intersection area, inserting at least one insulation displacement terminal with a fork-shaped insulation displacement geometry into the second bore and pushing the insulation displacement terminal into the intersection area, wherein the fork-shaped insulation displacement geometry is pushed over the connecting cable so that the insulation displacement geometry catches, cuts and electrically contacts the connecting cable.
[0013] According to the proposed method, the electrical contact is made within the housing, i.e., concealed. The connecting cable inserted into the first hole does not need to be pushed over the intersection area into the second hole, but only into the intersection area. Concealed electrical contact is then made using an insulation displacement connector, which is inserted into the second hole and pushed into the intersection area. The insulation displacement connector is pushed over the connecting cable from the side. This allows the forked insulation displacement connector geometry to catch, cut, and electrically contact the connecting cable.
[0014] The proposed process saves time and money by eliminating work steps. Furthermore, it can be largely automated. Although the electrical contacting is concealed, the process offers a high level of process reliability. This means that the electrical contacting is successful.
[0015] To securely catch the connecting cable inserted into the first hole, the forked insulation displacement connector geometry can have at least one insertion bevel, so that the connecting cable is centered relative to the insulation displacement connector during the connection. This allows for compensation for positional deviations between the connecting cable and the insulation displacement connector. Aligning the insulation displacement connector geometry relative to the connecting cable can be achieved manually using a centering pin and a centering hole. However, for large-scale production, the use of a camera to align the insulation displacement connector geometry or the insulation displacement connector is preferred.
[0016] In a further development of the invention, it is proposed that the at least one connecting cable is provided with a support structure before being inserted into the bore and is inserted into the bore together with the support structure. The support structure supports the connecting cable during insertion into the bore and during cutting. In particular, the support structure prevents the connecting cable from slipping out during cutting. The support structure can enclose the connecting cable over its entire circumference or only a partial circumference. The cross-sectional shape of the support structure is preferably adapted to the cross-sectional shape of the first bore, so that the position of the connecting cable within the bore is predetermined via the support structure, and the connecting cable is preferably centered in relation to the bore. In this case, the support structure has a centering function in addition to its supporting and guiding function.
[0017] Furthermore, it is proposed that the support structure have at least one opening for accommodating at least one insulation displacement terminal. To compensate for positional deviations, the opening should be sufficiently large so that the insulation displacement terminal can be inserted into the opening without collision to clamp the connecting cable.
[0018] According to a first preferred embodiment of the invention, the support structure is formed by overmolding the at least one connecting cable. In the area of the electrical contact to be established, the overmolding is recessed, leaving the connecting cable exposed.
[0019] According to a further preferred embodiment of the invention, the support structure is formed by two half-shells into which the at least one connecting cable is inserted, preferably clamped. The two half-shells replace the overmolding of the connecting cable and thus facilitate the formation of the support structure. The connecting cable only needs to be inserted into one half-shell, which then needs to be connected to the other half-shell. The connection can, in particular, be a plug-in, clamp-in, and / or snap-in connection. If the connecting cable is not only inserted but also clamped, it is simultaneously fixed in position within the support structure.
[0020] Alternatively or additionally, it is proposed that the two half-shells together form at least one cable duct to accommodate at least one connecting cable. The cable duct then determines the position of the connecting cable within the support structure, preventing the connecting cable from being pushed sideways when caught or cut.
[0021] As a further development, it is proposed that at least one connecting cable be crimped at its end. The crimped end can be used to fix the connecting cable in its axial position if the crimped end engages in a recess in the support structure or engages behind the support structure. The crimped end also provides additional support, which prevents the connecting cable from slipping and / or accidentally plasticizing during cutting. Crimping can be performed before or after the connecting cable is overmolded or inserted into the support structure. In the latter case, one of the two half-shells can be used as a crimping tool when connecting the two half-shells.
[0022] The at least one insulation displacement terminal is preferably made of bronze or a bronze alloy, as this material is electrically conductive and also very robust, especially compared to copper, which is very soft. Thus, high cutting forces can be applied via the insulation displacement terminal.
[0023] Furthermore, it is proposed that the at least one insulation displacement terminal is overmolded at its end facing away from the insulation displacement geometry in order to align the insulation displacement geometry and / or to form a plug or a plug receptacle. The overmold can also be carried out in several steps, so that a pre-overmold and a final overmold are formed. By means of the pre-overmold, for example, two insulation displacement terminals for electrically contacting two connection cables of the sensor can be aligned and fixed to one another. The final overmold then serves to form the plug or the plug receptacle. Preferably, the at least one insulation displacement terminal is overmolded before being inserted into the second bore in the housing, so that the insulation displacement terminal is mounted together with the plug or the plug receptacle.The connector receptacle can be designed with a stop surface located on the outside of the housing, allowing the insertion depth of the insulation displacement terminal to be specified. This ensures that the insulation displacement terminal catches, cuts, and electrically contacts the connecting cable.
[0024] Furthermore, a valve assembly for a fuel gas tank is proposed, comprising a housing with a first bore and a second bore arranged at an angle, in particular perpendicular, to the first bore. The first and second bores are connected via an intersection region. According to the invention, at least one connecting cable of a sensor is inserted into the first bore and electrically contacted via a fork-shaped insulation displacement connector inserted into the second bore.
[0025] The electrical contacting can be carried out, in particular, using the method according to the invention described above, so that the production of the valve assembly is less time-consuming and cost-intensive. Furthermore, production can be automated, so that the valve assembly can be produced cost-effectively in large series. At the same time, the insulation displacement connector ensures a very robust electrical contact. The insulation displacement connector is preferably made of bronze or a bronze alloy, ensuring high strength and thus robustness.
[0026] Preferably, at least one connecting cable is surrounded by a support structure. The support structure can be used to specify the position of the at least one connecting cable within the bore, further increasing the robustness of the electrical contact. The support structure can be formed by an overmolding or two half-shells.
[0027] Furthermore, the at least one connecting cable is preferably bent at the end. The bent end can engage in a recess in the support structure or engage behind the support structure, thus securing, in particular, the axial position of the connecting cable.
[0028] Furthermore, it is proposed that the at least one insulation displacement terminal be overmolded at its end facing away from the insulation displacement geometry and / or be connected to a plug or a plug receptacle. The overmold can serve, in particular, to align and fix two insulation displacement terminals with respect to each other. Each insulation displacement terminal can then electrically contact a connecting cable of the sensor. The overmold or a further final overmold can then simultaneously form the plug or the plug receptacle.
[0029] A preferred embodiment of the invention is explained in more detail below with reference to the accompanying drawings. These show:
[0030] Fig. 1 is a sectional view of a valve assembly according to the invention with a housing in which a sensor is integrated,
[0031] Fig. 2 is a side view of the valve assembly according to the invention of Figure 1,
[0032] Fig. 3 a perspective view of the sensor connection cables, inserted into a half-shell of a support structure,
[0033] Fig. 4 a perspective view of another half-shell of the support structure,
[0034] Fig. 5 a perspective view of the two half-shells forming the support structure with inserted insulation displacement terminals and
[0035] Fig. 6 is a perspective view of Fig. 5, but without the upper half shell.
[0036] Detailed description of the drawings
[0037] The valve assembly 1 shown in Figures 1 and 2 for a fuel gas tank (not shown) has a housing 2 into which, among other things, a sensor 3, in this case a temperature sensor, is integrated. The temperature sensor detects the temperature of the fuel gas in the fuel gas tank. The section of the housing 2 into which the temperature sensor is integrated is accordingly inserted into the fuel gas tank. The housing 2 also forms further connections and interfaces that are located outside the fuel gas tank and, in particular, serve to connect to at least one gas line for withdrawing fuel gas from the tank and filling the tank with fuel gas. To regulate these gas flows, the valve assembly has a plurality of valves that are concealed by the housing 2.
[0038] Since at least one valve of the valve assembly 1 is controllable, a magnet assembly 15 is provided, which is arranged laterally on the housing 2 with respect to the temperature sensor. A plug or plug receptacle 12 is arranged next to the magnet assembly 15, via which the valve assembly 1 can be connected to a power supply.
[0039] The sensor 3 or temperature sensor has two connecting cables 7 which are inserted into a bore 4 in the housing 2. The connecting cables 7 are surrounded by a support structure 10 which comprises two half-shells 10.1, 10.2. The connecting cables 7 are guided up to an intersection area 6 of the bore 4 with a further bore 5 in which contact elements connected to the plug or plug receptacle 12 are received for making electrical contact with the connecting cables 7. The contact elements are designed here as insulation displacement terminals 8. The insulation displacement terminals 8 are connected via an overmolding 13 to the plug or plug receptacle 12 which rests on the outside of the housing 2. A seal 14 is inserted between the plug or plug receptacle 12 and the housing 2.
[0040] The support structure 10, in which the two connecting cables 7 of the sensor 3 are accommodated, is described in more detail below with reference to Figures 3 to 6.
[0041] Figure 3 shows one of the two half-shells 10.1, 10.2 forming the support structure 10, with the connecting cables 7 being inserted into the half-shell 10.2. For this purpose, the half-shell 10.2 forms two parallel cable ducts so that the connecting cables 7 are guided in the support structure 10. The lower connecting cable 7 is also fixed in position within the support structure by a clamping body 16. Figure 4 shows the other of the two half-shells 10.1, 10.2 of the support structure 10. This is essentially designed identically to the first half-shell 10.2 so that it completes the two cable ducts for receiving the connecting cables 7. Furthermore, it has a clamping body 16 for fixing the other connecting cable 7. When joining the two half-shells 10.1, 10.2, the clamping bodies 16 each engage in a recess of the other half-shell 10.2, 10.2, so that they are fixed in position relative to each other.
[0042] Figure 5 shows the two half-shells 10.1, 10.2 after joining and with inserted insulation displacement terminals 8 for electrically contacting the connecting cables 7. For the sake of simplicity, the surrounding housing 2 is not shown. The insulation displacement terminals 8 are guided through lateral openings 11 in the half-shell 10.1 up to the connecting cables 7. As can be seen in particular from Figure 6, in which not only the housing 2 but also the half-shell 10.1 has been omitted, the insulation displacement terminals 8 have fork-shaped insulation displacement geometries 9 which clamp onto the connecting cables 7, thus ensuring electrical contact with the connecting cables 7. As can also be seen from Figure 6, the connecting cables 7 can be cranked at the ends for further positional fixation and / or support. For this purpose, the cranked end of a connecting cable 7 engages in a recess 17 of the half-shell 10.2 of the support structure 10.
Claims
Claims 1 . Method for electrically contacting a sensor (3), in particular a temperature sensor, within a housing (2) of a valve assembly (1), wherein the housing (2) comprises a first bore (4) and a second bore (5) arranged at an angle, in particular at right angles, to the first bore (4), and wherein the first and second bores (4, 5) are connected via an intersection region (6), comprising the steps: Inserting at least one connecting cable (7) of the sensor (3) into the first hole (4) and pushing the connecting cable (7) into the intersection area (6), Inserting at least one insulation displacement terminal (8) with a fork-shaped insulation displacement geometry (9) into the second bore (5) and pushing the insulation displacement terminal (8) into the intersection area (6), wherein the fork-shaped insulation displacement geometry (9) is pushed over the connecting cable (7) so that the insulation displacement geometry (9) catches, cuts and electrically contacts the connecting cable (7).
2. Method according to claim 1, characterized in that the at least one connecting cable (7) is provided with a support structure (10) before being inserted into the bore (4) and is inserted into the bore (4) together with the support structure (10), wherein the support structure (10) preferably has at least one opening (11) for receiving the at least one insulation displacement terminal (8).
3. Method according to claim 2, characterized in that the support structure (10) is formed by overmolding the at least one connecting cable (7).
4. Method according to claim 2, characterized in that the support structure (10) is formed by two half-shells (10.1, 10.2) into which the at least one connecting cable (7) is inserted, preferably clamped.
5. Method according to one of the preceding claims, characterized in that the at least one connecting cable (7) is bent at the end.
6. Method according to one of the preceding claims, characterized in that the at least one insulation displacement terminal (8) is overmolded at its end facing away from the insulation displacement geometry (9) for aligning the insulation displacement geometry (9) and / or for forming a plug or a plug receptacle (12).
7. Valve assembly (1) for a fuel gas tank, comprising a housing (2) with a first bore (4) and a second bore (5) arranged at an angle, in particular at right angles, to the first bore (4), wherein the first and the second bore (4, 5) are connected via an intersection region (6), characterized in that at least one connecting cable (7) of a sensor (3) is inserted into the first bore (4) and is electrically contacted via a fork-shaped insulation displacement connection geometry (9) of an insulation displacement connection (8) which is inserted into the second bore (5).
8. Valve assembly (1) according to claim 7, characterized in that the at least one connecting cable (7) is surrounded by a support structure (10), which is preferably formed by an overmolding or two half-shells (10.1, 10.2).
9. Valve assembly (1) according to claim 7 or 8, characterized in that the at least one connecting cable (7) is bent at the end.
10. Valve assembly (1) according to one of claims 7 to 9, characterized in that the at least one insulation displacement terminal (8) is overmolded at its end facing away from the insulation displacement geometry (9) and / or is connected to a plug or a plug receptacle (11).