Method for assembling an electronic battery sensor

Abstract

A battery pole terminal comprising a receiving portion (72) for a battery pole and a stopper (76) extending from the receiving portion (72) and designed to restrict rotational movement of an assembly (54) connected to the battery pole terminal (52) in at least one rotational direction.

Description

Technical Field

[0001] The present invention relates to a method for assembling an electronic battery sensor and a battery sensor designed to perform the method.

Background Art

[0002] A pole terminal is used to establish electrical contact with a pole, such as a pole of a battery. When electrical contact with a battery pole is provided, this is also referred to as a battery pole terminal or a battery terminal. For receiving or contacting a battery pole, a battery pole terminal typically includes a receiving portion. This receiving portion may be formed, for example, as a clamping portion.

[0003] The main function of a battery pole terminal is to conduct current from a battery pole to a ground cable or a battery sensor during operation of the battery. Here, the battery pole terminal withstands the tensile force from a ground cable, a battery sensor, and other loads during maintenance and fabrication within the service life of a vehicle in which the battery is installed.

[0004] DE102017219820A1 describes a self-locking battery pole terminal having a clamping portion for receiving a battery pole. Further, a fixing portion and a locking portion are also provided, and the locking portion is designed to engage with a battery pole. The fixing portion cooperates with the locking portion, and by operating the fixing portion, the locking portion pivots about a first pivot axis.

[0005] An electronic battery sensor (EBS) typically comprises integrated electronic equipment capable of detecting and, if necessary, evaluating battery variables such as current, voltage, and temperature. Since EBSs are preferably located near the battery, it is known that EBSs are combined with battery pole terminals. Here, typically, the battery pole terminal is a component of the EBS. Here, the EBS includes the battery pole terminal and assembly, the assembly typically further including a shunt, a plug or connector, and a housing. Here, the housing contains electronic equipment for detecting and evaluating battery variables, for example. [Overview of the Initiative] [Problems that the invention aims to solve]

[0006] When assembling an EBS, that is, when connecting the battery pole terminal to the assembly, care must be taken to ensure that the two components are correctly aligned with each other, i.e., not twisted relative to each other. This is particularly challenging during automated assembly. [Means for solving the problem]

[0007] Against this background, a method for assembling an electronic battery sensor and a battery sensor for carrying out the method are proposed. Embodiments will become apparent from the dependent claims and this specification.

[0008] The battery pole terminal presented herein comprises a receiving portion for or for receiving a battery pole, and a stopper. The receiving portion is formed, for example, with a circular cross-section corresponding to the battery pole, and can at least partially receive the battery pole. In this way, a reliable mechanical connection is obtained between the battery pole and the battery pole terminal, and good electrical contact is ensured.

[0009] The stopper extends from the receiving portion and is designed to restrict the rotational motion of the assembly connected to the battery pole terminal in at least one direction of rotation. The correct position of the assembly relative to the battery pole terminal is ensured when the assembly moves towards the stopper in rotational motion and the stopper prevents further rotation.

[0010] The battery pole terminal presented herein is intended to engage with a battery pole, thus providing a connection of the battery to the pole, or to contact the pole, thereby allowing, for example, an earth cable or a sensor cable to be connected to the pole.

[0011] To connect a battery pole terminal to a battery pole, the battery pole terminal is typically fitted over the battery pole, i.e., the battery pole is at least partially received by the battery pole terminal.

[0012] In one embodiment, the receiving portion is formed as a clamping portion for receiving the battery pole at least partially. The clamping portion may comprise, for example, two opposing clamping jaws.

[0013] In a further embodiment, the stopper is formed in the receiving portion of the battery pole terminal and is formed from the receiving portion and a piece. In this way, the battery pole terminal can be manufactured in a molding process, for example, by injection molding.

[0014] The stopper can be formed, for example, as a web typically extending from the receiving portion. In a further embodiment, the battery pole terminal has a flat base to which a receiving portion is attached. The base may have at least one opening for securing the assembly to the battery pole terminal.

[0015] Furthermore, an electronic battery sensor (EBS) is also presented. The function and structure of the battery sensor have already been mentioned. Please refer to the information above. The EBS comprises a battery pole terminal of the type described herein and an assembly. The assembly may include a connector or shunt, a housing, and a plug or connecting component.

[0016] The housing typically contains electronics for detecting and evaluating battery variables. The housing usually encloses this electronics at least partially. Furthermore, the assembly may be provided with at least one opening for securing it to a battery pole terminal. This at least one opening can cooperate with at least one opening in the battery pole terminal, for example, in the base of the battery pole terminal.

[0017] The assembly and the battery pole terminal can be fixedly connected to each other by rivets. The aforementioned openings can also be used here. This fixed connection can also be provided by cold forming, clinching, TOX bonding, or other suitable connection techniques.

[0018] Further advantages and embodiments of the present invention will become apparent from this specification and the accompanying drawings. It should be understood that the features described above and those further described below can be used not only in the combinations presented but also in other combinations or individually, without departing from the scope of the present invention. [Brief explanation of the drawing]

[0019] [Figure 1] This diagram shows an assembly apparatus for manufacturing an electronic battery sensor. [Figure 2] This is a diagram showing a portion of Figure 1. [Figure 3] This diagram shows the further assembly process. [Figure 4]It is a perspective view of an embodiment of the described electronic battery sensor. [Figure 5] It is a side view of the battery pole terminal of FIG. 4. [Figure 6] It is a plan view of the electronic battery sensor. [Figure 7] It is a diagram showing steps in the assembly of the battery sensor. [Figure 8] It is a diagram showing steps in the assembly of the battery sensor. [Figure 9] It is a diagram showing steps in the assembly of the battery sensor. [Figure 10] It is a diagram showing steps in the assembly of the battery sensor. [Figure 11] It is a diagram showing steps in the assembly of the battery sensor. [Figure 12] It is a diagram showing the load on the housing of the assembly during connection to the battery pole terminal in two graphs.

Embodiments of the Invention

[0020] The present invention is schematically shown in the drawings based on embodiments and will be described in detail below with reference to the drawings. FIG. 1 schematically shows an assembly apparatus for manufacturing an electronic battery sensor, and the assembly apparatus is indicated by reference numeral 10 as a whole. This figure shows an assembly arm 12, and the assembly arm 12 includes a work piece carrier 14 having a gripper 16 for receiving an assembly 18 or a shunt at its front end.

[0021] In the first step, the assembly 18 is loaded onto the work piece carrier 14. In the second step, the gripper 16 positions the assembly 18 on the battery pole terminal 20. The correct positioning of the two components, namely the assembly 18 and the battery pole terminal 20, relative to each other is very important. This results in a connection that allows rotation of the components. This rotation should be restricted or limited by the stoppers presented in this application.

[0022] In the final third step, the components are joined together, for example, by a riveting process. The components are then permanently connected to each other, and rotation is no longer possible. Figure 2 shows a portion of Figure 1 from a different perspective. Two assemblies 18 and two battery pole terminals 20 can be seen. During the assembly process, the centering device must hold the shunt, as a component of assembly 18, at an acceleration of 20 m / s² during the manufacturing process, and must also be positioned sufficiently accurately relative to the bolts. The shunt cannot be positioned 100% parallel to the side of the pole terminal. This positioning is indicated by arrow 22.

[0023] It was recognized that a design change was necessary to limit or restrict this lateral movement of the shunt. A common basic design for PF-type battery pole terminals uses spring positioning, as shown in Figure 3. This is indicated by arrow 30. One possible solution for positioning the battery pole terminal can be achieved with an additional spring (arrow 32). However, this solution requires additional space, which is often unavailable.

[0024] On the right side of Figure 3, a battery pole terminal 40 is shown, comprising a receiving section 42 and a bolt 44 for connecting to an assembly or shunt. Furthermore, a centering mechanism 46 and a marking 48 for a camera are also shown.

[0025] This design requires positioning based on two points. One point is given by a marking 48 for the camera, which is, for example, the hole for bolt 44. Without this marking 48, the assembly cannot be assembled. However, after connecting the assembly to the battery pole terminal, the assembly may twist relative to the battery pole terminal. This needs to be prevented.

[0026] Figure 4 shows the electronic battery sensor in two schematic diagrams, with the entire electronic battery sensor being shown as reference number 50. This figure shows the electronic battery sensor 50 before assembly with the battery pole terminal 52 and assembly 54. Assembly 54 includes a shunt 60, a housing 62, and a plug 64.

[0027] The battery pole terminal 52 comprises a base 70 to which a receiving portion 72 and bolts 74 are attached. Furthermore, a stopper 76 is formed on the receiving portion 72, which extends from the receiving portion 72 and is essentially formed in a web shape or as a web.

[0028] On the right side, the battery pole terminal 52 also has a marking 75 on the bolt 74. This supports the assembly of the two components, particularly when the opening 80 of the shunt 60 is guided by the bolt 74 of the battery pole terminal 52. After this joining, the assembly 54 can be rotated relative to the battery pole terminal 52. However, this rotational movement is restricted by the stopper 76, at least in the direction toward the receiving portion 72 (clockwise in this case).

[0029] Furthermore, it has been found that, during assembly, it is preferable for the opening 80 to have a diameter of 2 mm with a coneness of, for example, 0.2 mm. Figure 5 shows a side view of the battery pole terminal 52 from Figure 4. This figure shows a base 70, a bolt 74, and a screw 90 having a corresponding nut 92, the screw 90 being used to secure the battery pole terminal 52 and thus to assemble the entire electronic battery sensor 50 (Figure 4).

[0030] Figure 6 shows a plan view of the electronic battery sensor 50 of Figure 4. This figure shows the assembly 54 and the battery pole terminal 52 assembled such that a bolt 74 protrudes through an opening 80 in the assembly 54. This figure further shows a receiving portion 72 with a formed stopper 76, a screw 90 with a nut 92, a shunt 60 with an opening 80, a housing 62, and a plug 64 of the assembly 54. The stopper 76 cooperates with the housing 62 to ensure the correct position of the assembly 54 relative to the battery pole terminal 52. For this purpose, preferably, the end face of the assembly 54, and in particular the end face of the stopper 76 cooperating with the housing 62, is formed as a flat surface. The end face of the stopper 76 is preferably oriented parallel to the longitudinal axis of the assembly 54, which extends from the opening 80 across the housing 62 to the later fixing area. For example, after torsion caused by lateral sliding of the assembly 54 across its longitudinal axis in a transition area between the housing 62 and the plug 60 (which results in torsion of the assembly 54 with the bolt 74 as the axis of rotation), the end face of the stopper 76 becomes flush with the side wall of the housing 62.

[0031] The fixing mechanism 94 between the battery pole terminal 52 and the assembly 54 enables secure fastening that prevents twisting of the two components, and after this fixing process, the two components are securely connected to each other without twisting. For this to happen, it is necessary to correctly position the two components relative to each other, especially in terms of their orientation. The stopper 76 helps in this regard. When the assembly 54 is twisted and led to the stopper 76, the correct position is found.

[0032] Figures 7-11 show the assembly process for providing an electronic battery sensor 100, including a battery pole terminal 102 and an assembly 104, in which the two components are first assembled or joined and then fixedly connected to each other after precise positioning or alignment.

[0033] Figure 7 shows, on the left, a battery pole terminal 102 having a receiving portion 110, a web-shaped stopper 112 formed on the receiving portion 110, a base 114, an opening 116 for fixed connection, and a bolt 118. Here, the stopper 112 extends over a portion of the base 114.

[0034] Assembly 104 includes a shunt 120 having an opening 122 for receiving a bolt 118 of a battery pole terminal 102, a housing 124, and a plug 126.

[0035] Figure 7 shows the two components in a perspective view on the left and a plan view on the right. It can be seen that the central axis of the bolt 118 and the central axis of the opening 122 (also called the sensor opening) of the shunt 120 are not aligned. Therefore, assembly is not possible in this position.

[0036] Figure 8 shows the battery pole terminal 102 and assembly 104 aligned with each other. The indicated axis 130 (the central longitudinal axis of the bolt 118) extends through the opening 122 of the shunt. For this alignment, the markings 132 (e.g., holes) on the bolt 118 can be used. A camera is used here.

[0037] Figure 9 shows the feeding motion of assembly 104 to the battery pole terminal 102 (arrow 150). After this motion, the battery sensor 100 is assembled, as shown on the right side of Figure 9. However, assembly 104 may still be twisted relative to the battery pole terminal 102, particularly due to rotation around axis 130.

[0038] Next, Figure 10 shows the assembly 104 being rotated relative to the battery pole terminal 102 (arrow 160), and how it is hitting the stopper 112, for example, in the housing 124. Further rotation in this direction is not possible. Thus, the stopper 112 restricts the rotation of the assembly 104 relative to the battery pole terminal 102. Here, the components are correctly aligned with each other.

[0039] Figure 11 shows the electronic battery sensor after joining according to Figure 9 and positioning according to Figure 10. The two components can be fixedly connected to each other using a fixing mechanism 170, for example, an opening. This can be done, for example, by cold forming. In any case, it is ensured that the assembly 104 and the battery pole terminal 102 are correctly aligned or positioned relative to each other.

[0040] Figure 12 shows the load on the housing during the final joining process, for example, during TOX joining. This figure shows graph 200 on the left, with stress [%] plotted on the horizontal axis 202 and load [MPa] plotted on the vertical axis 204. Curve 210 shows the progression of the load. At a specific value 212, this load results in failure.

[0041] Furthermore, Figure 12 shows Graph 220 on the right, with temperature [°C] plotted on the horizontal axis 222 and the modulus of elasticity [MPa] plotted on the vertical axis 224. The first curve 230 shows the trend of measured values, and the second curve 232 shows the trend of fitted model values. Line 236 shows the modulus of elasticity at a temperature of 25°C.

Claims

1. A method for assembling an electronic battery sensor, wherein the battery pole terminals (20, 40, 52, 102) are - Receiving section for battery pole (42, 72, 110), - Stoppers (76, 112) extending from the receiving portions (42, 72, 110) and connected to the battery pole terminals (20, 40, 52, 102) are designed to restrict the rotational movement of the assembly (18, 54, 104) in at least one direction of rotation, - Bolts (44, 74, 118) and Includes, Assembly (18, 54, 104) - Shunt (60, 120) and, - Housing (62, 124) and, - Plugs (64, 126) and, - Openings (80, 122) for fixing the assembly (18, 54, 104) to the battery pole terminals (20, 40, 52, 102) and Includes, The method is - The steps of assembling the battery pole terminals (20, 40, 52, 102) and the assembly (18, 54, 104) to form an electronic battery sensor (50, 100), - The step of twisting the battery pole terminals (20, 40, 52, 102) and the assembly (18, 54, 104) until their rotational movement is restricted by the stoppers (76, 112), - The step of fixing the battery pole terminals (20, 40, 52, 102) and the assembly (18, 54, 104) in a manner that prevents rotation, A method by which the assembly (18, 54, 104) of the battery pole terminals (20, 40, 52, 102) is assembled using the markings (48, 75, 132) applied to the bolts (44, 74, 118).

2. The method according to claim 1, wherein the battery pole terminals (20, 40, 52, 102) and the assembly (18, 54, 104) are assembled such that the bolts (44, 74, 118) protrude through the openings (80, 122).

3. The method according to claim 1, wherein the assembly (18, 54, 104) is loaded onto the workpiece carrier (14).

4. The method according to claim 1, wherein the gripper (16) positions the assembly (18, 54, 104) on the battery pole terminals (20, 40, 52, 102).

5. The method according to claim 1, wherein the fixing is performed by a riveting process and / or by cold forming and / or TOX bonding.

6. An electronic battery sensor comprising at least one battery pole terminal and assembly, The aforementioned battery pole terminals (20, 40, 52, 102) - Receiving section for battery pole (42, 72, 110), - A stopper (76, 112) extending from the receiving portion (42, 72, 110) and connected to the battery pole terminal (20, 40, 52, 102) is designed to restrict the rotational movement of the assembly (18, 54, 104) in at least one direction of rotation, - Bolts (44, 74, 118) and Includes, The assembly (18, 54, 104) - Shunt (60, 120) and, - Housing (62, 124) and, - Plugs (64, 126) and, - Openings (80, 122) for fixing the assembly (18, 54, 104) to the battery pole terminals (20, 40, 52, 102) and Includes, The battery pole terminals (20, 40, 52, 102) and the assembly (18, 54, 104) are designed to perform the method according to claim 1, An electronic battery sensor wherein the battery pole terminal has a flat base, the receiving portion (42, 72, 110) is attached to the base, and at least one opening (116) is provided in the base (70, 114) for fixing the assembly (18, 54, 104) to the battery pole terminal (20, 40, 52, 102).

7. The electronic battery sensor according to claim 6, wherein the receiving portion (42, 72, 110) is formed as a clamp portion for receiving a battery pole at least partially.

8. The electronic battery sensor according to claim 6, wherein the stopper (76, 112) is formed on the receiving portion (42, 72, 110) of the battery pole terminal (20, 40, 52, 102) and is formed by the receiving portion (42, 72, 110) and a part thereof.

9. The electronic battery sensor according to claim 6, wherein the stopper (76, 112) is formed as a web and / or the stopper (76, 112) cooperates with the housing (62, 124).

10. The electronic battery sensor according to claim 6, wherein an electronic device for detecting and evaluating battery variables is housed within the housing (62, 124).

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