Device and method for connecting a connection assembly, connection assembly, battery having such a connection assembly, and motor vehicle having such a battery

Abstract

The invention relates to a method and a device (1) for connecting a connection assembly (3) having two housing parts (4, 5), wherein the first housing part (4) is inserted into the device (1) in such a way that a first flange (27) of the first housing part (4) is supported on a flange bearing (12) of the device (1). The second housing part (5) is inserted into the device (1) and thereby placed on the first housing part (4) in such a way that a second flange (33) of the second housing part (5) is supported on the first flange (27), as a result of which a flange portion (40) of the connection assembly (3) is formed. After the flange portion (40) has been formed in the device (1), a primary actuator element (22) of a primary actuator (20) of the device (1) is moved into the primary actuator position, and a secondary actuator element (26) of a secondary actuator (24) of the device (1) is moved into the secondary actuator position. In this way, a flange pressing punch (16) fixed to the secondary actuator element (26) is moved into a pressing position, in which a pressing force is exerted on the flange portion (40), by means of which pressing force the first flange (27) and the second flange (33) are pressed against each other. In addition, in the method, a connecting means (37) is applied, by means of which the first flange (27) and the second flange (33) are connected to each other with a form fit and / or an integral bond. The invention further relates to the connection assembly (3), to a battery (2), and to the motor vehicle having the battery (2).

Description

[0001] Device and method for connecting a connection arrangement, connection arrangement, battery with such a connection arrangement and motor vehicle with such a battery

[0002] The present invention relates to a device and a method for connecting a connection arrangement, as well as a connection arrangement produced by means of the device or the method. The invention further relates to a battery comprising such a connection arrangement. The invention also relates to a motor vehicle comprising such a battery, in particular as a traction battery.

[0003] Batteries, especially high-voltage storage systems, whose housings consist of two joined housing shells (e.g., each made of sheet metal), are, according to the state of the art, connected to each other using an auxiliary adhesive and an adhesive bond in the sealing flange areas of the housing shells. For the intended functionality of the high-voltage storage system, a surface-level connection of the housing shells to the high-voltage components of the battery, such as a battery cell pack, is also required. To achieve this, the adhesive used between the high-voltage components and the housing shells must be compressed to a specified dimension by a process called pre-compression. Due to the demand for increasingly larger high-voltage storage systems—especially in the automotive industry—ever larger quantities of adhesive are required.To make matters worse, the use of cold-curing one- or multi-component adhesives requires total clamping forces that cannot be achieved using conventional clamping techniques or dead weight. Pressing devices known from the prior art (for example, those of DE 102012 104 125 A1 or DE 102016 106 286 A1) are not suitable for use in battery manufacturing. Furthermore, it is essential that the joining partners, i.e., the housing shells and the high-voltage components, do not move relative to each other after the adhesive bond(s) have been applied; otherwise, the bond quality will be compromised.In other words, it is necessary that a geometric position of the joining partners is maintained until the adhesive in the joining plane has reached at least such a strength that a (non-abusive, i.e., intended) movement of the battery as a whole no longer negatively affects the stability / strength of the adhesive bond.

[0004] The object of the present invention is to improve the joining of two joining partners, particularly in the manufacture of a battery for a motor vehicle.

[0005] This problem is solved by the subject matter of the independent claims. Further possible embodiments of the invention are disclosed in the dependent claims, the description, and the figures. Features, advantages, and possible embodiments set forth in the description for one of the subject matter of the independent claims are to be regarded, at least analogously, across categories and embodiments as features, advantages, and possible embodiments of the respective subject matter of the other independent claims, as well as of any possible combination of the subject matter of the independent claims, optionally in conjunction with one or more of the dependent claims.

[0006] According to the invention, a device and a method for joining a connection arrangement are proposed. The device includes means for carrying out the method, at least partially. The connection arrangement, which is also an object of the present invention, has two joining partners, which can, for example, be formed by two housing parts. Other types of joining partners are, of course, conceivable. The joining partners / housing parts are joined to one another by means of the method or the device by means of a form-fit and / or material-fit connection. In this context, connections in which the joining partners are held together by atomic and / or molecular forces and which are not detachable or can only be separated by destroying the joining element are considered material-fit connections. Therefore, adhesive bonds are to be classified as material-fit connections.

[0007] One of the joining partners / housing parts is, in particular, a lower battery housing part of a battery, which itself constitutes a further object of the invention. The other joining partner / housing part is, in particular, an upper battery housing part of the battery, corresponding with the lower battery housing part to form a battery housing. In other words, the battery according to the invention comprises the lower battery housing part and the upper battery housing part, which were joined together to form the battery housing by means of the method or the device, whereby the battery has the connection arrangement. The battery is, for example, designed as a traction battery for a motor vehicle. A purely or hybrid-electrically powered motor vehicle constitutes a further object of the invention, wherein the battery or...The traction battery, in its intended installation position, forms an integral part of the motor vehicle.

[0008] The device, for example as part of a lower tool, has a flanged bearing onto which a flanged portion of the connection assembly – i.e., the unit consisting of the first housing part and the second housing part – can be supported. The device also has a flanged press die, for example as part of an upper tool. The flanged bearing and the flanged press die are arranged directly opposite each other along a vertical axis of the device (the device's vertical axis). Furthermore, the device includes a primary actuator, which is fixed to a fixture frame. A movable primary actuator element is linearly or translationally adjustable relative to the fixture frame, i.e., relative to a primary guide element of the primary actuator fixed to the fixture frame, between a first and a second primary actuator position along the device's vertical axis.

[0009] In the first primary actuator position, the primary actuator element is fully retracted, whereas in the second primary actuator position, the primary actuator element is fully extended. Moving the primary actuator element towards the second primary actuator position extends it towards the flange bearing. The device also includes a secondary actuator, the secondary guide element of which is fixed to the primary actuator element. A movable secondary actuator element of the secondary actuator is linearly or translationally adjustable relative to the primary actuator element, i.e., relative to the secondary guide element fixed to it, between a first and a second secondary actuator position along the device's vertical axis. In the first secondary actuator position, the secondary actuator element is fully retracted, whereas in the second secondary actuator position, the secondary actuator element is fully extended.When the secondary actuator element is moved towards the second secondary actuator position, it is extended towards the flange bearing. The primary and secondary actuators can be controlled and driven separately or independently of each other. For example, the primary and secondary actuators each have their own drive unit. In this device, it is particularly conceivable that the primary actuator element forms the secondary guide element. In other words, when the primary actuator element is moved between the two primary actuator positions, the secondary guide element is moved relative to the primary guide element. For example, the secondary guide element is extended from the primary guide element when moving towards the second primary actuator position, and retracted into the primary guide element when moving towards the first primary actuator position.

[0010] Furthermore, the device is configured such that when both actuator elements are arranged in the second actuator position, the flange press ram is in a pressing position. In other words, as soon as both the primary actuator element is in the second primary actuator position and the secondary actuator element is in the secondary actuator position, the flange press ram has been moved along the device's vertical axis in the pressing direction towards the flange bearing to such an extent that the flange press ram in the pressing position and the flange bearing are spaced apart from each other by a pressing distance along the device's vertical axis.If a flange component of the connection arrangement is supported on the flange bearing, it is clamped between the flange bearing and the flange press die, whereby a pressing force is exerted on the flange component due to the clamping between the flange bearing and the flange press die along the vertical axis of the device.

[0011] The device is used in the process for connecting the assembly as follows: The actuator elements are retracted—if not already done—at least far enough or moved against the pressing direction to allow easy insertion of the first housing part into the device. Then, in a first process step, the first housing part is inserted into the device such that a first flange of the first housing part rests on the flange bearing. If the actuator elements are not yet fully positioned in their respective first actuator positions, they are fully retracted before or after the first process step, i.e., each is moved into its corresponding first actuator position by moving the actuator elements against the pressing direction. This positions the flange press ram and the flange bearing as far apart as possible along the vertical axis of the device.This advantageously allows for particularly efficient handling between the flange bearing and the flange press die, enabling the execution of work and / or ancillary processes, etc. Due to the maximum distance between the flange press die and the flange bearing, the second housing part can be inserted into the fixture particularly efficiently in a second process step and thus placed onto the first housing part. For this purpose, it is particularly recommended to use a handling device, such as an articulated robot arm, which loads the fixture laterally with the second housing part. In any case, the second housing part is inserted into the fixture or placed onto the first housing part in such a way that a second flange of the second housing part is supported on the first flange, thereby forming a flange component of the connection arrangement.

[0012] After the flange portion of the connection assembly has been formed in the device, the primary actuator element is fully moved into the primary actuator position in a third process step, thereby moving the flange press ram a primary stroke towards the flange bearing. At this stage, no pressing force is yet exerted on the connection assembly by the device. Instead, the primary stroke of the device is purely a movement stroke to bring the flange press ram closer to the connection assembly or the flange portion. This means that with the primary actuator element fully extended and in the second primary actuator position, there is no contact between the flange press ram and the connection assembly without any further action or process step.Only in a fourth process step, in which the secondary actuator element is fully moved into the secondary actuator position, is such contact established between the flange press ram and the connection assembly. By fully moving the secondary actuator element into its secondary actuator position, the flange press ram is moved into the pressing position, thereby exerting the pressing force on the flange portion, which presses the first and second flanges together. Accordingly, the secondary stroke of the device is a pressing stroke.

[0013] The process further comprises a fifth process step in which a fastener is applied, by means of which the first flange and the second flange are positively and / or materially bonded to each other. The fifth process step can be carried out in two or more instances, wherein one instance can be carried out before the first process step and / or one instance between the first and the second process steps and / or one instance between the second and the third process steps and / or one instance after the fourth process step. Alternatively or additionally, one instance can be carried out during the first process step and / or one instance during the second process step and / or one instance during the fourth process step. The fastener comprises one or two or more connecting elements.

[0014] The device can include a monitoring unit that detects a counterforce acting on the upper tool and a travel distance covered by the upper tool. A counterforce-travel value pair is then specified, and the monitoring unit provides an error signal if the counterforce value of the counterforce-travel value pair is reached before the specified travel distance value is reached, or if, after reaching the travel distance value, the counterforce value deviates from the specified force value. Based on the error signal, an error message can be issued and / or the process can be aborted.

[0015] The device and the method executable with it are advantageous in that they achieve particularly effective clamping of the flange portion of the connection assembly between the flange press die and the flange bearing. The maximum distance set between the flange press die and the flange bearing before the second process step enables particularly efficient and cost-effective loading of the device with the second joining partner or housing part – especially when automated using an articulated robot arm, a side-loading unit, a traversing unit, etc. This is because the use of serially arranged actuators allows for a particularly large distance between the flange press die and the flange bearing. This ensures excellent accessibility to the space between the flange press die and the flange bearing.

[0016] According to another possible embodiment of the device, the primary or secondary actuator, or both the primary and secondary actuators, are each designed as a ball screw drive. The respective ball screw actuator of the device is particularly efficient because its operation is subject to very little friction and, consequently, very little wear. Furthermore, a ball screw drive offers particularly precise linear control, especially compared to a fluid-mechanical actuator. This allows for very precise metering of the pressing force.

[0017] According to another possible embodiment of the device, the primary or secondary actuator, or both the primary and secondary actuators, are free of any working fluid, such as hydraulic oil. In other words, one or both of the actuators are not designed as a hydraulic cylinder unit. This ensures that even in the event of a device malfunction, no working fluid escapes from the corresponding actuator and contaminates the components or housing parts to be joined. This is particularly important for the manufacture of products where technical cleanliness is paramount, for example, batteries, especially traction batteries for motor vehicles.In a possible further development, one or both of the actuators are designed as a purely electromechanical converter, which means that in the actuator in question electrical energy is directly converted into mechanical work, i.e. into movement of the actuator element.

[0018] In another possible embodiment, the device is designed such that the primary section, by which the primary actuator element can be adjusted from the first to the second primary actuator position, is shorter than the secondary section, by which the secondary actuator element can be adjusted from the first to the second secondary actuator position. For example, the secondary section is twice as long or even longer than the primary section. The primary actuator is therefore particularly short, so that in the second primary actuator position, the primary actuator element protrudes only a very small distance from the device frame. This ensures that the primary actuator element is guided laterally with particular reliability along the device's vertical axis, allowing the secondary actuator and the flange press die attached to the secondary actuator element to move with exceptional accuracy along the device's vertical axis.

[0019] According to another possible embodiment of the method, while the pressing force is applied to the flange component – ​​i.e., during the fourth process step – a (first) connecting element of the fastener is applied by connecting the first and second flanges using a connecting pin. This means that the fastener has, for example, a pin connection as its first connecting element, whereby the pins of the pin connection penetrate corresponding through-holes in the flange component and thus positively connect the joining partners or housing parts. Pin ends, which protrude from both sides of the flange component, are clamped to the upper and lower surfaces of the flange component.During the fourth process step, the flange component is supported on a bearing surface of the flange bearing via its underside, with a press die surface of the flange press die bearing against an upper side of the flange component. However, in order to properly apply the pins for creating the pin connection that positively engages the housing parts, it is necessary to have a clearance on both the upper and lower sides of the flange component, at least at the points where the respective pin penetrates the flange component, for a pin-setting tool to insert the pin.

[0020] To enable the formation of such a pin connection on the flange component while the pressing force is applied, the flange bearing, according to one possible embodiment, has one or more flange bearing engagement gaps. Furthermore, the flange press ram has one or more ram engagement gaps, and these engagement gaps are arranged in pairs opposite each other along the vertical axis of the device. In other words, one flange bearing engagement gap and one ram engagement gap are positioned opposite each other along the vertical axis of the device. This results in the bearing surface of the flange bearing and the press ram surface of the flange press ram being formed by respective ridges or teeth, so that in the fourth process step, the flange component is clamped between two symmetrical ridge arrangements.The ridges of the flange bearing and the ridges of the flange press die are spaced apart by the flange bearing engagement gaps and the die engagement gaps, respectively. The pin-setting tool can engage in the respective engagement gap to apply the pin connection. This is because the engagement gaps create a clearance on both the top and bottom of the flange component for the pin-setting tool, while the pressing force is applied to the flange component via the ridges. A screw bolt, for example, can be used as the pin for the pin connection. Preferably—because it is particularly easy and inexpensive to apply—a rivet is used as the pin for the pin connection; the pin connection is therefore, or is primarily, designed as a rivet connection. Due to the engagement gaps, the use of a welding gun is also conceivable, with which weld points can be applied to join the housing parts.In this case, the connection arrangement can be joined by means of a weld. In another possible embodiment of the method, before the second housing part is inserted into the device, a second flange surface of the second flange is coated externally with an adhesive, thereby applying a (second) connecting element of the fastener. Thus, the fastener has a (first) adhesive bond as its second connecting element, by means of which the joining partners or housing parts are materially bonded together. In particular, the second flange surface of the second flange is coated with a continuous bead of adhesive, so that the first adhesive bond is a fluidically tight connection between the housing parts. This ensures that unwanted foreign matter (liquids, dirt / dust particles, etc.) is prevented from penetrating the finished product, especially the (traction) battery.) does not pass between the joining partners. Provided that both the pin connection, especially the rivet connection, and the first adhesive connection are formed, the flanges of the housing parts are joined together particularly reliably and stably.

[0021] Another possible embodiment of the method involves placing an inner body onto a first inner surface of the first housing part. As the secondary actuator element is moved into the secondary actuator position, this inner body is bonded to a second inner surface of the second housing part. Thus, a (second) adhesive bond is formed between the second inner surface of the second housing part and the inner body, which can be considered the (third) connecting element of the fastener. The same adhesive is used for both the first and second adhesive bonds. The inner body is, in particular, a battery cell pack, which is inserted between the first and second housing parts to manufacture the battery. The battery cell pack can include other battery components, such as a cell contacting system, an electrical and / or electronic circuit, etc.Consequently, the battery's cell pack is formed by the inner body. This cell pack, or inner body, specifically comprises a foam core that encases the battery cells and, where applicable, other battery components. By bonding the inner body to the second housing part, it is securely and stably fixed in its intended installation position relative to the housing parts.

[0022] To compress the second adhesive bond as desired for curing, a further development of the device provides that the upper tool, in addition to the flange press punch, has a surface press punch. In the fourth process step, this surface press punch applies a surface pressure force to the second outer surface of the second housing part. When both actuators are in their second actuator position, the surface press punch covers / contacts a large portion of the second outer surface, in particular the entire second outer surface. This ensures that the adhesive between the inner body and the second inner surface is efficiently and evenly stressed for curing.

[0023] In this method, regardless of the specific design, the inner body can be placed externally onto the first inner surface of the first housing part, and then the first housing part, together with the inner body, is inserted into the device in the first process step. It can also be provided that a (first) handling unit is formed, comprising a workpiece carrier, the first housing part, and optionally the inner body. The first handling unit is then inserted into the device in the first process step. In the first handling unit, the first housing part is supported on the workpiece carrier, so that the first handling unit (i.e., the workpiece carrier, the first housing part resting on it and optionally attached to it, and, if applicable, the inner body lying on the first inner surface) can be handled / moved by moving the workpiece carrier.Therefore, it is conceivable that the device, in particular its lower tool, has a workpiece carrier receptacle corresponding to the workpiece carrier, so that in the first process step the first housing part is inserted into the device by placing the workpiece carrier together with the first housing part into the workpiece carrier receptacle. Furthermore, regardless of its design, the device can have a positioning device by means of which the first housing part, in particular the workpiece carrier, is positioned precisely in a machining position and / or fixed therein.

[0024] The process is particularly fast, thus exhibiting an advantageously short cycle time, if—as in another possible embodiment of the process—when the second flange surface of the second housing part is coated with the adhesive for the first bond, the second inner surface of the second housing part is coated with the same or a different adhesive in the same operation, thereby applying the third connecting element or the second adhesive bond of the fastener. It can therefore be provided that—each external to the device—the adhesive for the first bond and the adhesive for the second bond are applied to the second housing part, and then, in the second process step, the second housing part, together with the applied adhesives, is placed in the device and onto the first housing part. The adhesives falling off or detaching from the second housing part is prevented by the adhesives or...The adhesive strands adhere to the second housing part immediately after being applied.

[0025] To make the first and / or second adhesive bond particularly strong, a possible further development of the process involves combining the second housing part and a holding element bearing on a second outer surface of the second housing part into a (second) handling unit before the second housing part is inserted into the device. In the second process step, the second handling unit is then inserted into the device and thereby placed onto the first housing part. The holding element bearing on the second outer surface presses the first flange surface towards the second flange surface of the second housing part.Since the hold-down element is designed to cover a large part or the entire second outer surface, it prevents the second housing part from bulging when one of the actuators is disengaged from its corresponding second actuator position after the fourth process step, i.e., when the pressing force or surface pressing force is released. Thus, to advantageously cure the first and / or second adhesive bond using the hold-down element, the corresponding adhesive bond continues to be subjected to pressure even after one of the actuators has been disengaged from its corresponding second actuator position following the fourth process step.

[0026] The adjustment of the actuators or actuator elements, starting from the first actuator position, can be performed fully or partially simultaneously. According to a preferred embodiment of the method, after the second housing part is inserted into the device, the primary actuator element is adjusted to the second primary actuator position, while the secondary actuator element remains in the first secondary actuator position. Then, after the primary actuator element has been fully adjusted to the second primary actuator position, the secondary actuator element is adjusted to the second secondary actuator position, while the primary actuator element remains in the second primary actuator position. The pressing force is exerted on the flange portion solely by adjusting the secondary actuator element to the second secondary actuator position. In this way, the method is particularly easy to implement because controlling the actuators is especially straightforward.

[0027] Further features of the invention may become apparent from the claims, the figures, and the description of the figures. The features and combinations of features mentioned above in the description, as well as the features and combinations of features shown below in the description of the figures and / or in the figures themselves, can be used not only in the combinations specified, but also in other combinations or on their own, without departing from the scope of the invention.

[0028] The drawing shows in Figs. 1 to 5 a schematic and partially cutaway view of a device which has means for carrying out a method for joining a connection arrangement comprising two housing parts, wherein, to clarify the method,

[0029] Fig. 1 shows the device when the first housing part is inserted, in

[0030] Fig. 2 shows the device when the second housing part is inserted.

[0031] Fig. 3 shows the device when its primary actuator is adjusted, in

[0032] Fig. 4 shows the device during the adjustment of its secondary actuator and in

[0033] Fig. 5 shows a flange part of the connection arrangement in a perspective detail view, wherein the flange part is clamped between a flange press die and a flange bearing and is joined in a form-fit manner.

[0034] The device 1 and the method, as well as a battery 2 for a motor vehicle, the connection arrangement 3 that can be produced by means of the method or by means of the device 1, and a motor vehicle comprising the battery 2 (not shown) are described below in a joint description. In the figures, identical and functionally equivalent elements are designated with the same reference numeral.

[0035] The device 1 and the method are each configured for joining the connection arrangement 3, which has two joining partners. In this example, these partners are a first housing part 4 and a second housing part 5 (see Fig. 2, Fig. 3, Fig. 4) of a battery housing 6 of the battery 2 (see Fig. 4). Here, the first housing part 4 is an upper part of the battery housing 6, and the second housing part 5 is a lower part of the same battery housing 6. As can be seen in the figures, during the manufacture of the battery 2, a first outer surface 7 of the first housing part 4 – i.e., the upper part of the battery housing – faces in the Z-direction, i.e., downwards, and a second outer surface 8 of the second housing part 5 faces in the opposite direction, i.e., upwards. The connection arrangement 3, i.e., the arrangement of the housing parts 4 and 5 of the battery 2, is joined by means of the method and the device 1.The housing parts 4 and 5 are joined together using the device 1 in a form-fit and material-fit manner by forming a connecting element 37 that connects them in a form-fit and material-fit manner. In this example, the connecting element 37 comprises a first connecting element 37a, a second connecting element 37b, and a third connecting element 37c, which will be explained in more detail below.

[0036] The battery 2, which includes the connection arrangement 3 and the housing parts 4 and 5, is designed as a traction battery for the motor vehicle according to the present example. In its intended installation position, the battery 2, or traction battery, thus forms a component of the motor vehicle. The motor vehicle is therefore designed as a purely electric or hybrid-electric vehicle.

[0037] Figure 1 shows that the device 1 has a lower tool 9 and an upper tool 10, with the tools 9 and 10 both arranged along a vertical axis 11 of the device. The lower tool 9 has a flange bearing 12 and, in this case, a workpiece carrier holder 13 and a positioning device (not shown). In Figure 1,

[0038] Figure 5 shows that the flange bearing 12 in this example has flange bearing engagement gaps 14, across which the tines / teeth 15 of the flange bearing 12 are spaced apart. The upper tool 10 has a flange press punch 16 and, in this example, also a surface press punch 17, whereby the press punches 16 and 17 can be formed integrally. In this example, the flange press punch 16 has punch engagement gaps 18, across which the tines / teeth 19 of the flange press punch 16 are spaced apart. The flange bearing engagement gaps 14 and the punch engagement gaps 18, or the tines / teeth 15 and 19, are arranged in pairs opposite each other along the vertical axis 11 of the device. This can be seen in Figure 5.5, that each of the flange bearing engagement gaps 14 is exactly opposite one of the punch engagement gaps 18 along the device vertical axis 11, wherein each of the crenellations 15 is exactly opposite one of the crenellations 19 along the device vertical axis 11.

[0039] Furthermore, the device 1 comprises a primary actuator 20, which is fixed to a fixture frame 21 of the device 1. A movable primary actuator element 22 of the primary actuator 20 is linearly or translationally adjustable relative to the fixture frame 21, that is, relative to a primary guide element 23 of the primary actuator 20 fixed to the fixture frame, between a first primary actuator position (see Fig. 1, Fig. 2) and a second primary actuator position (see Fig. 3, Fig. 4) along the vertical axis 11 of the device. In the first primary actuator position, the primary actuator element 22 is completely retracted into the primary guide element 23, whereas in the second primary actuator position, the primary actuator element 22 is completely extended out of the primary guide element 23.

[0040] The device 1 also includes a secondary actuator 24, the secondary guide element 25 of which is fixed to the primary actuator element 22. A movable secondary actuator element 26 of the secondary actuator 24 is linearly or translationally adjustable relative to the primary actuator element 22, i.e., in relation to the secondary guide element 25 fixed to it, between a first secondary actuator position (see Fig. 1, Fig. 2, Fig. 3) and a second secondary actuator position (see Fig. 4) along the device's vertical axis 11. In the first secondary actuator position, the secondary actuator element 26 is fully retracted into the secondary guide element 25, whereas in the second secondary actuator position, the secondary actuator element 26 is fully extended out of the secondary guide element 25.The flange press die 16, or in this case the upper tool 10 comprising the flange press die 16 and the surface press die 17, is fixed to the secondary actuator element 26, so that the upper tool 10 can be moved translationally along the vertical axis 11 of the device by moving the secondary actuator element 26. The actuators 20 and 24 can be controlled and driven separately or independently of each other. In this example, the actuators 20 and 24 each have their own drive unit (not shown).

[0041] According to the example described here, the primary actuator 20 and the secondary actuator 24 are each free of a working fluid, which means that the actuators 20, 24 are neither designed as a hydraulic cylinder unit nor have a drive unit functioning on the basis of fluid dynamics. Rather, in this example, the primary actuator 20 and the secondary actuator 24 are each designed as a purely electromechanical transducer. This means that the primary actuator 20 and the secondary actuator 24 each have an electric motor as a drive unit, the output torque and / or force of which is directly converted into a movement of the respective actuator element 22, 26 within the respective actuator 20, 24. In the device 1, it is also provided that the primary actuator element 22 forms the secondary guide element 25.In other words, when the primary actuator element 22 is adjusted, the secondary guide element 25 is moved relative to the primary guide element 23 between the two primary actuator positions. In this example, the secondary guide element 25 is extended from the primary guide element 23 when adjusting towards the second primary actuator position, and retracted into the primary guide element 23 when adjusting towards the first primary actuator position.

[0042] In this case, actuators 20 and 24 are each designed as a ball screw drive. To ensure a particularly high degree of technical cleanliness during the execution of the process, it is specifically provided that the respective drive unit or electric motor of actuators 20 and 24 is encapsulated as effectively as possible.

[0043] In the method for connecting the connection arrangement 3, the device 1 is used in the following example: The actuator elements 22, 26 are – if not already done – fully retracted before a first process step, i.e., each is moved to its corresponding first actuator position by moving the actuator elements against the pressing direction z. This positions the flange press die 16 and the flange bearing 12 as far apart as possible along the device's vertical axis 11, as shown in Fig. 1. In the embodiment described here, it is further provided that an inner body 29 – in this case, a battery cell pack of the battery 2 – is placed externally onto a first inner surface 30 of the first housing part 4, and then the first housing part 4, together with the inner body 29, is placed on a workpiece carrier 31 that geometrically corresponds to the workpiece carrier receptacle 13 and fixed thereto.A first handling unit 32 is thus formed, comprising the workpiece carrier 31, the first housing part 4, and the inner body 29. In a first process step, the first handling unit 32 is then inserted into the device 1 by placing the workpiece carrier 31, together with the first housing part 4 and the inner body 29, into the workpiece carrier receptacle 13. The first flange 27 of the first housing part 4 is supported on the flange bearing 12 or on the ridges / teeth 15 of the flange bearing 12, with a first flange surface 28 facing in the opposite direction to the Z-axis. Using the positioning device, the first housing part 4 is positioned precisely into a machining position and fixed therein, in particular by aligning the workpiece carrier 31. This state of the first housing part 4, or the first handling unit 32, is shown in Fig. 2.In this example, before the second housing part 5 is inserted into the device 1 – i.e., before a second process step – a second flange surface 34 of a second flange 33 of the second housing part 5 and a second inner surface 35 of the second housing part 5 are coated externally with an adhesive 36, particularly in a single operation. The adhesive 36 applied to the second flange surface 34 creates the conditions for producing the second connecting element 37b of the fastener 37, wherein the second connecting element 37b is formed as a first adhesive bond between the flange surfaces 28 and 34.Furthermore, the adhesive 36 applied to the second inner surface 35 creates the conditions for producing the third connecting element 37c of the connecting means 37, wherein the third connecting element 37c is formed as a second adhesive connection between the inner body 29 and the second inner surface 35.

[0044] According to the present example, a hold-down element 38 is applied to the second outer surface 8 of the second housing part 5. The hold-down element 38 is designed to cover a large part or the entire second outer surface 8. Before the second housing part 5 is inserted into the device 1, the second housing part 5 and the hold-down element 38 are combined to form a second handling unit 39. In the second process step, the second handling unit 39 is then inserted into the device 1 and thereby placed onto the first housing part 4, such that the second flange 33 of the second housing part 5 is supported on the first flange 27 of the first housing part 4, forming a flange portion 40 of the connection arrangement 3 in which the flange surfaces 28 and 34 face each other.

[0045] Figure 2 illustrates how, due to the maximum distance between the flange press die 16 and the flange bearing 12, the second housing part 5 can be inserted into the device 1 particularly efficiently in the second process step and thereby placed onto the first housing part 4. For this purpose, a handling device (not shown) is used, in particular an articulated robot arm, by means of which the device 1 is laterally loaded with the second housing part 5. The second handling unit 39 – that is, the second housing part 5 coated with the adhesive 36, together with the hold-down element 38 bearing on its second outer surface 8 – is placed onto the first housing part 4 by means of the handling device. This state of the joining device 3 is shown in Figure 3. Figure 3 further illustrates...Figure 3 shows a third process step in which, after the flange portion 40 has been formed in the device 1, the primary actuator element 22 is moved to its lower dead center, i.e., completely into the second primary actuator position, while the secondary actuator element 26 remains in the first secondary actuator position. This moves the flange press ram 16 a primary stroke 41 towards the flange bearing 12. As can be seen in Figure 3, moving the primary actuator element 22 into the second primary actuator position does not yet exert any pressing force on the connection arrangement 3 by means of the device 1. Instead, this primary stroke of the device 1 is purely a movement stroke to move the flange press ram 16 closer to the connection arrangement 3 or the flange portion 40.The device 1 with primary actuator element 22 fully arranged in the second primary actuator position and secondary actuator element 26 fully arranged in the first secondary actuator position is shown in Fig. 3.

[0046] In a fourth process step, shown in Fig. 4, after the primary actuator element 22 has been fully moved into the second primary actuator position, the secondary actuator element 26 is moved to its bottom dead center, i.e., fully moved into the second secondary actuator position, while the primary actuator element 22 remains in the second primary actuator position. During this process, the secondary actuator element 26, and consequently the upper tool 10, is moved by a secondary travel 42 in the pressing direction z. It can be seen in Figs. 3 and 4 that the primary travel 41, by which the primary actuator element 22 can be moved from the first to the second primary actuator position, is shorter than the secondary travel 42, by which the secondary actuator element 26 can be moved from the first to the second secondary actuator position. For example, the primary travel 41 has a length of 400 millimeters, while the secondary travel 42 has a length of 1000 millimeters.

[0047] The actuators 20, 24, the tools 9, 10, and the fixture frame 21 are arranged such that when both actuator elements 22, 26 are each in the second actuator position, the flange press ram 16 is in a pressing position in which a pressing force is exerted on the flange portion 40, which is supported on the flange bearing 12, along the vertical axis 11 of the fixture. Accordingly, this secondary stroke of the fixture 1 is a pressing stroke. Thus, by moving the secondary actuator element 26 into the second secondary actuator position while the primary actuator element 22 is in the second primary actuator position, the pressing force is exerted on the flange portion 12, by means of which the first flange 27 and the second flange 33 are pressed together.Furthermore, in this position of the device 1, a surface pressure force is exerted on the second outer surface 8 of the second housing part 5 by means of the surface pressure die 17 via the holding mass element 38. This compacts or compresses the adhesive 36 between the flange surfaces 28, 34 and between the inner body 29 and the second inner surface 35, thereby creating the first and second adhesive bonds, or the second connecting element 37b and the third connecting element 37c. This results in the housing parts 4, 5 being bonded together by means of a material bond, whereby the inner body 29 and the second inner surface 35 are bonded together.

[0048] Once both the primary actuator element 22 and the secondary actuator element 26 are in the secondary actuator position, the flange press ram 16 is moved along the vertical axis 11 of the device in the pressing direction z towards the flange bearing 12 to such an extent that the flange press ram 16 in the pressing position and the flange bearing 12 are spaced apart from each other by a pressing distance 43 (see Fig. 4 and Fig. 5) along the vertical axis 11 of the device. As a result, the flange portion 40 is clamped between the flange bearing 12, or rather its tines / teeth 15, and the flange press ram 16, or rather its tines / teeth 19, whereby the pressing force is exerted on the flange portion 40 between the flange bearing 12 and the flange press ram 16 along the vertical axis 11 of the device.

[0049] A first instance of the fifth process step has already been carried out by applying the adhesive 36 to the second flange surface 34, and a second instance of the fifth process step has already been carried out by applying the adhesive 36 to the second inner surface 35. By carrying out the first and second instances of the fifth process step, the fastener 37 has already been partially produced or applied, and the housing parts 4 and 5 have been materially bonded together. The present process further provides for the execution of a third instance of the fifth process step, in which the housing parts 4 and 5 are positively bonded together.For this purpose, while the pressing force is applied to the flange portion – i.e., during the fourth process step – the first connecting element 37a of the fastener 37 is applied by connecting the first flange 27 and the second flange 33 to each other by means of a connecting pin (not shown), in this example by means of a rivet. This means that the fastener 37 has a rivet connection as its first connecting element 37a in this example. It can be clearly seen in Fig. 5 that the engagement gaps 14, 18 between the tines / teeth 15, 19 create respective clearances on the upper and simultaneously on the lower side of the flange portion 40, into which a riveting tool 44 engages to set the rivet(s). The rivet setting points 45, where a rivet is set, are located in the clearances or between the tines / teeth 15, 19.During the fourth process step, the housing parts 4, 5, arranged for the flange portion 40 and clamped between the two symmetrical tine arrangements of the tines / teeth 15, 19, are riveted together using the riveting tool 44 and thus positively connected to one another. Alternatively or additionally, the use of a welding gun is conceivable, with which weld points can be placed to join the housing parts 4, 5 between the tines / teeth 15, 19.

[0050] The problem outlined at the outset, namely to improve the joining of two components, particularly in the production of a battery for a motor vehicle, is solved by both the device 1 and the method. This results in a particularly efficiently manufactured battery 2 and, consequently, a particularly efficiently manufactured motor vehicle.

[0051] The invention is based, among other things, on the idea that, according to the prior art, a planar connection of the high-voltage components of the battery 2, in particular the battery cell pack, to the housing shells or housing parts 4, 5 using adhesives / foam materials is not necessary; an adhesive bond between one of the housing parts 4, 5 and the battery cell pack is sufficient for operational reliability and quality requirements. Thus, the pre-compression of the adhesive components to meet the quality requirements could be ensured using conventional clamping technology.

[0052] Reference symbol list

[0053] 1 Device

[0054] 2 batteries

[0055] 3 Connection arrangement

[0056] 4 first housing part

[0057] 5 second housing part

[0058] 6 battery cases

[0059] 7 first outdoor area

[0060] 8 second outdoor area

[0061] 9 lower tool

[0062] 10 Upper tool

[0063] 11 Device vertical axis

[0064] 12 flange bearings

[0065] 13 Workpiece carrier holder

[0066] 14 Flange bearing engagement gap

[0067] 15 tines / tooth

[0068] 16 flange press dies

[0069] 17 surface press dies

[0070] 18 Stamp intervention gap

[0071] 19 tines / tooth

[0072] 20 Primary actuator

[0073] 21 Device frame

[0074] 22 Primary actuator element

[0075] 23 Primary guide element

[0076] 24 Secondary actuator

[0077] 25 Secondary guide element

[0078] 26 Secondary actuator element

[0079] 27 first flange

[0080] 28 first flange surface

[0081] 29 inner body

[0082] 30 first inner surface

[0083] 31 workpiece carrier 32 first handling unit

[0084] 33 second flange

[0085] 34 second flange surface

[0086] 35 second inner surface 36 adhesive

[0087] 37 Fasteners

[0088] 37a first connecting element

[0089] 37b second connecting element

[0090] 37c third connecting element 38 holding mass element

[0091] 39 second handling unit

[0092] 40 flange share

[0093] 41 Primary section

[0094] 42 Secondary section 43 Pressing distance

[0095] 44 Rivet setting tool

[0096] 45 rivet setting point

Claims

Patent claims 1. Device (1) for connecting a connection arrangement (3), wherein the device (1) comprises: - a flange bearing (12), - a flange press die (16) which is positioned along a vertical axis (11) opposite the flange bearing (12), - a primary actuator (20) fixed to a device frame (21), the primary actuator element (22) of which is linearly adjustable relative to the device frame (21) between a first, fully retracted and a second, fully extended primary actuator position along the device vertical axis (11), - a secondary actuator (24) fixed to the primary actuator element (22), the secondary actuator element (26) of which is linearly adjustable relative to the primary actuator element (22) between a first, fully retracted and a second, fully extended secondary actuator position along the device vertical axis (11), wherein the flange press ram (16) is attached to the secondary actuator element (26), wherein, when both actuator elements (22, 26) are each arranged in the second actuator position, the flange press ram (16) is arranged in a pressing position in which a pressing force can be exerted on a flange portion (40) of the connection arrangement (3) supported on the flange bearing (12) along the device vertical axis (11).

2. Device (1) according to claim 1 , characterized in that one or both of the actuators (20, 24) is / are designed as a ball screw drive.

3. Device (1) according to claim 1 or 2, characterized in that one or both of the actuators (20, 24) is / are free of a working fluid, in particular is / are designed as a purely electromechanical transducer.

4. Device (1) according to one of the preceding claims, characterized in that a primary section (41) by which the primary actuator element (22) can be adjusted from the first to the second primary actuator position is shorter than a secondary section (42) by which the secondary actuator element (26) can be adjusted from the first to the second secondary actuator position.

5. Device (1) according to one of the preceding claims, characterized in that the flange bearing (12) has a flange bearing engagement gap (14) and the flange press punch (16) has a punch engagement gap (18), wherein the engagement gaps (14, 18) are located opposite each other in pairs along the vertical axis (11) of the device.

6. Method for connecting a connection arrangement (3) comprising two housing parts (4, 5) using the device (1) designed according to one of the preceding claims, wherein - the first housing part (4) is inserted into the device (1) in such a way that a first flange (27) of the first housing part (4) is supported on the flange bearing (12), - the second housing part (5) is inserted into the device (1) and thereby placed on the first housing part (4) in such a way that a second flange (33) of the second housing part (5) is supported on the first flange (27), thereby forming a flange portion (40) of the connection arrangement (3), - after the flange portion (40) has been formed in the device (1), the primary actuator element (22) is fully moved into the primary actuator position, - the secondary actuator element (26) is fully moved into the secondary actuator position, thereby moving the flange press ram (16) into the pressing position and consequently exerting the pressing force on the flange portion (40), by means of which the first flange (27) and the second flange (33) are pressed together, - a connecting element (37) is applied by means of which the first flange (27) and the second flange (33) are connected to each other in a form-fitting and / or material-fitting manner.

7. Method according to claim 6, characterized in that, while the pressing force is applied to the flange portion (40), a connecting element (37a) of the connecting means (37) is applied by connecting the flanges (27, 33) to each other by means of a connecting pin, in particular by riveting them together.

8. Method according to claim 6 or 7, characterized in that, prior to inserting the second housing part (5) into the device (1), a second flange surface (34) of the second flange (33) is coated externally with an adhesive. (36) is coated, thereby forming a connecting element (37b) of the connecting element (37) is applied.

9. Method according to one of claims 6 to 8, characterized in that an inner body (29) is placed on a first inner surface (30) of the first housing part (4), which is bonded to a second inner surface (35) of the second housing part (5) while adjusting the secondary actuator element (26) into the secondary actuator position.

10. Method according to claims 8 and 9, characterized in that when coating the second flange surface (34) with the adhesive (36) in the same operation the second inner surface (35) of the second housing part (5) is coated with adhesive (36) is coated, thereby forming a connecting element (37c) of the connecting element (37) is applied.

11. Method according to one of claims 6 to 10, characterized in that, prior to inserting the second housing part (5) into the device (1), the second housing part (5) and a hold-down mass element (38) bearing on a second outer surface (8) of the second housing part (5) are combined to form a handling unit (39) and are inserted together into the device (1) and thereby placed onto the first housing part (4).

12. Method according to one of claims 6 to 11, characterized in that, after the second housing part (5) is inserted into the device (1), the primary actuator element (22) is moved to the second primary actuator position while the secondary actuator element (26) remains in the first secondary actuator position, and, after the primary actuator element (22) has been completely moved to the second primary actuator position, the secondary actuator element (26) is moved to the second secondary actuator position while the primary actuator element (22) remains in the second primary actuator position, wherein the pressing force is exerted on the flange portion (40) solely by moving the secondary actuator element (26) to the second secondary actuator position.

13. Connection arrangement (3) which is produced by means of the device (1) designed according to one of claims 1 to 5 and / or by means of the method designed according to one of claims 6 to 12.

14. Battery (2) for a motor vehicle, comprising the connection arrangement (3) designed according to claim 13, wherein a battery housing lower part is formed by one of the housing parts (4, 5) and a battery housing upper part is formed by the other of the housing parts (5, 4).

15. Motor vehicle with a battery designed according to claim 14 (2).

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