Method and device for producing an electrical connection and for producing a connection cable

Abstract

A method and a device for producing an electrical connection between a solar panel and a converter or a further solar panel or between a converter and a grid feed point by means of a connecting cable provided by a mobile cable provision unit. The mobile cable provision unit comprises: a housing that can be laid, rolled or moved. The housing contains at least one cable supply which is accessible from the outside and / or inside. The cable supply comprises at least one cable. A cutting unit, a stripping unit and a crimping unit are contained in the housing so as to be accessible from the outside and / or inside. The crimping unit comprises a crimping supply. The crimp supply includes at least a plurality of first and second connectors. The housing contains at least one plug fabrication unit which is accessible from the outside and / or inside. The plug fabrication unit comprises a connector housing supply. The connector housing supply comprises at least a plurality of first and second connector housings.

Description

[0001] Method and apparatus for making an electrical connection and for making a connecting cable

[0002] Description

[0003] background

[0004] This document describes a method for establishing an electrical connection between at least one solar panel and an inverter or another solar panel, or between an inverter and a grid connection point, using a connecting cable provided by a mobile cable supply unit, and a device for manufacturing such a connecting cable. Details are defined in the claims. The description includes relevant information on the method, the individual method steps, the device, and individual components used to manufacture the connecting cable.

[0005] The number of solar installations, both in the private and industrial sectors, such as solar parks, is steadily increasing due to the energy transition towards renewable energies. When installing solar systems, especially solar parks, the necessary connecting cables with connectors for joining the solar modules are usually manufactured manually on-site, as the cable lengths often cannot be determined precisely enough in advance. However, this process is very prone to errors, particularly when crimping the connectors onto the cable and when attaching and securing the connector housing. In current installation situations, pre-made connecting cables of a specific length are also sometimes delivered, which are then either the correct length, too long (resulting in material waste), or too short, necessitating reordering of suitable cables and delaying the installation of the solar systems.

[0006] An error in crimping the connectors can result in the contact area of ​​the connector being too small in relation to the stripped section of the cable, which can lead to an increase in electrical resistance and thus to increased temperature development.

[0007] An incorrectly installed connector housing can cause it to shift relative to the internal connector. This can result in the internal connectors not making contact or the contact area being significantly reduced when two connector housings are connected. Similar to a crimping error, this can lead to a significantly increased temperature inside the connector housing, which is not visible from the outside. At best, these faults will cause the solar power system or solar park to fail, increasing service costs and reducing yield. At worst, they can lead to a fire and the destruction of the solar power system or solar park.

[0008] Underlying problem

[0009] Based on this, a method for producing an electrical connection between at least one solar panel and an inverter or another solar panel or between an inverter and a grid feed-in point, as well as a device for producing a connecting cable, is to be provided.

[0010] Proposed solution

[0011] The problem is solved by the subject matter of the attached independent claims. The solution is disclosed below in terms of method and apparatus aspects, the apparatus aspects also relating to the method and vice versa.

[0012] According to one aspect, a method for establishing an electrical connection between at least one solar panel and an inverter or another solar panel, or between an inverter and a grid connection point, is provided by means of a connecting cable supplied by a mobile cable supply unit. The mobile cable supply unit comprises one or more of the following components: A deployable, rollable, or mobile housing. The housing contains, in one variant, at least a supply of cables, accessible from the outside and / or inside. The cable supply comprises, in one variant, at least one cable of a first cable type. The housing contains, in one variant, at least a cutting unit, accessible from the outside and / or inside. This cutting unit can be omitted if the cable is inserted into the housing already cut to length.

[0013] The housing contains, in one variant accessible from the outside and / or inside, at least one stripping unit. The housing contains, in one variant accessible from the outside and / or inside, at least one crimping unit. In one variant, the crimping unit includes a supply of connectors (also called a crimp supply). In one variant, the crimp supply includes at least a plurality of first connectors. In one variant, the crimp supply includes at least a plurality of second connectors. The housing contains, in one variant accessible from the outside and / or inside, at least one connector assembly unit. In one variant, the connector assembly unit includes a supply of connector housings. In one variant, the connector housing supply includes at least a plurality of first connector housings. In one variant, the connector housing supply includes at least a plurality of second connector housings.

[0014] The process includes one or more of the following steps:

[0015] - Specifying a required cable length for the connecting cable; and / or

[0016] - Feeding the cable from the cable supply into the stripping unit; and / or

[0017] - Stripping a first end of the cable by a first stripping length using the stripping unit; and / or

[0018] - Fitting the stripped first end of the cable with at least one first connector from the crimp supply using the crimping unit; and / or

[0019] - Crimping the first connector onto the first end of the cable with an adjustable initial crimp force by the crimping unit; and / or

[0020] - Pulling the cable into the cutting unit to the required length and cutting the pulled-in cable to create a cable section of the required length, with the first end of the cable forming the first end of the cable section; and / or

[0021] - Stripping a second end of the cable section by a second stripping length using the stripping unit; and / or

[0022] - Fitting the stripped second end of the cable section with at least one second connector from the crimp supply using the crimping unit; and / or

[0023] - Crimping at least one second connector onto the second end of the cable section with an adjustable second crimp force by the crimping unit; and / or

[0024] - Applying a first connector housing from the connector housing supply onto the at least one first connector and / or applying a second connector housing onto the at least one second connector with an adjustable first application torque by the connector assembly unit; and / or applying a feed force to the first connector housing or the second connector housing and subsequently closing it by a closing torque applied to the first connector housing or the second connector housing relative to the other connector housing;

[0025] - and / or wherein the cable segment, after the application of the first connector housing and the second connector housing, forms the connecting cable; and / or

[0026] - Connecting the first end of the connecting cable to the corresponding terminal on the solar panel, to a string from the solar panel, a string connector, or the corresponding second terminal of the inverter; and / or

[0027] - Connecting the second end of the connecting cable to the corresponding first terminal of the inverter, the corresponding terminal of the other solar panel, or the corresponding terminal of the grid connection point. In another variant, the cable is labeled for the unambiguous identification and marking of final inspection test results. The marking can also include the result of monitoring the crimping process, in which a force-displacement curve of the crimping process is recorded. If this curve is within a predefined tolerance, the crimping process is considered successful, and this result, possibly along with other results (dimensional accuracy, insulation resistance, dielectric strength, etc.), is recorded in the marking.

[0028] In one variant, after the first cable has been cut, the end of the first cable and the beginning of the second cable are stripped simultaneously.

[0029] In one version, after the first end of the cable has been stripped, the cable can be automatically transferred from the stripping unit to the crimping unit.

[0030] In one version, the cable can be automatically transferred from the crimping unit to the cutting unit before at least the first connector is crimped. In another version, the cable can be automatically transferred from the crimping unit to the cutting unit before at least the first connector is crimped.

[0031] In one variant, the cable section can be automatically transferred from the cutting unit to the stripping unit after being cut. The cable section can be automatically transferred from the cutting unit to the stripping unit after being cut.

[0032] After the second end of the cable section has been stripped, it can be automatically transferred from the stripping unit to the crimping unit.

[0033] The first connector can be a pin connector in one version. The first connector can be a socket connector in another version. The second connector can be a pin connector in one version. The second connector can be a socket connector in another version. The first connector housing can have a locking mechanism to prevent accidental disconnection in one version. The second connector housing can have a locking mechanism to prevent accidental disconnection in one version. Connector housings with a locking mechanism to prevent accidental disconnection offer the advantage that the connector housings remain firmly fixed to the connecting cable, thus preventing the connector housings from shifting relative to the internal connector.Otherwise, when two connector housings are connected, an invisible loss of contact or a reduction in the contact area between the internal connectors can occur, which in turn can lead to a significantly increased temperature development inside the connector housing.

[0034] The mobile cable dispensing unit can, in one variant, include a test unit. This test unit tests the mechanical and / or electrical properties of the manufactured connecting cables (e.g., checking the actual length of the connecting cable compared to the set target length, insulation voltage of the connecting cable, etc.).

[0035] One version of the crimping unit may include an integrated first test unit. One version of the connector assembly unit may include an integrated second test unit.

[0036] The application of the first connector to the connecting cable can be checked by the test unit in one variant. The application of the second connector to the connecting cable can be checked by the test unit in one variant. The application of the first connector housing can be checked by the test unit in one variant. The application of the second connector housing can be checked by the test unit in one variant.

[0037] The application of the first connector to the connecting cable can be checked in one variant by the integrated first test unit. The application of the second connector to the connecting cable can be checked in one variant by the integrated first test unit. The application of the first connector housing can be checked in one variant by the integrated second test unit. The application of the second connector housing can be checked in one variant by the integrated second test unit.

[0038] The electrical conductivity of the connecting cable can be checked in one variant using the test unit. In another variant, the electrical conductivity of the connecting cable can be checked using the integrated first test unit. In yet another variant, the electrical conductivity of the connecting cable can be checked using the integrated second test unit. Using the test unit, the integrated first test unit, and / or the integrated second test unit, it can be ensured in one variant that only connecting cables with correctly crimped connectors and connector housings, and with the specified crimping force or application torque, are used to establish the electrical connection. This significantly reduces the occurrence of faults during the operation of the solar panels, thereby lowering the probability of failure and service costs.

[0039] The cable supply unit can include a control unit in one version. In one version, the control unit can control the cutting unit. In another version, the control unit can control the stripping unit.

[0040] In one version, the controller can control the crimping unit. In another version, the controller can control the connector assembly unit.

[0041] The first stripping length can be set manually in one variant. In another variant, the first stripping length can be automatically determined by the controller depending on the cable type and the first connector used. The second stripping length can be set manually in one variant. In yet another variant, the second stripping length can be automatically determined by the controller depending on the cable type and the second connector used.

[0042] In one variant, the stripping unit may include a first monitoring unit.

[0043] In one variant, the stripping unit can include at least one initial stripping blade.

[0044] In one variant, the first monitoring unit can monitor the cutting depth of at least one stripping blade into the cable insulation during stripping. In another variant, the first stripping length can be monitored by the first monitoring unit. In yet another variant, the second stripping length can also be monitored by the first monitoring unit.

[0045] Monitoring the cut depth and the first and second stripping lengths offers the advantage that potential production errors, such as damage to the electrical conductor of the connecting cable due to excessive cut depth, can be detected during the process. Furthermore, in one variant, monitoring the individual parameters can detect wear on at least one stripping blade. In another variant, the crimping unit can incorporate a second monitoring unit.

[0046] In one version, the first crimping force can be monitored by the second monitoring unit during the crimping process. In another version, the second crimping force can also be monitored by the second monitoring unit during the crimping process.

[0047] A stripping fault can be detected by the first monitoring unit in one scenario. In another scenario, the stripping fault can be detected by the second monitoring unit. The stripping fault can manifest as insulation remaining on the stripped first end of the cable or cable segment in one scenario. In another scenario, insulation remaining on the stripped second end of the cable segment can manifest as damage to an electrical conductor of the cable or cable segment, such as the breaking of individual conductor strands.

[0048] Detecting potential stripping errors during the process ensures that the stripped ends of the cable or cable section are correctly prepared for crimping. This can prevent a faulty connection between the electrical conductor and the corresponding connector, thus reducing the probability of cable failure.

[0049] In one variant, a crimping error can be detected by the second monitoring unit.

[0050] The crimping error can be caused by damage to the insulation of the cable or cable segment. Alternatively, the crimping error can be caused by incorrect positioning of the first connector relative to the stripped first end of the cable. Finally, the crimping error can be caused by incorrect positioning of the second connector relative to the second end of the cable segment.

[0051] In one variant, the crimping unit can apply a single-conductor seal between the cable insulation and a section of the first connector. In another variant, the crimping unit can apply a single-conductor seal between the cable segment's insulation and a section of the second connector. In one variant, the crimping defect can be an incorrect positioning of the single-conductor seal relative to the first connector. In another variant, the crimping defect can be an incorrect positioning of the single-conductor seal relative to the second connector. By detecting crimping defects during the process, cable segments with incorrectly applied connectors can be immediately rejected in one variant, thus preventing them from being used for making an electrical connection.Sorting out cable sections with faulty connectors thus significantly reduces the probability of failure of the connecting cable in one variant, e.g. due to loss of contact of the connectors or the occurrence of a fire due to increased temperature development.

[0052] The first crimping force can range from approximately 10 kN to approximately 20 kN in one variant. The second crimping force can also range from approximately 10 kN to approximately 20 kN in one variant.

[0053] The first crimp force can be manually adjusted in one variant. The second crimp force can also be manually adjusted in one variant. In another variant, the first crimp force can be automatically determined by the controller based on the cable type and the first connector used. The second crimp force can also be automatically determined by the controller based on the cable type and the second connector used in one variant.

[0054] The initial application torque can range from approximately 2 Nm to approximately 6 Nm in one variant.

[0055] The initial application torque can be set manually in one variant. In another variant, the initial application torque can be automatically determined by the controller depending on the cable type, connectors, and connector housings used.

[0056] In one variant, automatically setting the first and second crimping forces and the initial application torque increases the production capacity of the connecting cables, as manual adjustments are no longer necessary. Furthermore, in another variant, this automatic setting prevents errors that can arise from incorrect manual input of the aforementioned parameters. The system also accommodates the use of different crimps and allows for easy conversion to different crimp types by keeping a sufficient supply of the various crimps on hand. The first and second crimping forces are automatically set according to the crimp type used.

[0057] The cable dispensing unit can, in one variant, include a logging unit. This logging unit can, in one variant, output a log. In one variant, the log can include at least information about the number of dispensed connection cables. In one variant, the log can include at least information about the length of the dispensed connection cables. In one variant, the log can include at least information about the first crimp force. In one variant, the log can include at least information about the second crimp force. In one variant, the log can include at least information about the first application torque. In one variant, the log can include at least information about the cable type used. In one variant, the log can include at least information about the first connector used.The protocol can, in one variant, include at least information about the second connector used. The protocol can, in one variant, include at least information about the first connector housing used. The protocol can, in one variant, include at least information about the second connector housing used. The protocol can, in one variant, include at least information about a test result of the first test unit. The protocol can, in one variant, include at least information about a test result of the integrated first test unit. The protocol can, in one variant, include at least information about a test result of the integrated second test unit. The protocol can, in one variant, include at least information about a stripping error. The protocol can, in one variant, include at least information about a crimping error.

[0058] The output of a log allows an operator of the cable supply unit to view all parameters relating to the supply of the connection cable(s) in order to assess whether the connection cables meet the desired quality requirements. Furthermore, the log can serve as proof of compliance with the required quality standards for the connection cables, for example, to an insurance company or the client.

[0059] This also involves assigning the protocol to a uniquely identifiable key, which can be done by labeling the cable.

[0060] According to another aspect, a mobile cable supply unit is provided for establishing an electrical connection according to the method described above. In one variant, the mobile cable supply unit comprises one or more of the following components: A layable, rollable, or mobile housing. In one variant, the housing contains at least a supply of cables, accessible from the outside and / or inside. In one variant, the cable supply comprises at least one cable of a first cable type. In one variant, the housing contains at least one cutting unit, accessible from the outside and / or inside. The cutting unit is not strictly necessary if pre-cut cables are supplied to the system.

[0061] The housing contains, in one variant, at least one stripping unit accessible from the outside and / or inside. The housing contains, in one variant, at least one crimping unit accessible from the outside and / or inside. In one variant, the crimping unit includes a supply of crimps. In one variant, the crimping supply includes at least a plurality of first connectors. In one variant, the crimping supply includes at least a plurality of second connectors. The housing contains, in one variant, at least one connector assembly unit accessible from the outside and / or inside. In one variant, the connector assembly unit includes a supply of connector housings. In one variant, the connector housing supply includes at least a plurality of first connector housings. In one variant, the connector housing supply includes at least a plurality of second connector housings.

[0062] The cable supply, the cutting unit, the stripping unit, the crimping unit and the connector assembly unit can, in one variant, be accessible from the outside through at least one opening in the housing of the mobile cable supply unit.

[0063] The cable supply, cutting unit, stripping unit, and crimping unit can, in one variant, be integrated as a single unit within the housing of the mobile cable dispensing unit. The cutting unit (if present), the stripping unit, and the crimping unit can also be integrated as a single unit within the housing of the mobile cable dispensing unit.

[0064] The cable supply unit can, in one variant, include a test unit. The crimping unit can, in one variant, include an integrated first test unit. The connector assembly unit can, in one variant, include an integrated second test unit.

[0065] In one version, the cable supply can include at least one cable drum. In another version, the cable can be wound onto at least one cable drum.

[0066] In one variant, the stripping unit may include a first monitoring unit.

[0067] In one variant, the crimping unit may include a second monitoring unit.

[0068] The mobile cable deployment unit can, in one variant, include a logging unit. Brief description of the drawings.

[0069] Further details, features, advantages, and effects of the arrangements and procedures described herein will become apparent from the following description of currently preferred variants and from the drawings. These show:

[0070] Fig. 1 shows a variant of a mobile cable deployment unit;

[0071] Fig. 2 shows an example connection diagram;

[0072] Fig. 3a a cable after being fed from the cable supply into the stripping unit;

[0073] Fig. 3b a cable after stripping the first end;

[0074] Fig. 3c shows a cable after the insertion and crimping of at least one connector;

[0075] Fig. 3d shows a cable after it has been pulled through to the required length;

[0076] Fig. 3e shows a piece of cable after cutting;

[0077] Fig. 3f shows a piece of cable after the second end has been stripped;

[0078] Fig. 3g shows a piece of cable after the second connector has been fitted and crimped;

[0079] Fig. 3h shows a connecting cable after the first and second connector housings have been applied.

[0080] Detailed description of the drawings

[0081] The proportions and dimensions of the objects and sections depicted in the figures are not to scale. Individual objects and sections may be greatly enlarged or reduced in size.

[0082] Fig. 1 shows a variant of a mobile cable supply unit 1000. In the embodiment shown here, the cable supply unit 1000 is designed with a rollable housing 1001. In other words, the mobile cable supply unit

[0083] The 1000 is designed as a trailer that can be towed by a tractor or tractor unit to be transported to a deployment site. The 1000 mobile cable deployment unit can also be configured as a mobile housing in other variants.

[0084] The mobile cable supply unit 1000 can comprise a portable housing 1001 in which the mobile cable supply unit is stored. The unit may, for example, be designed as a portable container.

[0085] The cable supply unit 100, in the version shown here, is designed to be walk-in, allowing access to the internal components. Other versions are possible, in which the components are accessible from the outside, for example, by opening a flap or cover. Furthermore, versions are also possible in which the components are accessible from both the inside and outside.

[0086] The mobile cable supply unit 1000, in the variant illustrated here, includes at least a cable supply 100, a cutting unit 200, a stripping unit 300, a crimping unit 400 and a connector assembly unit 500.

[0087] The cable supply 100 is designed in the variant illustrated here as a cable drum on which a cable 810 of a first cable type is wound.

[0088] The cutting unit 200, the stripping unit 300 and the crimping unit 400 are designed as a single unit in the variant illustrated here.

[0089] The cutting unit 200, in the variant illustrated here, is set up to cut the cable 810 from the cable drum 100 to a required length 801, so that a cable piece 820 with the required length 801 is created.

[0090] In the variant illustrated here, the stripping unit 300 comprises at least a first stripping knife, which is not explicitly shown here, and a first monitoring unit 330.

[0091] In the variant illustrated here, the stripping unit 300 is configured to strip the first end 821 of the cable 810 from the cable drum 100 by a first stripping length 830. Furthermore, in this variant, the stripping unit 300 is configured, after the cable has been cut by the cutting unit 200, to strip the second end 822 of the cable section 820 by a second stripping length 831. After being cut by the cutting unit 200, the first end 821 of the cable 810 becomes the first end 821 of the cable section 820. In the following, only the terms "the first end 821" and "the second end 822" will be used. The section of cable 820 that has been stripped by the first or second stripping length after stripping is taken into account by the formulation “the first end 821” or “the second end 822”.A detailed description of the individual process steps is given in the description of Figures 3a-3h. The first stripping length 830 and the second stripping length 831 can be set by an operator of the cable supply unit 1000. Alternatively or additionally, the first stripping length 830 and the second stripping length 831 can be determined automatically by the stripping unit 300 or a control system not shown here, depending on the cable type used and the first and second connectors 840 / 841 used.

[0092] In the variant illustrated here, the first stripping blade is configured to strip the first end 821 and the second end 822 by the first stripping length 830 and the second stripping length 831, respectively. Alternatively, the stripping unit 300 comprises a second stripping blade in addition to the first, wherein the first stripping blade is configured to strip the first end 821 by the first stripping length 830 and the second stripping blade is configured to strip the second end 822 by the second stripping length 831.

[0093] The first monitoring unit 330, in the variant illustrated here, is configured to monitor the cutting depth of at least one of the first stripping blades and / or the second stripping blade. The cutting depth represents the depth to which the first and / or the second stripping blade cuts into the cable or cable section.

[0094] Furthermore, in the variant illustrated here, the first monitoring unit 330 is configured to monitor the first stripping length 830 and the second stripping length 831. The first monitoring unit 330 can issue a warning to an operator if, during stripping, a value for the cut depth, the first stripping length, or the second stripping length is detected that does not correspond to a preset or automatically calculated value. Alternatively or additionally, the first monitoring unit 330 can adjust the settings based on the detected values ​​to compensate for a possible deviation between a measured value and a set value, e.g., due to wear of the first stripping blade.

[0095] In the variant illustrated here, the first monitoring unit 330 is still configured to detect a stripping fault. The stripping fault could, for example, be the remaining insulation on the stripped first end 821 or the stripped second end 822. This can occur, for instance, if the stripping knife does not cut the insulation to a uniform depth around the entire circumference of the cable and thus does not completely separate it from the insulation on the cable segment. In this case, a residue may remain on the stripped first end 821 or the stripped second end 822 after the insulation is removed. The stripping fault could also be damage to the electrical conductor of the cable 810 or the cable segment 820.This can occur, for example, if the wire stripper cuts too deep into the cable, thereby not only cutting through the insulation but also damaging the electrical conductor, for example by cutting through individual strands of the electrical conductor.

[0096] The first monitoring unit 330, in the variant illustrated here, can, for example, be configured as an optical monitoring unit. The first monitoring unit 330 can also include motion sensors that detect movement of the stripping blade. Furthermore, in the variant illustrated here, the first monitoring unit 330 can include position sensors that detect the exact position of the cable 810 or the cable section 820 in the stripping unit 300.

[0097] In the variant illustrated here, the crimping unit 400 comprises a crimp supply 420, an integrated first test unit 410, and a second monitoring unit 430. The crimp supply 420 stores the connectors required to make the electrical connection. In this variant, the crimp supply 420 includes at least a plurality of first connectors 840 and at least a plurality of second connectors 841. The first connector 840 is a pin connector. The second connector 841 is a socket connector.

[0098] In the variant illustrated here, the crimping unit 400 is configured to crimp at least one first connector 840 onto the stripped first end 821. The crimping unit 400 is also configured to crimp at least one second connector 841 onto the stripped second end 822. In other variants, depending on the connector type, the crimping unit 400 can apply a single-conductor seal between the insulation of the cable 810 or cable section 820 and a section of the first connector 840 or the second connector 841.

[0099] In the variant illustrated here, the crimping unit 400 is configured to crimp at least one connector 840 onto the first end 821 with an adjustable initial crimping force. In the variant illustrated here, the crimping unit 400 is also configured to crimp at least one second connector 841 onto the second end 822 with an adjustable second crimping force.

[0100] The first crimp force can be set between approximately 10 kN and 20 kN, depending on the cable and connector type. The second crimp force can also be set between approximately 10 kN and 20 kN, depending on the cable and connector type. Both the first and second crimp forces can be manually set by the operator of the cable dispensing unit 1000 or automatically by a control unit (not shown) depending on the cable type and connectors 840 / 841 used.

[0101] The integrated first test unit 410, in the variant illustrated here, is configured to verify the application of the first connector 840 to the first end 821 and the application of the second connector 841 to the second end 822. The verification may, for example, be a tensile test and / or a torsion test. The verification may also include other test procedures for checking mechanical connections, which are not described in detail here.

[0102] In the variant illustrated here, the second monitoring unit 430 is configured to detect stripping errors, analogous to the first monitoring unit 330. The second monitoring unit 430 is also configured to monitor the first crimp force and the second crimp force during crimping. Additionally, in the variant illustrated here, the second monitoring unit 430 can detect a crimping error. A crimping error could be, for example, damage to the insulation of the cable 810 or the cable section 820 during crimping, or incorrect positioning of the first connector 840 or the second connector 841 relative to the stripped first end 821 or the stripped second end 822, respectively. The crimping error could also be incorrect positioning of the single-conductor seal relative to the first connector 840 or the second connector 841.

[0103] In the variant illustrated here, the second monitoring unit 430 can issue a warning to the operator upon detecting a stripping or crimping error. Alternatively or additionally, in the variant illustrated here, the second monitoring unit 430 can adjust the crimping force settings or the positioning of the cable 810 in the crimping unit 400 based on the detected errors, or mark the cable 810 or cable section 820 as damaged and reject it.

[0104] The second monitoring unit 430, in the variant illustrated here, can, for example, be configured as an optical monitoring unit. The first monitoring unit 430, in the variant illustrated here, can also include position sensors that detect the exact position of the cable 810 or the cable section 820 in the crimping unit 400.

[0105] The connector assembly unit 500, in the variant illustrated in Fig. 1, comprises a connector housing supply 520 and an integrated second test unit 510. The connector housing supply 520 contains the connector housings required to make the electrical connection. In the variant illustrated here, the connector housing supply comprises at least a plurality of first connector housings 850 and at least a plurality of second connector housings 851. In the variant illustrated here, the first connector housing 850 is designed to fit the first connector 840, and the second connector housing is designed to fit the second connector 841. In alternative variants, the connector housing supply may also contain more than two different connector housing types.

[0106] In the variant illustrated here, both the first connector housing 850 and the second connector housing 851 feature a locking mechanism to prevent unintentional detachment from the cable. This locking mechanism could, for example, be a clip that prevents the screw thread of the respective connector housing from being turned and thus loosened after it has been placed on the cable.

[0107] In the variant illustrated here, the connector assembly unit 500 is configured to place the first connector housing 850 onto the first connector 840 and the second connector housing 851 onto the second connector 840, and to tighten them with an initial installation torque. In the variant illustrated here, the initial installation torque can be manually set by the operator of the cable supply unit 1000 or automatically determined by an electronic control unit (not shown) depending on the cable type, connectors 840 / 841, and connector housings 850 / 851 used.

[0108] The integrated second test unit 510, in the variant illustrated here, is configured to verify the application of the first connector housing 850 to the first connector 840 and the application of the second connector housing 851 to the second connector 841. The verification may, for example, be a tensile test and / or a torsion test. The verification may include further test procedures for checking mechanical connections, which are not described in detail here.

[0109] In the variant illustrated here, the cable dispensing unit 1000 also includes a logging unit 900, which is configured to output a log. The operator of the cable dispensing unit 1000 can configure how often the log should be output and what information it should contain. For example, the logging unit 900 can output a log after each dispensed connection cable 800. Alternatively or additionally, the logging unit 900 can output a log after a number of dispensed connection cables 800 specified by the operator.In the variant illustrated here, the protocol can, depending on the operator's settings, include information about the number of connection cables 800 provided, the length 801 of the individual connection cables 800, the initial crimping force applied, the initial application torque, the cable type used, the first and second connectors 840 / 841, the first and second connector housings 850 / 851, a test result of the integrated first test unit 410 and the integrated second test unit 510, and a monitoring result of the first monitoring unit 330 and the second monitoring unit 430.

[0110] Alternatively or additionally to the integrated first test unit 410 and the integrated second test unit 510, the mobile cable supply unit 1000 can, in the variant illustrated here, include a general test unit 1100. The general test unit 1100 is configured, analogous to the integrated first test unit 410 and the integrated second test unit 510, to check the application of the first connector 840, the second connector 841, the first connector housing 850 and the second connector housing 851, as well as the electrical conductivity of the connecting cable 800.

[0111] Fig. 2 schematically shows an exemplary connection diagram of two solar panels 600 with an inverter 700. The inverter 700 is further connected to a grid feed-in point 750.

[0112] The solar panels 600 each have a connection 610, the connection 610 being designed as a connection module to which all connection cables 800 required for the operation of the solar panels 600 are connected.

[0113] Similarly, the first terminal 710 of the inverter 700 provides all the necessary connections for connecting the solar panel 600 to the inverter 700. The second terminal 720 of the inverter 700 provides all the connections on the inverter 700 side for a connection to the grid connection point 750. Terminal 760 of the grid connection point 750 provides all the connections on the grid connection point 750 side for a connection to the inverter 700.

[0114] In the embodiment shown here, the two solar panels 600 are connected in series via a connecting cable 800 provided by the mobile cable supply unit 1000 and connected to the first connection 710 of the inverter 700.

[0115] The connecting cable 800 has a first connector housing 850 at its first end 821 and a second connector housing 851 at its second end 822. In the variant illustrated here, the inverter 700 is connected to the grid feed-in point 750 via two connecting cables 800 provided by the mobile cable supply unit 1000. For the sake of clarity, all connecting cables 800 are shown as identical in this example connection diagram.

[0116] 800 is shown. However, the connecting cables 800 may differ in their design depending on the connection, e.g. solar panel 600 to solar panel 600 or inverter 700 to grid feed-in point 750.

[0117] Depending on the application of the 600 solar panels, the 700 converter can function as either an inverter or a charge controller. The inverter converts the direct current (DC) generated by the 600 solar panels into alternating current (AC), while the solar charge controller regulates the DC current to a predetermined value.

[0118] Depending on the use of the solar panels 600, the grid feed-in point 750 can be, for example, an electricity meter, a connection to the public grid or an energy storage device, e.g. in the form of a battery.

[0119] The following section explains in detail the individual steps for establishing an electrical connection using a connecting cable 800 provided by the mobile cable supply unit 1000.

[0120] Fig. 3a shows a cable supply 100 designed as a cable drum of the mobile cable supply unit 1000 according to Fig. 1, on which a cable 810 of a first cable type is wound. In this step, the first end 821 is inserted into the combination of the cutting unit 200, the stripping unit 300 and the crimping unit 400, which is designed as a unit 200 / 300 / 400.

[0121] Fig. 3b shows the cable 810 inserted into the unit 200 / 300 / 400 after stripping the first end 821 by the first stripping length 830.

[0122] Fig. 3c shows the first end 821 of the cable 810 after it has been fitted with a first connector 840 and the first connector 840 has been crimped onto the first end 821 with the first crimp force. The first connector 840 is designed as a pin connector.

[0123] In the process step shown in Fig. 3d, the cable 810 is cut to the required length.

[0124] Cable 801 is inserted into unit 200 / 300 / 400 and then cut to the required length 801, resulting in a cable section 820 of the required length 801, as shown in Fig. 3e. After cutting, the first end 821 of cable 810 with the first connector 840 already attached forms the first end 821 of cable section 820. The uninsulated end of the cut cable section 820 forms the second end 822.

[0125] In the process step shown in Fig. 3f, the second end 822 is stripped by the second stripping length 831, so that subsequently, as shown in Fig. 3g, a second connector 841 is crimped onto the second end 822 with a second crimping force. The second connector 841 is designed as a socket connector.

[0126] In a final step, the connector assembly unit 500 (not explicitly shown here) applies a first connector housing 850 to the first connector 840 and a second connector housing 851 to the second connector 841 according to Fig. 1. The connector housings 850 / 851 are applied to the connectors 840 / 841 with a preset or automatically calculated initial application torque.

[0127] The cable section 820 with the attached connector housings 850 / 851 forms the now finished connecting cable 800 for making an electrical connection as shown, for example, in Fig. 2.

[0128] The previously described variants of the device, as well as their design and operational aspects, serve only to facilitate a better understanding of its structure, function, and properties; they do not limit the disclosure to these exemplary embodiments. The figures are partly schematic, with essential properties and effects sometimes significantly enlarged to illustrate the functions, operating principles, technical configurations, and features. Each function, principle, technical configuration, and feature disclosed in the figures or text can be freely and arbitrarily combined with all claims, features in the text and in the other figures, other functions, principles, technical configurations, and features contained in or arising from this disclosure, so that all conceivable combinations can be attributed to the described procedure.This includes combinations of all individual descriptions in the text, that is, in every section of the description, in the claims, and also combinations of different variants in the text, in the claims, and in the figures. The claims do not limit the disclosure and thus the possible combinations of all the features shown. All disclosed features are explicitly disclosed here, both individually and in combination with all other features.

Claims

Patent claims 1. A method for establishing an electrical connection between at least one solar panel (600) and an inverter (700) or another solar panel (600) or between an inverter (700) and a grid connection point (750) by means of a connecting cable (800) provided by a mobile cable supply unit (1000), wherein the mobile cable supply unit (1000) comprises a layable, rollable or mobile housing (1001) in which at least some of the following components are accessible from the outside and / or inside: - a cable supply (100) comprising at least one cable (810) of a first cable type; - an optional cutting unit (200); - one wire stripping unit (300); - a crimping unit (400) with a crimp supply (420) comprising at least a plurality of first connectors (840) and a plurality of second connectors (841); - a connector assembly unit (500) with a connector housing supply (520) comprising at least a plurality of first connector housings (850) and a plurality of second connector housings (851); and wherein the method comprises the following steps: i) specifying a required cable length (801) for the connecting cable (800); and / or ii) feeding the cable (810) from the cable supply (100) into the stripping unit (300); and / or iii) stripping a first end (821) of the cable (810) by a first stripping length (830) by the stripping unit (300); and / or iv) fitting the stripped first end (821) of the cable (810) with at least one first connector (840) from the crimp supply (420) by the crimping unit (400); and / or v) crimping the at least one first connector (840) onto the first end (821) of the cable (810) with an adjustable first crimp force by the crimping unit (400);and / or vi) drawing the cable (810) by the required cable length (801) into the cutting unit (200) and cutting the drawn-in cable (810) to create a cable section (820) of the required length (801), wherein the first end of the cable (810) forms the first end of the cable section (820); and / or vii) stripping a second end (822) of the cable section (820) by a second stripping length (831) by the stripping unit (300); and / or; viii) Inserting at least one second connector (841) from the crimp supply (420) into the stripped second end (822) of the cable piece (820) by the crimping unit (400); and / or ix) crimping the at least one second connector (841) onto the second end (822) of the cable piece (820) with an adjustable second crimping force by the crimping unit (400); and / or x) applying a first connector housing (850) from the connector housing supply (520) onto the at least one first connector (840) and / or applying a second connector housing (851) onto the at least one second connector (841) with an adjustable first application torque by the connector assembly unit (500); wherein the cable section (820) forms the connecting cable (800) after the first connector housing (850) and the second connector housing (851) have been applied;and / or xi) connecting the first end (821) of the connecting cable (800) to the associated terminal (610) on the solar panel (600) or the associated second terminal of the inverter (720); and / or xii) connecting the second end (822) of the connecting cable (800) to the associated first terminal (710) of the inverter (700) or the associated terminal (610) of the additional solar panel (600) or the associated terminal of the grid connection point (760).; 2. The method of claim 1, wherein the method comprises the following steps: - Automated transfer of the cable (810) after stripping the first end (821) of the cable (810) from the stripping unit (300) to the crimping unit (400); and / or - Automated transfer of the cable (810) after crimping the first connector (840) from the crimping unit (400) to the cutting unit (200); and / or - Automated transfer of the cable section (820) after cutting from the cutting unit (200) to the stripping unit (300); and / or - Automated transfer of the cable piece (820) after stripping the second end (822) of the cable piece (820) from the stripping unit (300) to the crimping unit (400).

3. The method according to any of the preceding claims, wherein - the first connector (840) is a pin connector or a socket connector; and / or - the second connector (841) is a pin connector or a socket connector.

4. The method according to any one of the preceding claims, wherein the cable supply unit (1000) comprises a test unit (1100) and / or the crimping unit (400) comprises an integrated first test unit (410) and / or the connector assembly unit (500) comprises an integrated second test unit (510); and wherein the method comprises the following steps: - Checking the application of the respective connectors (840 / 841) and connector housings (850 / 851) to the connecting cable (800) by the test unit (1100) or by the integrated first test unit (410) and the integrated second test unit (510); and / or - Checking the electrical conductivity of the connecting cable (800) by the test unit (1100) or by the integrated first test unit (410) and / or the integrated second test unit (510).

5. The method according to any of the preceding claims, wherein - the first crimping force and the second crimping force should be approximately 10 kN to approximately 20 kN; and / or - the initial application torque ranges from approximately 2 Nm to approximately 6 Nm.

6. The method according to claim 4 or 5, wherein the cable provisioning unit (1000) comprises a logging unit (900); and wherein the method comprises the following step: - Output of a protocol, wherein the protocol includes at least information about a number of connection cables provided (800) and / or the length (801) of each connection cable (800) and / or the first crimp force and / or the first application torque and / or the cable type used and / or the first and second connectors (840 / 841) and / or the first and second connector housings (850 / 851) and / or a test result of the test unit (1100) or the integrated first test unit (410) and / or the integrated second test unit (510), and / or a logging unit for printing the test result on the cable.

7. The method according to any of the preceding claims, wherein the stripping unit (300) comprises a first monitoring unit (330) and / or the crimping unit (400) comprises a second monitoring unit (430); and wherein the method comprises the following steps: - Monitoring of the first stripping length and / or the second stripping length during stripping by the first monitoring unit (330) and / or - Monitoring of the first crimp force and / or the second crimp force during crimping by the second monitoring unit (430).

8. A mobile cable provision unit (1000) designed and configured to perform the method according to claim 1, wherein the mobile Ka bei bereitstell lung sein heit (1000) comprises a relocatable, rollable or mobile housing (1001) in which at least some of the following components are accessible from the outside and / or inside: - a cable supply (100) comprising at least one cable (810) of a cable type; and / or - one cutting unit (200); and / or - one wire stripping unit (300); and / or - a crimping unit (400) with a crimp supply (420) comprising at least a plurality of first connectors (840) and a plurality of second connectors (841); and / or - a connector assembly unit (500) with a connector housing supply (520) comprising at least a plurality of first connector housings (850) and a plurality of second connector housings (851).

9. The mobile cable supply unit (1000) according to claim 7, wherein the cable supply (100), the cutting unit (200), the stripping unit (300) and the crimping unit (400) are designed as a single unit.

10. The mobile cable deployment unit (1000) according to any one of the preceding claims, wherein - the cable supply unit (1000) includes a test unit (1100) or the crimp unit (400) has an integrated first test unit (410) and / or the connector assembly unit (500) has an integrated second test unit (510); and / or wherein - the stripping unit (300) comprises a first monitoring unit (330) and / or the crimping unit (400) comprises a second monitoring unit (430); and / or wherein - the cable supply (100) comprises a cable drum on which at least one cable (810) of a cable type is wound; and / or wherein - the mobile cable deployment unit (1000) includes a logging unit (900).

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