CN109494542B - 用于将电的铝导线与铝管道连接的方法 - Google Patents
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- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 title claims abstract description 34
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- H—ELECTRICITY
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- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
- H01R43/048—Crimping apparatus or processes
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
- H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
- H01R4/183—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section
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- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
- H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
- H01R4/187—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping combined with soldering or welding
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- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/58—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation characterised by the form or material of the contacting members
- H01R4/62—Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors
- H01R4/625—Soldered or welded connections
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- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
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- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/28—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for wire processing before connecting to contact members, not provided for in groups H01R43/02 - H01R43/26
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Abstract
本发明涉及用于将电的铝导线与铝管道连接的方法，具体而言用于将具有至少一个由铝制成的线材的电导线(1)与由铝制成的、具有管道(4)的联接元件(7)连接的方法应如此改进，即使得尽可能电导线的所有的区域能够与联接元件焊接。对此建议以下步骤：将电导线的优选的剥皮的区域引入到管道中，在电导线的端部区域(8)所位于的区域中如此挤压管道，即使得所述至少一个线材如此保持在管道中，即阻止在管道和至少一个线材之间的相对运动，在剥皮的电导线的第二区域中挤压管道，该第二区域相比于第一挤压区域(9)相距电导线的端部更远，其中除了横截面变化之外还引起所述至少一个线材的伸长，且将管道与所述至少一个线材在第二挤压区域(10)中进行电阻焊接。
Description
技术领域
本发明涉及一种用于将具有至少一个由铝或铝合金制成的线材的电导线与由铝或相同的铝合金制成的、具有管道或者套管的联接元件连接的方法。
背景技术
对于电导线尤其在机动车中的应用而言已知，使用铜或者铜合金。但是铜或者铜合金具有高的重量。为了节省重量和由此燃油费用，例如由文件EP 2 362 491 B1已知，应用铝导线，该铝导线配备有由其它的材料制成的联接元件。
在机动车中已知这样的电联接，即对于所述电联接而言联接元件例如通过卷边(Crimpen)和/或钎焊(Löten)与导体(Leiter)连接。具有一定的电阻的这种连接对于许多应用而言基本上足够。但是如果如例如对于电动车而言例如在汽车的高压区域中应创造用于高的电流的电连接部或带有大的横截面的连接部(高的电流稳定地或在负载变化的情况下流动通过所述连接部)，之前提到的电阻已经导致在联接元件和导线之间的连接部的不允许的发热。
因此上文提到的文件EP 2 362 491 B1除了卷边步骤之外还建议了紧接着的焊接步骤。
但是在铝导体与由其它的材料制成的联接元件卷边的情形中产生带有材料的不同的热膨胀系数的问题，所述问题根据文件EP 2 362 491 B1应通过高耗费地将位于内部的凹入部引入到联接元件的卷边区段中来消除。
另外的问题在加工铝时产生，因为铝通常由氧化层包围。如果所述铝应被焊接，必须施加超过1500°C的温度，以为了熔化氧化层。但是因为铝本身已经在大约660°C时熔化，故而用于熔融氧化层的高的温度将导致，在熔化氧化层之后铝芯体将汽化，从而不产生可用的焊接连接。
出于该原因文件EP 2 362 491 B1首先建议卷边过程，在该卷边过程中通过挤压铝线材该铝线材的氧化层至少部分地破裂。
这种破碎在线材或者由所述线材组成的绞合线少的情形中可能还起作用，在汽车中对于电流供应必需的更粗的电导线的情形中氧化层的这种至少部分的破裂不再足以能够建立差不多可接受的焊接连接。
发明内容
因此本发明的任务在于，指明一种方法，借助于该方法尽可能电导线的所有的区域能够与联接元件焊接。
为了解决该任务建议，首先电导线的端部段被剥皮(abisolieren，有时称为去除绝缘皮)，电导线的剥皮的区域引入到联接元件的管道中，管道在这样的区域(即该区域位于导线的剥皮的顶部的区域中)中如此被挤压，即使得所述至少一个线材如此保持在管道中，即使得阻止在管道和所述至少一个线材之间的相对运动，紧接着管道在剥皮的电导线的第二区域中(该第二区域相比于第一挤压区域相距电导线的端部更远)第二次被挤压且紧接着在第二挤压区域中进行管道与所述至少一个线材的电阻焊接。
但是还存在这样的可能性，即应用绝缘的线材例如漆绝缘的线材，其中剥皮不是强制必需的，因为绝缘体在之后的焊接过程时汽化。
通过第一挤压过程实现了，具有任意的横截面的所述至少一个线材、但通常绞合线且那么绞合线的全部的线材如此固定，即相对运动既不在管道和单个的线材之间也不在单个的线材本身之间是可行的。因为绞合线在电导线的另一端部处还插在绝缘体中，故而此处也不能够期待线材彼此的相对运动。但是不言而喻还能够优选地同时执行两个挤压过程且第二挤压过程处于两个第一挤压位置之间。由此所述至少一个线材、通常绞合线的线材对于第二挤压过程从两侧如此固定，即使得线材的运动根本上不再相对彼此是可行的。
如果现在执行第二挤压过程，则具有任意的横截面的所述至少一个线材或者电导线的绞合线的单个线材除了本身被压挤之外仅还保留单个的线材中的每个的伸长。对于绞合线的所有线材实现了所述伸长。在此线材的氧化层裂开，从而绞合线的所有线材通过伸长还去除了氧化层。后面接着的焊接过程能够现在在对于铝而言常见的温度中进行。因为所有的铝线材和还有管道已去除了氧化层，故而引起非常良好的焊透(Durchschweißen)，可能的绝缘体在该温度时汽化。
尽管第二挤压过程例如能够由挤压工具执行且紧接着焊接电极才能够安置在第二挤压过程的部位处，但是已经证实为有利的是，第二挤压过程由至少两个焊接电极执行。由此能够成本适宜地节省用于第二挤压过程的压缩工具(Stauchwerkzeug)且压缩过程由焊接电极执行。
如果仅一个线材、例如电线圈的细的联接线材应与管道或者套管焊接，则当该线材的端部在第一挤压的区域中固定地保持时，在此最优的伸长和由此氧化层的最优的移除也是可行的。
有利的是，第二挤压过程和焊接同时进行时。当然在此有意义的是，焊接在第二挤压过程结束时才执行。
适宜地，由压缩工具促使第一挤压过程，其中压缩工具应构造为至少两件式的且该两件式的或更多件式的压缩工具在挤压过程之后完全地包围管道。
尽管不言而喻存在这样的可能性(即执行第一挤压过程，紧接着使电导线继续运动一段距离且然后实施第二挤压过程)，已证明合适的是，压缩工具在第二挤压过程期间保持闭合、即导线不运动，且在第二部位处被挤压，且在焊接过程结束之后才打开压缩工具。由此虽然在相应的压缩装置和焊接装置的情形中节省用于使电导体运动的装置。但是用于第二挤压工具的第二驱动器是必需的。但是当挤压工具在两个相邻布置的部位处布置在焊接机中时，两个挤压过程能够明显更快地相继实施。
已证明合适的是，给基本上在径向方向上起作用的第二挤压过程叠加在所述至少一个线材的轴向的方向上的、远离第一挤压区域的分量。
当这还仅涉及在轴向的方向上的非常小的运动时，得到所述至少一个线材的还更好的伸长，且由此得到氧化层的还更好的移除。
附图说明
根据图纸进一步解释本发明。其中：
图1显示了在挤压和焊接步骤之前的根据本发明的电导体以及相关联的联接元件，且
图2显示了在挤压和焊接步骤之后的根据本发明的电导体以及相关联的联接元件。
参考符号列表
1 电导线
2 铝绞合线
3 绝缘体
4 管道
5 敞开的第一端部
6 第二端部
7 联接元件
8 铝绞合线的端部
9 第一挤压区域
10 第二挤压区域
11 焊接熔核。
具体实施方式
图1显示了电导线1，该电导线具有铝绞合线2，该铝绞合线由绝缘体3包围。已表明了铝绞合线2的单个的线材。此外显示了管道4，电导线1的剥皮的端部的铝绞合线2推入到该管道的敞开的第一端部5中，且联接元件7模制在该管道的第二端部6处。
图2显示了在挤压和焊接过程之后的电导线1以及联接元件7。在铝绞合线2的端部8的区域中能够看出第一挤压区域9。在此铝绞合线2如此由管道4夹住，即铝绞合线2的单个的线材不再能够彼此相对运动。在朝向绝缘体3的方向上在第一挤压区域9旁边能够看出第二挤压区域10。在第二挤压区域10中通过挤压过程且通过铝绞合线2既不能够在挤压区域9的区域中也不能够在绝缘体3的区域中执行彼此的相对运动，铝绞合线2被拉伸和压挤。由此在铝绞合线2的几乎所有的线材上的氧化层破裂。通过挤压管道4，管道的位于内部的氧化层也破裂。
通过紧接着的焊接过程，铝绞合线2大面积地与管道4焊接，这可通过表明的焊接熔核(Schweißlinse)11看出。
Claims (9)
1.一种用于将具有至少一个由铝或铝合金制成的线材的电导线(1)与由铝或相同的铝合金制成的、具有管道(4)的联接元件(7)连接的方法，带有以下方法步骤：
a) 将所述电导线(1)的区域引入到所述管道(4)中，
b) 在第一挤压过程中，在所述电导线(1)的端部区域所位于的区域中如此挤压所述管道(4)，即使得所述至少一个线材如此保持在所述管道(4)中，即阻止在管道(4)和所述至少一个线材之间的相对运动，
c) 在第二挤压过程中，在所述电导线(1)的第二区域中挤压所述管道(4)，该第二区域相比于所述端部区域相距所述电导线的端部(8)更远，其中除了横截面变化之外还引起所述至少一个线材的伸长，且
d) 将所述管道(4)与所述至少一个线材在所述第二区域中进行电阻焊接。
2.根据权利要求1所述的方法，其特征在于，第二挤压过程由至少两个焊接电极执行。
3.根据权利要求1或2所述的方法，其特征在于，第二挤压过程和焊接同时进行。
4.根据权利要求1或2所述的方法，其特征在于，焊接在所述第二挤压过程结束时才进行。
5.根据权利要求1或2所述的方法，其特征在于，第一挤压过程由压缩工具引起。
6.根据权利要求5所述的方法，其特征在于，至少两件式的所述压缩工具包围被挤压的所述管道(4)。
7.根据权利要求5所述的方法，其特征在于，所述压缩工具在第二挤压过程期间保持闭合且在结束焊接过程之后才打开。
8.根据权利要求7所述的方法，其特征在于，给在径向的方向上起作用的所述第二挤压过程叠加在所述至少一个线材的轴向的方向上的、远离所述端部区域的分量。
9.根据权利要求1所述的方法，其特征在于，所述电导线(1)的引入到所述管道(4)中的区域被剥皮。
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DE102017215970.7A DE102017215970B3 (de) | 2017-09-11 | 2017-09-11 | Verfahren zum Verbinden einer elektrischen Aluminiumleitung mit einem Aluminiumrohr |
| DE102017215970.7 | 2017-09-11 |
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| Publication Number | Publication Date |
|---|---|
| CN109494542A CN109494542A (zh) | 2019-03-19 |
| CN109494542B true CN109494542B (zh) | 2020-10-23 |
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| CN201811056020.5A Active CN109494542B (zh) | 2017-09-11 | 2018-09-11 | 用于将电的铝导线与铝管道连接的方法 |
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| Country | Link |
|---|---|
| US (1) | US11038312B2 (zh) |
| EP (1) | EP3454420B1 (zh) |
| JP (1) | JP6720258B2 (zh) |
| CN (1) | CN109494542B (zh) |
| DE (1) | DE102017215970B3 (zh) |
| MX (1) | MX2018010945A (zh) |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE102017215970B3 (de) * | 2017-09-11 | 2018-07-26 | Strunk Connect automated solutions GmbH & Co. KG | Verfahren zum Verbinden einer elektrischen Aluminiumleitung mit einem Aluminiumrohr |
| CN114220311B (zh) * | 2022-01-11 | 2024-01-26 | 重庆煌能科技有限公司 | 一种用于特种作业低压电工安全技术实操考核平台 |
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| US3842487A (en) * | 1971-10-18 | 1974-10-22 | Essex International Inc | Terminating of electrical conductors |
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| FR2501923A1 (fr) * | 1981-03-13 | 1982-09-17 | Pechiney Aluminium | Procede de raccordement d'un cable electrique sous une cosse ou analogue par sertissage mecanique assiste par des vibrations ultrasonores |
| GB8319264D0 (en) * | 1983-07-15 | 1983-08-17 | Omniglass Ltd | Corner for spacer strip of sealed window units |
| GB9002629D0 (en) * | 1990-02-06 | 1990-04-04 | Raychem Pontoise Sa | Electrical connection |
| DE19908031B4 (de) * | 1999-02-24 | 2009-08-13 | Auto-Kabel Management Gmbh | Verbindung eines elektrischen Aluminiumkabels mit einem aus Kupfer oder dergleichen Metall bestehenden Anschlußteil |
| JP2001357903A (ja) * | 2000-06-13 | 2001-12-26 | Sumitomo Wiring Syst Ltd | 電線間接続用の圧着端子 |
| JP2003338330A (ja) * | 2002-05-20 | 2003-11-28 | Mitsubishi Cable Ind Ltd | 端子接続方法及び端子接続構造 |
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| JP2006190662A (ja) * | 2004-12-10 | 2006-07-20 | Hitachi Cable Ltd | 配線材およびその製造方法、並びにその製造に用いる抵抗溶接機 |
| DE102004063056A1 (de) * | 2004-12-22 | 2006-07-13 | Fröhlich, Bernhard | Vorrichtung und Verfahren zur Verbindung einer Anschlusshülse mit einem Kabel |
| DE102007020210A1 (de) * | 2006-06-03 | 2007-12-06 | Hirschmann Automotive Gmbh | Schweißen einer Umformverbindung |
| JP2010146739A (ja) * | 2008-12-16 | 2010-07-01 | Sumitomo Wiring Syst Ltd | 電線接続スリーブ、電線接続スリーブの製造方法、電線接続スリーブが予め圧着されたリペア電線、および電線の接続方法 |
| EP2362491B1 (de) | 2010-02-26 | 2017-10-04 | Delphi Technologies, Inc. | Verfahren zum Verbinden einer elektrischen Leitung mit einem elektrischen Anschlusselement |
| DE102010038465A1 (de) * | 2010-07-27 | 2012-02-02 | Robert Bosch Gmbh | Elektrische Verbindung |
| US8826533B2 (en) | 2011-06-24 | 2014-09-09 | Delphi Technologies, Inc. | Crimp connection to aluminum cable |
| JP2013020761A (ja) * | 2011-07-08 | 2013-01-31 | Swcc Showa Cable Systems Co Ltd | アルミリッツ線の端子接続方法及び端子接続部 |
| JP5884986B2 (ja) | 2012-07-31 | 2016-03-15 | 矢崎総業株式会社 | 圧着端子付きアルミ電線 |
| FR2995459B1 (fr) * | 2012-09-07 | 2014-10-10 | Mecatraction | Procede d'assemblage d'un dispositif de connexion sur un troncon terminal denude d'un cable electrique et ensemble comportant un tel dispositif assemble solidairement sur un tel troncon de cable |
| KR101505793B1 (ko) | 2013-02-24 | 2015-03-24 | 후루카와 덴키 고교 가부시키가이샤 | 전선 접속 구조체의 제조방법 및 전선 접속 구조체 |
| DE102015012906A1 (de) * | 2015-02-27 | 2016-09-01 | Gentherm Gmbh | Hülse, Kontaktier-Einrichtung und Verfahren zum Schweißen von dünnen strangförmigen Leitern mittels Ultraschall |
| CN106207499A (zh) | 2016-07-05 | 2016-12-07 | 昆山徳可汽车配件有限公司 | 一种汽车连接线及其摩擦焊接工艺 |
| CN206353610U (zh) | 2016-08-22 | 2017-07-25 | 长春一汽富晟李尔汽车电器电子有限公司 | 压接铝电线的端子 |
| DE102017215970B3 (de) * | 2017-09-11 | 2018-07-26 | Strunk Connect automated solutions GmbH & Co. KG | Verfahren zum Verbinden einer elektrischen Aluminiumleitung mit einem Aluminiumrohr |
-
2017
- 2017-09-11 DE DE102017215970.7A patent/DE102017215970B3/de active Active
-
2018
- 2018-09-06 EP EP18192956.3A patent/EP3454420B1/de active Active
- 2018-09-10 MX MX2018010945A patent/MX2018010945A/es unknown
- 2018-09-10 JP JP2018168515A patent/JP6720258B2/ja active Active
- 2018-09-10 US US16/125,836 patent/US11038312B2/en active Active
- 2018-09-11 CN CN201811056020.5A patent/CN109494542B/zh active Active
Also Published As
| Publication number | Publication date |
|---|---|
| EP3454420A1 (de) | 2019-03-13 |
| DE102017215970B3 (de) | 2018-07-26 |
| MX2018010945A (es) | 2019-03-12 |
| JP2019050202A (ja) | 2019-03-28 |
| JP6720258B2 (ja) | 2020-07-08 |
| US11038312B2 (en) | 2021-06-15 |
| CN109494542A (zh) | 2019-03-19 |
| US20190081446A1 (en) | 2019-03-14 |
| EP3454420B1 (de) | 2023-11-01 |
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