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EP2219269A2 - Device and method for connecting at least two electrical connections - Google Patents

Device and method for connecting at least two electrical connections Download PDF

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Publication number
EP2219269A2
EP2219269A2 EP09179728A EP09179728A EP2219269A2 EP 2219269 A2 EP2219269 A2 EP 2219269A2 EP 09179728 A EP09179728 A EP 09179728A EP 09179728 A EP09179728 A EP 09179728A EP 2219269 A2 EP2219269 A2 EP 2219269A2
Authority
EP
European Patent Office
Prior art keywords
terminal
clinching
connection
measuring element
connections
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP09179728A
Other languages
German (de)
French (fr)
Other versions
EP2219269A3 (en
EP2219269B1 (en
Inventor
Stephan Mazingue-Desailly
Roland Hellwig
Michael Mueller
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Robert Bosch GmbH
Original Assignee
Robert Bosch GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Robert Bosch GmbH filed Critical Robert Bosch GmbH
Publication of EP2219269A2 publication Critical patent/EP2219269A2/en
Publication of EP2219269A3 publication Critical patent/EP2219269A3/en
Application granted granted Critical
Publication of EP2219269B1 publication Critical patent/EP2219269B1/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • 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
    • H01R4/06—Riveted connections
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K25/00—Uniting components to form integral members, e.g. turbine wheels and shafts, caulks with inserts, with or without shaping of the components
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R11/00—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
    • H01R11/11—End pieces or tapping pieces for wires, supported by the wire and for facilitating electrical connection to some other wire, terminal or conductive member
    • H01R11/28—End pieces consisting of a ferrule or sleeve
    • H01R11/281—End pieces consisting of a ferrule or sleeve for connections to batteries
    • H01R11/287—Intermediate parts between battery post and cable end piece
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02—Contact members
    • H01R13/03—Contact members characterised by the material, e.g. plating, or coating materials
    • 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
    • H01R4/58—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
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49117—Conductor or circuit manufacturing

Definitions

  • the invention relates to a device and a method for connecting two electrical connections according to the preamble of the independent claims.
  • a battery pole terminal arrangement is already known.
  • a fastening element is provided, wherein the fastening element includes a passing through the mounting portion of the battery sensor bolt with a comprehensive insulating this.
  • the fastening element includes a passing through the mounting portion of the battery sensor bolt with a comprehensive insulating this.
  • the inventive device and method for connecting two electrical connections have the advantage that an electrical and mechanical connection without the use of a Einpressbolzens can be produced.
  • an electrical measuring element without additional parts to be electrically conductively attached to a pole terminal.
  • the clinching is particularly well suited for this.
  • the recess is a hole which is slightly countersunk or chamfered on the back side. This makes it possible that when pressed the connection in this recess, the material thus pressed also forms an undercut, so that a rivet head is formed. This has a particularly positive effect on the mechanical and electrical properties of the compound.
  • the materials used for the connections on the one hand a cutting alloy CuZn39Pb2 and for shunt termination SE-Cu58 used.
  • the softer material SE-Cu58 for shunt termination is inserted in the direction of the hard material CuZn39Pb2 for the pole terminal.
  • the pole clamp is a forged part which, after the forming, which leads to the solidification of the material while at the same time reducing the elongation at break, could be subjected to a heat treatment to improve the processability.
  • Crack-free compounds could preferably be produced with the following material combinations: CuZn37 with SE-Cu58, CuZn37 with SE-Cu58 at different thicknesses.
  • a connection between the materials CuZn39Pb2 and SE-Cu58 could be safely produced with a back-countersunk hole in the material CuZn39Pb2.
  • one electrical connection is a pole terminal, and the other electrical connection is a measuring resistor.
  • the pole terminal is preferably designed so that it can be arranged on a battery terminal of a vehicle battery in order to close by means of measuring resistor and integrated electronics to certain battery state variables such as state of charge or state of aging of the battery.
  • the battery terminal is made of the material CuZn39Pb2, the connection element of the resistor made of SE-Cu58.
  • the clinching is suitable with arranged in the terminal post recess.
  • a bus bar 44 which is connected by a connection 42 to a ground cable 40.
  • the ground cable 40 is provided for this purpose with a connection 41.
  • connection 42 On the left side, different variants of the connection 42 are shown, with which bus bar 44 (as a possible example for a connection) and terminal 41 according to FIG. 1 can be connected. All the connections 42 have in common that they are made by means of clinching.
  • Terminal 41 has an opening 30 with a chamfer 32 at the bottom.
  • the terminal 41 is arranged on an anvil 20.
  • Above the terminal 41 is the busbar 44.
  • Above the opening 30 concentrically an embossing die 10 is arranged, which is guided movably in relation to a hold-down 12. Initially, the die 10 is still above the bus bar 44.
  • the die 10 is moved down and displaces the material of the connection 41 located at this point into the opening 30.
  • the embossing stamp 10 moves into its end position. The displaced by the die 10 material of the terminal 41 completely fills the opening 30 including chamfer 32, so that an undercut 34 is formed, although the chamfer 32 is completely provided with the material of the terminal 41.
  • a pole terminal 50 is shown, which can be connected to a battery post, not shown, of a battery, for example a motor vehicle battery.
  • the assembly further includes a measuring element 52.
  • the measuring element 52 is connected on one side by a compression 42 by means of clinching directly to the pole terminal 50.
  • the pole terminal 50 has an opening 30 with chamfer 32 on the back. In this opening 30, the terminal, the bus bar 44 and the measuring element 52 was pressed by means of clinching so that an undercut 34 of the terminal 41 is formed in the chamfer 32. From the FIGS.
  • the pole terminal 50 has a further recess 70, which serves to fasten a bolt 54.
  • This bolt 54 is designed, for example, cylindrical and protrudes perpendicular to the planar plane of the measuring element 52 upwards.
  • a sleeve 56 is arranged radially surrounding the bolt. This is made of an electrically non-conductive material for the isolation of the second connection point of the measuring element 52 of the pole terminal 50. This ensures that the battery current between pins 54 for connecting the ground cable 40 and the terminal, connected to the battery, actually via the measuring element 52nd flows and not shorted.
  • a corresponding further recess 72 of the measuring element 52 is matched to the outer diameter of the bolt 54.
  • the measuring element 52 is partly on a radially enlarging collar 68 on the bolt 54, partially on the top of the sleeve 56.
  • the upwardly projecting side of the bolt 54 may be provided with a thread, not shown, to fasten a cable lug of a cable, preferably the ground cable 40, by means of screw connection.
  • the measuring element 52 is only laterally surrounded by a housing 64 in the region of the bolt 54, while the surface of the measuring element 52 is exposed. Since the measuring element 52 is connected at this point only via the sleeve 56 with the pole terminal 50, no electrical contact takes place at this point.
  • the measuring element 52 is guided in the direction of the housing 64 in its interior.
  • the actual measuring element such as a resistor made of a certain material such as manganin.
  • electronics is arranged, which detects the voltage drop across the measuring resistor and evaluates in a further signal processing.
  • further data such as battery voltage, temperature or similar battery state variables such as the state of charge (SOC) or state of health (SOH) of the battery can be determined.
  • SOC state of charge
  • SOH state of health
  • This data can be transmitted via a data line, not shown, which is connected via the plug 66 to other control devices such as a power management control unit.
  • the measuring element 52 is led out of the housing 64 on the side facing away from the bolt 54 side. There is also the electrical contact by means of the compound obtained by clinching 42, as already described.
  • the electrical contacting between the measuring element 52 and the pole terminal 50 takes place only on the side facing away from the bolt 54-based on the actual measuring resistor.
  • the measuring resistor which is passed from the battery pole via the pole terminal 50 via the connection 42 to the left connection point of the measuring element 52, via the measuring resistor inside the housing 64, is led to the bolt 54, to which the ground cable 40 is then connected.
  • connection 42 is formed by clinching.
  • This is understood to mean a method for joining metal sheets without using a filler material.
  • the joining is achieved here by forming at least one material.
  • terminal 41 and bus bar 44 as an example of another terminal, as shown on the left, have undergone plastic deformation after clinching, so that a mechanically strong and also electrically conductive connection 42 is produced.
  • busbar 44 and 41 are deformed. However, this is not mandatory. It is also sufficient deformation of only one sheet, either the busbar 44 or the terminal 41, from.
  • the terminal 41 corresponds to the pole terminal 50, the bus bar 44 to the connection of the measuring element 52.
  • the pole terminal 50 is preferably a forging, which leads to the deformation, which leads to the solidification of the material while reducing the elongation at break. To improve the processability, the materials to be deformed could be subjected to a heat treatment. It is particularly suitable for this purpose a Zerspan alloy, particularly preferably CuZn39Pb2.
  • the connection of the measuring element 52 consists of SE-Cu58. Through the clinching a mechanical and electrical connection between the measuring element 52 and pole terminal 50 is achieved.
  • the measuring element 52 which consists of a softer material than the pole terminal 50, is pressed into the opening 30.
  • the clinching is completed when the displaced material of the measuring element 52 also enters the chamfer 32 of the opening 30, so that an undercut 34 is formed.
  • the diameter of the opening 30 is preferably in the range of about 5 mm or larger (for example, 6.4 mm or larger (such as 7.4 mm if there is enough space).)
  • the pole terminal 50 is made of CuZn39Pb2 with a back side Countersunk opening 30.
  • the ductile copper (SE-Cu58) is so through the chamfered hole 30 pulled that the undercut 34 is formed and forms a rivet head.
  • dies 10 and anvil 20 are to be adapted.
  • the clinching for creating the connection 42 is particularly suitable for contacting terminal 41 and bus bar 44 (as an example of another connection) of a control unit 46. However, due to the material selection made, clinching is particularly preferred for establishing the connection 42 between terminal 50 and measuring element 52.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Connection Of Batteries Or Terminals (AREA)
  • Details Of Connecting Devices For Male And Female Coupling (AREA)

Abstract

The device is provided with two electrical connections which are connected together by clinching. The connections are made of materials of different rigidity. One of the connections has an opening, in which the other connection is deformed by clinching, where the opening is provided with a chamfer. One of the connections is made of a chipping alloy and the other connection is made of a ductile material, particularly copper. One of the connections is made of an alloy containing copper, zinc and lead (CuZn39Pb2) and the other connection is made of pure copper (SE-Cu58). An independent claim is also included for a method for connecting two electrical connections, particularly a pole terminal and a measuring element.

Description

Die Erfindung geht aus von einer Vorrichtung und einem Verfahren zur Verbindung zwei elektrischer Anschlüsse nach der Gattung der unabhängigen Ansprüche. Aus der DE 10 2004 046 855 B3 ist bereits eine Batteriepolklemmenanordnung bekannt. Zur Befestigung eines Messwiderstands an einer Polklemme ist ein Befestigungselement vorgesehen, wobei das Befestigungselement einen durch den Befestigungsbereich des Batteriesensors passierenden Bolzen mit einer diesen umfassenden Isolierhülse enthält. Zum Aufbau einer Verbindung sind somit mindestens drei Teile erforderlich.The invention relates to a device and a method for connecting two electrical connections according to the preamble of the independent claims. From the DE 10 2004 046 855 B3 a battery pole terminal arrangement is already known. For fixing a measuring resistor to a pole terminal, a fastening element is provided, wherein the fastening element includes a passing through the mounting portion of the battery sensor bolt with a comprehensive insulating this. To build a connection thus at least three parts are required.

Davon ausgehend ist es Aufgabe der Erfindung, trotz Verringerung der Teilezahl des Verbindungsaufbaus eine hohe Festigkeit zu erreichen. Diese Aufgabe wird gelöst durch die Merkmale der unabhängigen Ansprüche.On this basis, it is an object of the invention to achieve a high strength despite reducing the number of parts of the connection structure. This object is solved by the features of the independent claims.

Vorteile der ErfindungAdvantages of the invention

Die erfindungsgemäße Vorrichtung und Verfahren zur Verbindung zweier elektrischer Anschlüsse haben demgegenüber den Vorteil, dass eine elektrische und auch mechanische Verbindung ohne Verwendung eines Einpressbolzens hergestellt werden kann. Somit ist es möglich, bei der Anwendung bei einer Polklemme ein elektrisches Messelement ohne zusätzliche Teile stromleitend an einer Polklemme zu befestigen. Das Durchsetzfügen eignet sich hierfür besonders gut.The inventive device and method for connecting two electrical connections have the advantage that an electrical and mechanical connection without the use of a Einpressbolzens can be produced. Thus, it is possible, when used in a pole terminal, an electrical measuring element without additional parts to be electrically conductively attached to a pole terminal. The clinching is particularly well suited for this.

In einer zweckmäßigen Weiterbildung ist vorgesehen, dass zum Durchsetzfügen in einem der elektrischen Anschlüsse zumindest eine Ausnehmung vorgesehen ist, in der der zweite Anschluss zumindest teilweise verpresst angeordnet ist. Vorzugsweise handelt es sich bei der Ausnehmung um ein Loch, welches rückseitig etwas angesenkt bzw. angefast ist. Dadurch wird es möglich, dass bei einem Verpressen des Anschlusses in diese Ausnehmung das so verpresste Material auch einen Hinterschnitt bildet, so dass ein Nietkopf entsteht. Dies wirkt sich insbesondere positiv auf die mechanischen und elektrischen Eigenschaften der Verbindung aus.In an expedient refinement, provision is made for at least one recess to be provided for insertion in one of the electrical connections is, in which the second connection is arranged at least partially compressed. Preferably, the recess is a hole which is slightly countersunk or chamfered on the back side. This makes it possible that when pressed the connection in this recess, the material thus pressed also forms an undercut, so that a rivet head is formed. This has a particularly positive effect on the mechanical and electrical properties of the compound.

In einer zweckmäßigen Weiterbildung sind als Werkstoffe für die Anschlüsse einerseits eine Zerspanungslegierung CuZn39Pb2 sowie für die Shuntterminierung SE-Cu58 verwendet. Das weichere Material SE-Cu58 für die Shuntterminierung wird in Richtung des harten Materials CuZn39Pb2 für die Polklemme durchsetzgefügt. Die Polklemme ist hierbei ein Schmiedeteil, das nach der Umformung, die zur Verfestigung des Materials bei gleichzeitiger Herabsetzung der Bruchdehnung führt, zur Verbesserung der Verarbeitbarkeit einer Wärmebehandlung unterzogen werden könnte. Bevorzugt ließen sich rissfreie Verbindungen herstellen mit folgenden Werkstoffkombinationen: CuZn37 mit SE-Cu58, CuZn37 mit SE-Cu58 bei unterschiedlichen Dicken. Eine Verbindung zwischen den Materialen CuZn39Pb2 und SE-Cu58 konnte sicher hergestellt werden bei einem rückseitig angesenkten Loch in dem Material CuZn39Pb2.In an expedient development, the materials used for the connections on the one hand a cutting alloy CuZn39Pb2 and for shunt termination SE-Cu58 used. The softer material SE-Cu58 for shunt termination is inserted in the direction of the hard material CuZn39Pb2 for the pole terminal. In this case, the pole clamp is a forged part which, after the forming, which leads to the solidification of the material while at the same time reducing the elongation at break, could be subjected to a heat treatment to improve the processability. Crack-free compounds could preferably be produced with the following material combinations: CuZn37 with SE-Cu58, CuZn37 with SE-Cu58 at different thicknesses. A connection between the materials CuZn39Pb2 and SE-Cu58 could be safely produced with a back-countersunk hole in the material CuZn39Pb2.

In einer zweckmäßigen Weiterbildung handelt es sich bei dem einen elektrischen Anschluss um eine Polklemme, bei dem anderen elektrischen Anschluss um einen Messwiderstand. Die Polklemme ist bevorzugt so ausgebildet, dass sie an einem Batteriepol einer Fahrzeugbatterie angeordnet werden kann, um mittels Messwiderstand und integrierter Elektronik auf bestimmte Batteriezustandsgrößen wie Ladezustand oder Alterungszustand der Batterie zu schließen. Die Batterieklemme ist hierbei aus dem Material CuZn39Pb2, das Anschlusselement des Widerstands aus SE-Cu58 aufgebaut. Für diese Kombination eignet sich insbesondere das Durchsetzfügen mit in der Polklemme angeordneter Ausnehmung.In an expedient development, one electrical connection is a pole terminal, and the other electrical connection is a measuring resistor. The pole terminal is preferably designed so that it can be arranged on a battery terminal of a vehicle battery in order to close by means of measuring resistor and integrated electronics to certain battery state variables such as state of charge or state of aging of the battery. The battery terminal is made of the material CuZn39Pb2, the connection element of the resistor made of SE-Cu58. For this combination, in particular, the clinching is suitable with arranged in the terminal post recess.

Weitere zweckmäßige Weiterbildungen ergeben sich aus weiteren abhängigen Ansprüchen und aus der Beschreibung.Further expedient developments emerge from further dependent claims and from the description.

Ausführungsbeispielembodiment

Mehrere Ausführungsbeispiele sind in der Zeichnung dargestellt und werden nachfolgend näher beschrieben.Several embodiments are shown in the drawing and will be described in more detail below.

Es zeigen:

  • die Figur 1 den prinzipiellen Aufbau zur Verbindung eines Steuergeräts mit einem Kabel mittels Durchsetzfügens,
  • die Figur 2 unterschiedliche Arten des Durchsetzfügens,
  • die Figur 3 Schnittansichten dreier Fertigungsschritte,
  • Figur 4 eine perspektivische Ansicht einer Polklemme mit elektrischem Messelement sowie
  • die Figur 5 die Anordnung gemäß Figur 4, teilweise geschnitten dargestellt.
Show it:
  • the FIG. 1 the basic structure for connecting a control unit with a cable by means of clinching,
  • the FIG. 2 different types of clinching,
  • the FIG. 3 Sectional views of three production steps,
  • FIG. 4 a perspective view of a pole terminal with electrical measuring element as well
  • the FIG. 5 the arrangement according to FIG. 4 , partially cut.

Gemäß dem Ausführungsbeispiel nach Figur 1 ragt aus einem Steuergerät 46 eine Stromschiene 44, welche durch eine Verbindung 42 mit einem Massekabel 40 verbunden ist. Das Massekabel 40 ist hierzu mit einem Anschluss 41 versehen.According to the embodiment according to FIG. 1 protrudes from a control unit 46, a bus bar 44 which is connected by a connection 42 to a ground cable 40. The ground cable 40 is provided for this purpose with a connection 41.

In Figur 2 sind auf der linken Seite unterschiedliche Varianten der Verbindung 42 gezeigt, mit denen Stromschiene 44 (als mögliches Beispiel für einen Anschluss) und Anschluss 41 nach Figur 1 verbunden werden können. All den Verbindungen 42 ist gemein, dass sie mittels Durchsetzfügens hergestellt sind.In FIG. 2 On the left side, different variants of the connection 42 are shown, with which bus bar 44 (as a possible example for a connection) and terminal 41 according to FIG FIG. 1 can be connected. All the connections 42 have in common that they are made by means of clinching.

In Figur 3 ist exemplarisch eine mögliche Art der Herstellung der Verbindung 42 gezeigt. Anschluss 41 weist eine Öffnung 30 mit einer unterseitigen Anfasung 32 auf. Der Anschluss 41 ist auf einem Amboss 20 angeordnet. Oberhalb des Anschlusses 41 befindet sich die Stromschiene 44. Oberhalb der Öffnung 30 ist konzentrisch ein Prägestempel 10 angeordnet, der gegenüber einem Niederhalter 12 beweglich geführt ist. Anfangs befindet sich der Prägestempel 10 noch oberhalb der Stromschiene 44. Im nachfolgenden Schritt, dargestellt in der zweiten Abbildung nach Figur 3, wird der Prägestempel 10 nach unten bewegt und verdrängt das an dieser Stelle befindliche Material des Anschlusses 41 in die Öffnung 30. In der dritten Darstellung fährt der Prägestempel 10 in seine Endstellung. Das vom Prägestempel 10 verdrängte Material des Anschlusses 41 füllt komplett die Öffnung 30 inklusive Anfasung 32, sodass sich ein Hinterschnitt 34 ausbildet, wenn auch die Anfasung 32 komplett mit dem Material des Anschlusses 41 versehen ist.In FIG. 3 By way of example, one possible way of producing the compound 42 is shown. Terminal 41 has an opening 30 with a chamfer 32 at the bottom. The terminal 41 is arranged on an anvil 20. Above the terminal 41 is the busbar 44. Above the opening 30 concentrically an embossing die 10 is arranged, which is guided movably in relation to a hold-down 12. Initially, the die 10 is still above the bus bar 44. In the subsequent step, shown in the second figure after FIG. 3 , the die 10 is moved down and displaces the material of the connection 41 located at this point into the opening 30. In the third illustration, the embossing stamp 10 moves into its end position. The displaced by the die 10 material of the terminal 41 completely fills the opening 30 including chamfer 32, so that an undercut 34 is formed, although the chamfer 32 is completely provided with the material of the terminal 41.

Im Ausführungsbeispiel gemäß Figur 4 ist eine Polklemme 50 gezeigt, die mit einem nicht dargestellten Batteriepol einer Batterie, beispielsweise einer Kraftfahrzeugbatterie, verbunden werden kann. Dazu können die nicht näher bezeichneten Schenkel der Polklemme so aufeinander zubewegt werden, dass sie den Batteriepol klemmend umschließen. Die Anordnung enthält ferner ein Messelement 52. Das Messelement 52 ist auf der einen Seite durch eine Verpressung 42 mittels Durchsetzfügens unmittelbar mit der Polklemme 50 verbunden. In Übereinstimmung mit der Herstellung gemäß Figur 3 weist die Polklemme 50 eine Öffnung 30 mit rückseitiger Anfasung 32 auf. In diese Öffnung 30 wurde der Anschluss, die Stromschiene 44 bzw. das Messelement 52 mittels Durchsetzfügens so verpresst, dass sich im Bereich der Anfasung 32 ein Hinterschnitt 34 des Anschlusses 41 ausbildet. Aus den Figuren 4 und 5 sind noch die Ausnehmungen 62 des Anschlusses 44 bzw. des Messelements 52 ersichtlich, die der Prägestempel 10 aufgrund der plastischen Verformung des Anschlusses 44 bzw. des Messelements 52 ausgebildet hat. Neben der mechanischen Kontaktierung zwischen Polklemme 50 und Messelement 52 wird auf diese Weise auch eine sichere elektrische Kontaktierung erreicht, um den Batteriestrom über das Messelement 52 zu führen und zu erfassen.In the embodiment according to FIG. 4 a pole terminal 50 is shown, which can be connected to a battery post, not shown, of a battery, for example a motor vehicle battery. For this purpose, the unspecified legs of the pole terminal can be moved towards each other so that they enclose the battery terminal by clamping. The assembly further includes a measuring element 52. The measuring element 52 is connected on one side by a compression 42 by means of clinching directly to the pole terminal 50. In accordance with the preparation according to FIG. 3 the pole terminal 50 has an opening 30 with chamfer 32 on the back. In this opening 30, the terminal, the bus bar 44 and the measuring element 52 was pressed by means of clinching so that an undercut 34 of the terminal 41 is formed in the chamfer 32. From the FIGS. 4 and 5 are still the recesses 62 of the terminal 44 and the measuring element 52 can be seen, which has formed the die 10 due to the plastic deformation of the terminal 44 and the measuring element 52. In addition to the mechanical contact between the pole terminal 50 and measuring element 52, a secure electrical contact is achieved in this way to guide the battery current through the measuring element 52 and detect.

Die Polklemme 50 weist eine weitere Ausnehmung 70 auf, die der Befestigung eines Bolzens 54 dient. Dieser Bolzen 54 ist beispielsweise zylinderförmig ausgeführt und ragt senkrecht zur planaren Ebene des Messelements 52 nach oben. Zwischen Bolzen 54 und Polklemme 50 ist radial den Bolzen umgebend eine Hülse 56 angeordnet. Diese besteht aus einem elektrisch nicht leitenden Material zur Isolation des zweiten Anschlusspunkts des Messelements 52 von der Polklemme 50. Dadurch wird sichergestellt, dass der Batteriestrom zwischen Bolzen 54 zum Anschluss des Massekabels 40 und der Klemme, mit dem Batteriepol verbunden, tatsächlich über das Messelement 52 fließt und nicht kurzgeschlossen wird. Eine entsprechende weitere Aussparung 72 des Messelements 52 ist auf den Außendurchmesser des Bolzens 54 abgestimmt. Das Messelement 52 liegt teilweise auf einem sich radial vergrößernden Kragen 68 auf dem Bolzen 54, teilweise auch auf der Oberseite der Hülse 56 auf. Die nach oben ragende Seite des Bolzens 54 kann mit einem nicht dargestellten Gewinde versehen sein, um einen Kabelschuh eines Kabels, vorzugsweise das Massekabel 40, mittels Schraubverbindung zu befestigen. Das Messelement 52 wird im Bereich des Bolzens 54 lediglich seitlich von einem Gehäuse 64 umgeben, während die Oberfläche des Messelements 52 freiliegend ist. Da das Messelement 52 an dieser Stelle lediglich über die Hülse 56 mit der Polklemme 50 verbunden ist, erfolgt kein elektrischer Kontakt an dieser Stelle. Das Messelement 52 wird in Richtung des Gehäuses 64 in dessen Inneres geführt. Dort befindet sich das eigentliche Messelement, beispielsweise ein Widerstand aus einem bestimmten Material wie beispielsweise Manganin. Innerhalb des Gehäuses 64 ist auch eine nicht dargestellte Elektronik angeordnet, die den Spannungsabfall am Messwiderstand erfasst und in einer weiteren Signalverarbeitung auswertet. Weiterhin können anhand weiterer Daten wie beispielsweise Batteriespannung, Temperatur oder ähnliches Batteriezustandsgrößen wie der Ladezustand (SOC) oder State of Health (SOH) der Batterie ermittelt werden. Diese Daten können über eine nicht dargestellte Datenleitung, die über den Stecker 66 angeschlossen wird, an weitere Steuergeräte wie beispielsweise ein Energiemanagement-Steuergerät weitergegeben werden. Das Messelement 52 wird an der von dem Bolzen 54 abgewandten Seite aus dem Gehäuse 64 herausgeführt. Dort erfolgt auch die elektrische Kontaktierung mittels der durch Durchsetzfügen erhaltenen Verbindung 42, wie bereits beschrieben. Wesentlich ist, dass jedoch die elektrische Kontaktierung zwischen Messelement 52 und Polklemme 50 erst - bezogen auf den eigentlichen Messwiderstand - auf der von dem Bolzen 54 abgewandten Seite erfolgt. Dann wird nämlich der vom Batteriepol über die Polklemme 50 über die Verbindung 42 zum linken Anschlusspunkt des Messelements 52, über den im Inneren des Gehäuses 64 liegenden Messwiderstand hin zum Bolzen 54 geführt, an den dann das Massekabel 40 anzuschließen ist.The pole terminal 50 has a further recess 70, which serves to fasten a bolt 54. This bolt 54 is designed, for example, cylindrical and protrudes perpendicular to the planar plane of the measuring element 52 upwards. Between bolt 54 and pole terminal 50, a sleeve 56 is arranged radially surrounding the bolt. This is made of an electrically non-conductive material for the isolation of the second connection point of the measuring element 52 of the pole terminal 50. This ensures that the battery current between pins 54 for connecting the ground cable 40 and the terminal, connected to the battery, actually via the measuring element 52nd flows and not shorted. A corresponding further recess 72 of the measuring element 52 is matched to the outer diameter of the bolt 54. The measuring element 52 is partly on a radially enlarging collar 68 on the bolt 54, partially on the top of the sleeve 56. The upwardly projecting side of the bolt 54 may be provided with a thread, not shown, to fasten a cable lug of a cable, preferably the ground cable 40, by means of screw connection. The measuring element 52 is only laterally surrounded by a housing 64 in the region of the bolt 54, while the surface of the measuring element 52 is exposed. Since the measuring element 52 is connected at this point only via the sleeve 56 with the pole terminal 50, no electrical contact takes place at this point. The measuring element 52 is guided in the direction of the housing 64 in its interior. There is the actual measuring element, such as a resistor made of a certain material such as manganin. Within the housing 64 also not shown electronics is arranged, which detects the voltage drop across the measuring resistor and evaluates in a further signal processing. Furthermore, based on further data such as battery voltage, temperature or similar battery state variables such as the state of charge (SOC) or state of health (SOH) of the battery can be determined. This data can be transmitted via a data line, not shown, which is connected via the plug 66 to other control devices such as a power management control unit. The measuring element 52 is led out of the housing 64 on the side facing away from the bolt 54 side. There is also the electrical contact by means of the compound obtained by clinching 42, as already described. It is essential, however, that the electrical contacting between the measuring element 52 and the pole terminal 50 takes place only on the side facing away from the bolt 54-based on the actual measuring resistor. In that case, the measuring resistor which is passed from the battery pole via the pole terminal 50 via the connection 42 to the left connection point of the measuring element 52, via the measuring resistor inside the housing 64, is led to the bolt 54, to which the ground cable 40 is then connected.

Wie in Figur 2 gezeigt, wird die Verbindung 42 mittels Durchsetzfügens gebildet. Darunter versteht man ein Verfahren zum Verbinden von Blechen ohne Verwendung eines Zusatzwerkstoffes. Das Fügen wird hierbei durch Umformen zumindest eines Werkstoffs erreicht. Gemäß Figur 2 wird ersichtlich, dass Anschluss 41 und Stromschiene 44 als Beispiel für einen weiteren Anschluss, wie links dargestellt, nach dem Durchsetzfügen eine plastische Verformung erfahren haben, so dass eine mechanisch feste und auch elektrisch leitende Verbindung 42 hergestellt wird. Bei den in Figur 2 dargestellten Varianten werden sowohl Stromschiene 44 als auch Anschluss 41 verformt. Dies ist jedoch nicht zwingend erforderlich. Es reicht auch eine Verformung lediglich eines Blechs, entweder die Stromschiene 44 oder der Anschluss 41, aus.As in FIG. 2 As shown, the connection 42 is formed by clinching. This is understood to mean a method for joining metal sheets without using a filler material. The joining is achieved here by forming at least one material. According to FIG. 2 As can be seen, terminal 41 and bus bar 44, as an example of another terminal, as shown on the left, have undergone plastic deformation after clinching, so that a mechanically strong and also electrically conductive connection 42 is produced. At the in FIG. 2 Variants shown both busbar 44 and 41 are deformed. However, this is not mandatory. It is also sufficient deformation of only one sheet, either the busbar 44 or the terminal 41, from.

Bei dem in den Figuren 4 und 5 gezeigten Ausführungsbeispiel zur Verbindung eines Messelements 52 mit der Polklemme 50 hat sich das Durchsetzfügen wie in Figur 3 dargestellt bewährt. Hierbei entspricht dem Anschluss 41 die Polklemme 50, die Stromschiene 44 dem Anschluss des Messelements 52. Die Polklemme 50 ist vorzugsweise ein Schmiedeteil, das nach der Umformung, die zur Verfestigung des Materials bei gleichzeitiger Herabsetzung der Bruchdehnung führt. Zur Verbesserung der Verarbeitbarkeit könnten die zu verformenden Werkstoffe einer Wärmebehandlung unterzogen werden. Es eignet sich hierfür insbesondere eine Zerspanlegierung, besonders vorzugsweise CuZn39Pb2. Vorzugsweise besteht der Anschluss des Messelements 52 aus SE-Cu58. Durch das Durchsetzfügen wird eine mechanische und elektrische Verbindung zwischen Messelement 52 und Polklemme 50 erzielt. Hierzu wird mit dem Fertigungsverfahren nach Figur 3 die beiden Bleche 44, 52; 41, 50 ohne zusätzliches Bauteil durch Durchsetzfügen quasi eine Nietverbindung 42 hergestellt. Durch den Prägestempel 10 wird das Messelement 52, das aus einem weicheren Material besteht als die Polklemme 50, in die Öffnung 30 verpresst. Das Durchsetzfügen ist abgeschlossen, wenn das verdrängte Material des Messelements 52 auch in die Anfasung 32 der Öffnung 30 gelangt, so dass ein Hinterschnitt 34 ausgebildet wird. Der Durchmesser der Öffnung 30 liegt vorzugsweise im Bereich von ca. 5 mm oder größer, (beispielsweise 6,4 mm oder größer (wie beispielsweise 7,4 mm, wenn genügend Platz vorhanden ist). Dabei besteht die Polklemme 50 aus CuZn39Pb2 mit einer rückseitig angesenkten Öffnung 30. Das duktile Kupfer (SE-Cu58) wird so durch das angefaste Loch 30 gezogen, dass der Hinterschnitt 34 entsteht und sich ein Nietkopf bildet.In the in the FIGS. 4 and 5 shown embodiment for connecting a measuring element 52 to the pole terminal 50 has the clinching as in FIG. 3 shown proven. Here, the terminal 41 corresponds to the pole terminal 50, the bus bar 44 to the connection of the measuring element 52. The pole terminal 50 is preferably a forging, which leads to the deformation, which leads to the solidification of the material while reducing the elongation at break. To improve the processability, the materials to be deformed could be subjected to a heat treatment. It is particularly suitable for this purpose a Zerspan alloy, particularly preferably CuZn39Pb2. Preferably, the connection of the measuring element 52 consists of SE-Cu58. Through the clinching a mechanical and electrical connection between the measuring element 52 and pole terminal 50 is achieved. This is done with the manufacturing process FIG. 3 the two sheets 44, 52; 41, 50 without additional component by clinching quasi a rivet 42 made. By the embossing die 10, the measuring element 52, which consists of a softer material than the pole terminal 50, is pressed into the opening 30. The clinching is completed when the displaced material of the measuring element 52 also enters the chamfer 32 of the opening 30, so that an undercut 34 is formed. The diameter of the opening 30 is preferably in the range of about 5 mm or larger (for example, 6.4 mm or larger (such as 7.4 mm if there is enough space).) The pole terminal 50 is made of CuZn39Pb2 with a back side Countersunk opening 30. The ductile copper (SE-Cu58) is so through the chamfered hole 30 pulled that the undercut 34 is formed and forms a rivet head.

Bei einer geeigneten Materialauswahl könnte auch auf das Vorsehen einer Öffnung 30 verzichtet werden, so dass die in Figur 2 dargestellten Geometrien erreicht werden. In entsprechender Weise sind Prägestempel 10 und Amboss 20 anzupassen.With a suitable choice of material could be dispensed with the provision of an opening 30 so that the in FIG. 2 shown geometries are achieved. In a corresponding manner, dies 10 and anvil 20 are to be adapted.

Das Durchsetzfügen zum Erstellen der Verbindung 42 eignet sich insbesondere für eine Kontaktierung von Anschluss 41 und Stromschiene 44 (als Beispiel für einen weiteren Anschluss) eines Steuergeräts 46. Aufgrund der vorgenommenen Materialauswahl eignet sich das Durchsetzfügen jedoch besonders bevorzugt zur Erstellung der Verbindung 42 zwischen Polklemme 50 und Messelement 52.The clinching for creating the connection 42 is particularly suitable for contacting terminal 41 and bus bar 44 (as an example of another connection) of a control unit 46. However, due to the material selection made, clinching is particularly preferred for establishing the connection 42 between terminal 50 and measuring element 52.

Claims (12)

Vorrichtung zur Verbindung zumindest zweier elektrischer Anschlüsse, insbesondere einer Polklemme (15) und einem Messelement (52), dadurch gekennzeichnet, dass die beiden Anschlüsse (41, 50; 44, 52) mittels Durchsetzfügens miteinander verbunden sind.Device for connecting at least two electrical connections, in particular a pole terminal (15) and a measuring element (52), characterized in that the two terminals (41, 50; 44, 52) are interconnected by means of clinching. Vorrichtung nach Anspruch 1, dadurch gekennzeichnet, dass die Anschlüsse (41, 50; 44, 52) aus Materialien unterschiedlicher Festigkeit bestehen.Device according to claim 1, characterized in that the connections (41, 50, 44, 52) consist of materials of different strength. Vorrichtung nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass einer der Anschlüsse (41, 50) zumindest eine Öffnung (30) aufweist, in die der andere Anschluss (44, 52) mittels Durchsetzfügens zumindest teilweise verformt ist.Device according to one of the preceding claims, characterized in that one of the terminals (41, 50) has at least one opening (30), in which the other terminal (44, 52) is at least partially deformed by means of clinching. Vorrichtung nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass die Öffnung (30) mit einer Anfasung (32) versehen ist.Device according to one of the preceding claims, characterized in that the opening (30) is provided with a chamfer (32). Vorrichtung nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass der andere Anschluss (44, 52) durch Durchsetzfügen im Bereich der Anfasung (32) einen Hinterschnitt (34) ausbildet.Device according to one of the preceding claims, characterized in that the other connection (44, 52) forms an undercut (34) by clinching in the region of the chamfer (32). Vorrichtung nach einem der vorhergehenden Ansprüche, das zumindest einer der Anschlüsse (41, 50) aus einer Zerspanungslegierung und/oder der andere Anschluss (44, 52) aus duktilem Material, vorzugsweise Kupfer, besteht.Device according to one of the preceding claims, which consists of at least one of the connections (41, 50) of a cutting alloy and / or the other connection (44, 52) of ductile material, preferably copper. Vorrichtung nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass der eine Anschluss als Polklemme (50) und/oder der andere Anschluss als Messelement (52) ausgebildet ist.Device according to one of the preceding claims, characterized in that the one terminal is designed as a pole terminal (50) and / or the other terminal as a measuring element (52). Vorrichtung nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass die Polklemme (50) und Messelement (52) an zumindest einer Stelle mittels Durchsetzfügens und an einer anderen Stelle mittels eines Bolzens (54) verbunden sind, vorzugsweise durch eine Hülse (56) voneinander isoliert.Device according to one of the preceding claims, characterized in that the pole terminal (50) and measuring element (52) are connected at least at one point by means of clinching and at another location by means of a bolt (54), preferably by a sleeve (56) from each other , Vorrichtung nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass der eine Anschluss aus CuZn39Pb2, und/oder der andere Anschluss (44, 52) aus SE-Cu58 besteht.Device according to one of the preceding claims, characterized in that the one terminal of CuZn39Pb2, and / or the other terminal (44, 52) consists of SE-Cu58. Verfahren zur Verbindung zumindest zweier elektrischer Anschlüsse, insbesondere einer Polklemme (50) und einem elektrischen Messelement (52), dadurch gekennzeichnet, dass die beiden Anschlüsse (41, 50; 44, 52) mittels Durchsetzfügens miteinander verbunden werden.Method for connecting at least two electrical connections, in particular a pole terminal (50) and an electrical measuring element (52), characterized in that the two connections (41, 50; 44, 52) are connected to one another by means of clinching. Verfahren nach dem vorhergehenden Anspruch, dadurch gekennzeichnet, dass in einem der Anschlüsse (41, 50) zumindest eine Öffnung (30) vorgesehen ist, in die der andere Anschluss (44, 52) mittels Durchsetzfügens gepresst wird.Method according to the preceding claim, characterized in that in one of the connections (41, 50) at least one opening (30) is provided into which the other connection (44, 52) is pressed by means of clinching. Verfahren nach einem der vorhergehenden Verfahrensansprüche, dadurch gekennzeichnet, dass die Öffnung (30) eine Anfasung (32) aufweist, in die der andere Anschluss (44, 52) mittels Durchsetzfügens gepresst wird, so dass sich ein Hinterschnitt (34) ausbildet.Method according to one of the preceding method claims, characterized in that the opening (30) has a chamfer (32) into which the other terminal (44, 52) is pressed by means of clinching, so that an undercut (34) is formed.
EP09179728.2A 2009-02-13 2009-12-17 Device and method for connecting at least two electrical connections Active EP2219269B1 (en)

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EP2219269A3 (en) 2013-01-16
EP2219269B1 (en) 2013-11-20

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