Method and device for producing an electrical connection of sub-assemblies and modules

p0001BACKGROUND OF THE INVENTION 1. Field of the Invention The invention relates to a method for producing an electrical connection of assemblies and modules with a current generator unit which is provided with electrical contact elements and with magnetic bodies and with a current receiving unit which is provided with electrical countercontact elements and with magnetic bodies which are oppositely polarized with respect to the magnetic bodies in the current generator unit Respectively.

p0002The invention also relates to a device for carrying out the method.

p0003An electromechanical connecting device is described in PCT / EP 01/14503, wherein an electrical connection is established between a current generator unit and a power unit unit by magnetic forces. The current connection is thereby provided by a movable magnetic slide with contact points, which are connected to current supply connections. By means of a retaining device in the form of a permanent magnet, the magnetic slide is held in a resting state, ie, when no current receiving unit with magnetic bodies is placed on the power supply unit, at a distance from contact elements which are located on the upper side or the side of the power supply unit facing the power supply unit. When the power unit unit approaches the power unit, a contact connection is established by closing the magnetic circuit between the magnetic bodies of the power unit and the power unit.

p0004For the sake of simplicity, the following is generally referred to as magnetic bodies. These can be magnets, magnetizable parts or magnetic parts which react magnetically under the influence of a magnet. It is essential that the magnetic bodies of the current generator unit and of the current-carrying unit cooperate in such a way that a magnetic force is applied to both parts by a magnetic field.

p0005WO 01/03249 A1 also describes an electromechanical connecting device in which a plurality of magnet elements and contact elements are arranged in one unit. A preferred application area for the multiple contacts is the small or low voltage range up to 24 volts, in order to provide control voltage, switching pulses or data transmissions. For reinforcing the contact connection, which takes the form of flat contacts, at least one elastic wall is provided in which the contact elements are arranged. In this case as well, the electrical contact between a current generator unit and a current receiving unit for the separately arranged contact elements is effected via the magnet elements.

p0006EP 1 194 983 describes a mechanical connecting device wherein an electrical connection is established between a power supply unit and a power unit via coded magnet elements.

p0007The electrical connection devices described so far are used for the fast and frequent connection of loads to a current source.

p0008For the production of electrical connections of modules which are provided for a long time, for example in motor vehicle construction, connectors have so far been used. A connection is made by means of sockets and pins. For this purpose, the bushes are provided with one or more springs per contact for better connection with the pins, which are usually turned or stamped parts. The contact force and thus the electrical connection is generated by the spring force. The higher the spring force, the better the transmission quality and the higher the currents to be transmitted.

p0009It is also disadvantageous that fatigue phenomena can occur during operation, as a result of which the spring force is reduced.

p0010In motor vehicle construction, but also in other fields, currents of 30 amperes and more are often transmitted via multi-pole plug connections.

p0011Due to the required high contact force during the transmission of such high currents, high forces are required during the assembly in order to minimize the contact resistance due to the sum of the contact forces of the individual contacts for multipoint plugs. These can be up to 100 N or more. Technical aids are frequently not applicable for assembly of assemblies, as the installation space is too small and therefore difficult to access. This means that the contact connection has to be carried out manually by a fitter, which means that a perfect plug-in connection depends on the operation of the fitter. Due to the time pressure, working time with fatigue phenomena and the like, therefore, incorrect connections due to an incomplete plugging process can not be excluded. Insufficient connections lead to a later disconnection of the plug connection during operation and thus the transmission is interrupted. A further danger is that, in order to facilitate its work, the installer uses the ancillary means, such as hammers and the like, to produce the connection, which can lead to damage to the plug-in connection.

p0012The present invention is therefore based on the object of providing a method and a device for producing an electrical connection of assemblies and modules by which the above-described disadvantages are avoided, in particular by which a secure connection is provided, Reliability of a mechanic.

p0013According to the invention, this object is achieved in an electrical connection method for assemblies and modules having the features specified in claim 1.

p0014A connecting device for producing an electrical connection is shown in claim 3.

p0015According to the invention, the electrical connection of assemblies and modules is now divided into two phases, namely:

p0016In a first step, a mechanical connection is provided between the power unit and the power unit, which can be carried out without great effort and which can be produced unequivocally and reliably by means of a corresponding design of the connecting elements.

p0017After the mechanical connection has been established, an automatic electrical contact, which can no longer be influenced by a fitter, is carried out with precise orientation of the contacts to one another and with high contact forces.

p0018This is made possible by the fact that the mechanical connection is created in such a way that, in its end position, the magnetic bodies of the current generator unit and of the current-receiving unit are sufficiently close to each other that the magnetic attraction forces act between the individual magnetic bodies. This leads to the switching process and thus to an electrical connection of the contact elements of the power supply unit with the counter-contact elements of the power unit. This means that in any case it is ensured that a complete electrical connection occurs. Due to the magnetic forces, a high adhesion between the electrical contact elements and the counter-contact elements is ensured, in particular when the magnetic bodies simultaneously represent the contact elements. If flat contacts are used for the contact elements, very high currents can be transmitted. This also applies, in particular, when, as envisaged, the vehicle voltage in motor vehicles is increased to 42 volts.

p0019If one wishes to avoid the fact that current is applied to the contact elements of the current generator unit, which are exposed at the upper side of the sensor unit, when a current receiving unit is mounted, a magnetic slide can be used, as described, for example, in EP 0 573 471. At the same time, switching under load, in particular also with high contact forces and few contacts, is possible in this way.

p0020The magnetic bodies can also be encoded, if necessary, as described, for example, in EP 1 194 983. In this way, erroneous assignments of contact elements and counter-contact elements are avoided. The same applies to a faulty tripping in the presence of a magnetic switch. In addition, an even better positioning of the contacts results.

p0021For the manufacture of a mechanical connection in a first step, various mechanical connecting devices are possible. For example, the power supply unit can be pushed onto the power supply unit from the side by a corresponding guide. Vertical positioning is also possible.

p0022In addition to a lateral or vertical pushing on or fitting on, a bayonet-like connection can also be provided. A latching in the end position, which may also be displayed acoustically, is also possible.

p0023Advantageous refinements and refinements are given in the subclaims and in the exemplary embodiments described below in principle with reference to the drawing.

p0024It shows:<dl id="dl0001"><dt>FIG</dt><dd>A power supply unit in section, on which a power unit is placed, with a coarse guide therefor; and</dd><dt>FIG</dt><dd>A perspective view of a current generator unit with which a current receiving unit is connected as a coarse guide via a side guide.</dd></dl>

p0025In the following, two exemplary embodiments of the invention are described in principle. Since the electrical connecting device is already known in principle via the magnetic bodies of the power supply unit and the power unit, for which reference is made, for example, to PCT / EP 01/14508, WO 98/09346, WO 97/50152 and WO 01/03249 A1 In the following only in the details essential to the invention.

p0026DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A power supply unit 1 shown in FIG. 1 with contact elements 2 configured as surface contacts and a power unit 3 with contact elements 4 also designed as flat contacts are described in detail in their structure and their mode of operation in WO 01/03249 A1 becomes. WO 01/03249 A1 therefore also forms the disclosure of the present application.

p0027The contact elements 2 of the current generator unit 1 are at the same time designed as switching magnets or magnetic switching elements, and the contact elements 4 of the current unit unit 2 simultaneously form tripping magnets or magnetic tripping elements. The contact elements 2 of the current generator unit 1 are each connected individually, via line connections 5, to a current, voltage or pulse source (not shown). The same applies to the contact elements 4 of the power unit 3, from which connection lines 6 lead in each case to a consumer (also not shown). The contact elements 2 and 4 are flat on their mutually facing end faces 7 and are at least approximately flush with the respective surface of the associated unit 1 or 3. The contact elements 2 and 4 are each potted in an elastic wall 8.

p00281, at least two frustoconical expansions 9 arranged at a distance from one another project out of the housing of the current generator unit 1 on the side facing the power supply unit 3 to be applied.

p0029The complementary current receiving unit 3 is provided with frustoconical recesses 10 in the housing of the power unit 3. For guidance, the cone angles of the extension 9 and the recess 10 are adapted to each other. In contrast to "normal" such taper guides, however, an oversized clearance is provided between the two guide parts, because only a coarse guide is provided by the frustoconical extensions 9 and the recesses 10. In addition, introduction bevels, as shown in dashed lines in the head region of the frustoconical extensions 9, can also be provided for this purpose in order to achieve an easy and safe introduction and to take account of the inevitable production and assembly tolerances which are 1 to 2 mm and more in the automobile sector can. The play with "X" in the cone angle is indicated on the power unit 3. Likewise, a clearance must be provided between the head side of the extension 9 and the bottom of the depression 10, so that, after the power supply unit 3 has been placed on the power supply unit 1 and an insertion of the extensions 9 into the recesses 10 in the last introduction step, the contact elements 2 and 4, The last exact positioning and centering.

p0030In order to avoid jamming and to facilitate the handling of the installer, in any case, such a play must be provided in such a way that it is also possible with the greatest possible tolerance or production<b>-</b> Or mounting accuracy during the connection of the power unit 3 to the power unit 1 does not result in any jamming.

p0031Instead of a frusto-conical widening and recess, other guide elements which allow a vertical coarse feed can also be provided within the scope of the invention, such as, for example, pins and bores, which can also be conical, or pyramidal connecting members and the like.

p0032FIG. 2 schematically shows a connection of the power unit 3 with the power unit 1 by a lateral push-on. As can be seen, dovetail guides 11a and 11b are provided in the current generator unit 1 and the power unit 3 for the lateral guidance and thus for a lateral pushing in the direction of the arrow.

p0033In contrast to dovetail guides 11a and 11b of conventional design, an oversized clearance is also provided between the two guides in order to compensate for manufacturing and assembly tolerances. Again, the clearance should be at least 1 mm, preferably 2 mm or even more.

p0034Of course, in the context of the present invention, other constructive configurations of coarse guides are also possible instead of the two coarse guides with the frustoconical extensions 9 and the recesses 10 adapted thereto or the dovetail guides 11a and 11b. What is important is merely that in this way a nearly force-free approach and connection is provided in a first step between the power supply unit 1 and the power unit 3, whereupon automatic positioning and centering by the magnetic effects of the contact elements 2 and 4 automatically and without any influence by the installer Respectively.

p0035It is, of course, also not necessary for the contact elements 2 and 4 to be identical with the magnets in the context of the invention. If the space conditions permit, magnets can also be provided independently of the contact elements 2 and 4 in the power unit 3 and the power unit 1.

p0036An exemplary embodiment is also shown in FIG. 2 in a dashed line, wherein a magnetic slide 12 is provided, which is provided with current feed contacts 16. On the magnetic slide 12, in this case, separate magnets 13 and contact members 13a are arranged, wherein the contacts 13a are attracted together with the magnetic slide 12 by magnets 14 in the power unit 3 while the power unit unit 3 is mounted on the power unit unit 1 and contact elements 2 from the rear side Her. In this way, a current connection is provided. The more detailed structure and mode of operation of this device is described, for example, in EP 0 573 471, which also provides the disclosure content for the present application.

p0037In the rest state, that is to say when the current receiving unit 3 is not mounted, the magnetic slide 12 is attracted by a magnet 15 or a material of a magnetic material, which is located on the side facing away from the power unit 3 in the current generator unit 1. In this state, therefore, no current is applied to the contact elements 2 because the contact members 13a are spaced apart from each other.