Line/Current Collector Details TRIZ Cases

Surface-mount board locks eliminate PCB through-holes, enabling aligned card edge connectors on both sides with easier rework and denser layouts.

Split conductor strands near the plug contact decouple vibration while preserving high current capacity and reliable mating contact.

A ferrule and ultrasonic weld create a metallurgical bond for Litz wire termination while preserving the braid pattern and avoiding heat and wire damage.

A metallic enclosure diffusion-bonds stranded wire into a compact PCB terminal, avoiding solder, cavities, and insulation removal damage.

A shared driving member links crimping and cable stripping in one hand motion, cutting tool switching and easing cable connector assembly.

A hinged cover and mounting box keep the light housing elevated during installation, enabling safer two-handed wiring without extra safety cables.

Convex spring busbar contacts absorb tolerance variation during joining, preventing welding cracks and tool-heavy assembly in inverter commutation cells.

A spring-mounted die part lets the crimping drum adapt to different wire ferrule cross-sections without manual adjustment.

A piezo film sensor and integrated electronics track crimping force in real time, improving crimp quality assurance and documentation.

A staged foil peeling process forms space between wire members, cuts the foil safely, and removes shielding without core damage.

Offset conductive layers in through holes shift pushing load to the insulating layer, preventing cracks, peeling, and conduction failure.

A reusable jig holds ribbon cable and connector in position during crimping, reducing shorts and improper electrical termination.

A clevis, nest, and movable indenter replace heavier crimping setups to enable compact one-handed use in repetitive and tight-access work.

A distance-controlled bundling head keeps a fixed gap to twisting heads, improving twisted wire length consistency and avoiding unnecessary motion.

A friction brake with a preset torque threshold keeps an electrical plug adjustable in angle while resisting vibration-driven rotation.

A low-resistance conductive rubber connector helps glass plate terminals carry high current while limiting peeling, compression set, and heat rise.

A C-clamp and pivoting wire clamp hold heavy gauge wires at terminal structures, freeing both hands for safer, faster work.

Automatic bending and peeling of connector ribbon film improves peeling uniformity, reduces manual work, and prevents welding interference.

Integrated anti-rotation features emboss into the attachment during rotary fixing, enabling flexible, rotation-proof clamping without special part shaping.

Adjustable press jaws form guided indentations in a crimp sleeve to secure conductor and shielding contact without material damage.

Crimped outer conductors lock the dielectric and avoid welding heat, preserving connector shape and stable electrical contact.

A shear-thinning grease sealant balances dispensability, positional stability, and sealing to protect crimp connections and electrical resistance.

A friction wheel feed links cutting, stripping, crimping, and printing in one handheld cable tool for simpler field processing and parameter documentation.

Selective hooking portions bend and separate core wires from a drain wire, automating multi-core cable processing with stable handling.

Localized heating softens epoxy on bus bars for precise automated cutting, exposing clean contact areas with minimal conductor damage.

A transverse guide groove bends non-crimped cores by 90° to limit wire-end length variation, prevent damage, and ease multi-core cable crimping.

Separate stop surfaces and a wire guide hold outer contacts and inner conductors in position, reducing crimping spread without process changes.

Robotic wire spreading and vision-guided positioning automate crimping of short multi-wire cable tips despite tight spacing and wire interference.

A deformed metal ring grips the cable sheath and anchors plastic overmolding to prevent connector-to-cable disconnection.

A pre-applied low-friction sleeve protects exposed fibre ends during duct blowing while reducing jamming, restarts, and post-installation trimming.

An insulating body and conductive contact part align small cable cores on PCB conductor areas for accurate spacing, soldering, and handling.

Automated cable feeding and sensor-guided alignment cut cycle time and improve repeatable quality in shielded cable solder sleeve installation.

Fixing exposed terminal conductors before ultrasonic joining prevents dispersion, stabilizes alignment, and improves cable connection quality.

Automatic accessory recognition plus force and travel tracking lets a power tool confirm crimp completion and die compatibility in real time.

Welded crimping sleeve legs create a closed cable plug structure that resists torsion, improves pull-out strength, and preserves shielding.

Independent, pitch-free carrier movement removes synchronous bottlenecks in cable assembly, raising station utilization and layout flexibility.

By removing the separate applicator, this crimp tooling frees space for cameras and sensors while lowering cost and maintaining precise terminal crimping.

A concentric wire barrel with guided feed, tension equalization, and lubrication cuts pulling force and enables single-person conductor installation.

A movable detection mechanism compensates for conductor size variation to keep heat-shrink tube wrapping aligned on exposed wire surfaces.

A primary and spring-biased secondary shear move the terminal shear out of the extrusion path to protect crimp quality and consistency.

A liquid metal reservoir connector maintains electrical continuity under strain by balancing flow, sealing, and pressure in deformable wires.

Welding cable conductors and filling the joint gap with a metal sleeve lowers contact resistance, limits oxidation, and reduces overheating risk.

Side-surface positioning structures guide an alignment tool to align power module terminals with board contact holes and prevent bending.

Welding aluminum conductors and filling the insulation gap with a metal sleeve cuts contact resistance and overheating in prefabricated cable accessories.

A guide-track gripper assembly automates terminal loading and positioning in crimping machines, cutting cycle time and operator injury risk.

Slots and magnets give a crimp terminal holder linear and rotary adjustment, improving terminal orientation and reducing faulty terminations.

A rotary return valve controls hydraulic pressure while a quick-release coupling lets the tool head be removed without external tools.

Real-time force and path monitoring lets interchangeable wire tool heads cut, strip, and crimp with fewer execution errors.

An opening beside the wire spring lets the lock arm and protection wall be molded on one side, keeping the connector slim and improving heat release.

A housing pressing portion holds the fixing barrel at the proper crimping position, preventing springback and protecting connector communication quality.