Line/Current Collector Details TRIZ Cases

A multi-storage conveyor and transfer grippers automate heavy rigid cable-end handling, improving processing accuracy and reducing manual intervention.

An axial metal transition and weld metal let a bimetallic conductor join a single-metal section with stronger, more reliable welding.

Sidewall concavities in metallization block solder creepage onto shunts and thermistors, preserving measurement accuracy and preventing shorts.

A tin-containing terminal film absorbs laser energy faster than copper, shortening coil wire welding time and limiting heat damage.

A two-clamp crimping approach fixes the contact before crimping to stop twisting and axial shift, improving assembly accuracy.

A coreless motor and cycloid gear shrink crimp tool size while delivering high force and precise crimp height without complex stops.

A multi-store cable transport and transfer gripper setup automates rigid cable end processing with less manual handling and better repeatability.

A staged lock engages only at full insertion depth, preventing partial connector locking and improving coupling reliability.

A universal end plug and sensor-ready module simplify heating cable field termination, improving connection reliability without specialized tools.

Rotating cams pierce heating cable insulation to make secure high-current field connections without full stripping or specialized tools.

A rotary insert lets one cable tool switch between crimping, cutting, and stripping to reduce tool changes, inventory, and cost.

A switching block and support base let one crimping tool handle 90° and 180° network jacks while avoiding cutter head changes and tipping.

Segmented dielectrics and an annular collar let RF connector pins float with bidirectional restraint, reducing assembly stress and PCB misalignment issues.

By touching the higher coil tip before arc separation, TIG welding can evenly melt terminals of different heights and form a uniform bead.

Separated holding and conductive crimp zones help small-diameter wires maintain joint strength and low electrical resistance.

A reactive multilayer film creates localized heat to join a superconductive strip with low resistance while limiting thermal damage, space, and weight.

A guide channel and rail constrain the ram head to maintain axial alignment, resist off-center loading, and improve crimp consistency.

A groove-based X-ray CT jig holds multiple wire harnesses in position for faster crimping state inspection without sacrificing accuracy.

A standardized motor-transmission-pump unit fits different handle assemblies, cutting tool complexity and cost while preserving hydraulic force.

A single laser pre-cut releases foil tension, enabling simultaneous side cutting and faster cable aluminum foil removal at lower cost.

Butt welding through the insulation coating joins wires without overlap, cutting joint diameter and extra process steps in sensor wiring.

Tilted multi-region clamping secures ultra-fine wires against slip under load and temperature changes while preserving electrical contact.

A regeneration check valve and pilot-operated valve let a hydraulic tool switch from rapid piston advance to controlled high-force cutting or crimping.

A welded metal carrier mounts a sensor on each battery cell, improving temperature accuracy while keeping traction battery production fast and low cost.

A double-supported locking beam in the dielectric cavity reduces gaps around the inner conductor and helps maintain stable connector impedance.

A viscoelastic matrix with stiff-core, flexible conductive webs reinforces contact pads while limiting wear and sealing out moisture.

A retractable spring-loaded crimp jaw keeps the actuation path consistent while adapting crimping and cutting to different cable diameters.

Bundle-type connection pins laser welded through PCB and ceramic through-holes improve pin accuracy, bonding strength, and heat dissipation.

A folded-back sheet conductor secures wire contact in less space, improving connection reliability while lowering electrical resistance.

An automatic swivel arm and magazine select and clamp cable guide units to cut manual cable change time across different cable types.

A coreless motor and cycloidal gearing shrink crimping tools while simplifying precise crimp height setting for mobile and stationary use.

A preconfigured microcontroller lets a press tool connect to the cloud on its own for data exchange, remote monitoring, and firmware updates.

An angled shield and cable layout holds foil coverage through the bend to simplify assembly, cut cost, and improve impedance control.

Interwoven copper nanowire micro-bumps and confined reflow improve substrate bonding reliability while avoiding brittle intermetallics and overflow shorts.

A comb structure adds parallel capacitance to long interconnects, balancing inductance to cut impedance, crosstalk, and voltage fluctuation.

Laser through-holes in connector housing walls enable welding of multi-row terminals and wires inside the chambers, simplifying automation.

Curvilinear cam ramps vary mechanical advantage during crimping, improving force consistency and ergonomics across different wire barrel diameters.

Two-part clamping jaws let automated cable handlers swap receiving contours without tools while keeping secure cable fixation.

Separate ferrule and blade forming cuts machining scrap and cost while enabling adaptable fuse terminal configurations.

Digital positioner data automates crimp depth calibration and logging, reducing operator errors and outdated tool settings.

Cup-shaped ferrules joined to connector blades cut machining waste, lower terminal cost, and simplify fuse terminal inventory.

Parallax-reduced imaging of cable end-faces guides precise layer cutbacks, lowering manual preparation defects in grid cable connections.

A slotted bus bar aperture enables terminal alignment and laser welding, cutting contact resistance and eliminating separate fasteners.

An added press section spans multiple ribs to keep the rib intersection outside the opening contour, improving pressing uniformity and reducing ridges.

By comparing pressing-element travel to earlier crimp-height settings, this case detects wear early and helps maintain crimp quality.

A bendable hook closes around winding wire for easier insertion, stronger resistance welding, and less axial space in electric machines.

A roll aligned parallel to the cable axis applies polymer film uniformly on conductor joints, reducing voids, poor geometry, and air entrapment.

Oscillating rotary untwisting smooths twisted cable ends, reduces residual waves, and aligns fine conductors for reliable assembly.