Adjustable Compression Chamber for Consolidation Welding
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Solution Overview
Problem
Existing consolidation welding methods for electrical conductors to terminals lack flexibility, requiring retooling or using different terminals to accommodate varying conductor widths, leading to throughput penalties and cost disadvantages.
Innovation Solution
An apparatus with adjustable top and bottom tools, featuring movable and deformable welding jaws, allows for variable weld widths without retooling, enabling connection of conductors with different thicknesses to terminals of varying connection zone widths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the width of electrodes or connection zone is adjusted to match conductor size in traditional consolidation welding, then welding precision is improved, but device flexibility deteriorates requiring retooling for different conductor-terminal pairings
Solution Approach 1:
The patent applies the dynamics principle by making the compression chamber width adjustable during the welding process. The top tool is movable relative to the bottom tool, allowing the compression chamber width to be dynamically adjusted to match different conductor sizes. This resolves the contradiction by enabling both precise welding (through proper width matching) and device flexibility (through adjustability without retooling).
Solution Approach 2:
The patent applies parameter changes by varying the width of the compression chamber as a controllable parameter. Instead of fixed electrode widths, the system allows the compression chamber width to be changed according to the conductor size being welded. This enables the same apparatus to accommodate different conductor-terminal pairings while maintaining optimal welding precision for each configuration.
2Manufacturing precision
If a previous consolidation operation is added to weld thin conductors to large connection zones, then welding quality is improved, but device complexity and production cost increase
Solution Approach 1:
The patent applies the merging principle by combining the consolidation of conductor strands and the welding to terminal into a single integrated operation within the compression chamber. The movable top tool and bottom tool work together to simultaneously consolidate the conductor material and weld it to the terminal connection zone in one process step, eliminating the need for separate consolidation and welding operations.
Solution Approach 2:
The patent applies universality by designing the compression chamber and tooling system to perform multiple functions: it consolidates conductor strands, welds to terminals of various sizes, and accommodates different conductor-terminal pairings all within a single apparatus configuration. This multi-functional design eliminates the need for additional specialized equipment or operations.
3Device complexity
If fixed-width electrodes are used in consolidation welding, then device complexity is reduced, but productivity deteriorates due to retooling requirements for different conductor-terminal pairings
Solution Approach 1:
The patent applies dynamics by implementing a movable top tool that can be adjusted relative to the bottom tool to change the compression chamber width. This dynamic adjustment capability allows the apparatus to quickly adapt to different conductor and terminal sizes without requiring physical retooling, thereby maintaining high productivity while managing device complexity through a single adjustable mechanism rather than multiple fixed tools.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables flexible and efficient welding of conductors to terminals of different widths, increasing the useful life of electrodes and eliminating the need for additional consolidation steps, thus improving production efficiency and reducing costs.
Implementation Method 1
The welding jaw (510) is movably provided on a side of the welding device (410)... The welding jaw (520) is movably provided on a side of the welding device (420)... both having a movable or deformable welding tool, which is movable or deformable in such a way that, working with a different welding tool of the bottom tool and top tool respectively, they seal off a compression chamber
Data Source
Figure 1
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AI summary
The invention concerns an apparatus for consolidation welding of an electrical conductor (304), in particular to an electrical terminal (10), preferably for resistance-monitored circuitry in a motor vehicle, comprising a bottom welding tool (420), on which a conductor (304) section (305) to be consolidated can be arranged, as well as three movable welding tools (410, 510, 520), whereby with a movable welding tool (510), which has two translational degrees of freedom, a width (B305) of the conductor (304) section (305) to be consolidated can be variably adjusted with reference to the bottom welding tool (420), and the other two movable welding tools (410, 520) can be moved in such a way that they seal off a compression chamber (45) delimited by the width (B305) of the conductor (304) section (305) to be consolidated in a direction of its perimeter.