Braided Shield Connection Structure for Accurate Laser Welding
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Solution Overview
Problem
The existing methods for connecting shielded cables to terminals, such as crimping and laser welding, face challenges with low productivity and accuracy due to the flexible nature of shield braids and the need for multiple jigs and tools, leading to inefficiencies in joining the shield braid and conductive members.
Innovation Solution
A braided part connection structure is introduced, where a conductive member with a braid joining portion, featuring a series of openings and welded protruding pieces, is overlapped onto the shield braid, allowing for precise laser welding, improving positioning accuracy and reducing heat transmission, thus enhancing connection reliability and productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the shield braid and shield terminal are joined by a laser joining method, then the number of jigs and tools can be reduced and takt time can be shortened, but joining accuracy is poor due to the unstable shape of the flexible shield braid
Solution Approach 1:
The shield braid is preliminarily positioned and fixed onto the shield terminal before laser welding. This preliminary positioning action stabilizes the flexible braid, ensuring accurate alignment and maintaining stable positioning during the laser welding process, thereby achieving both high productivity and high joining accuracy
Solution Approach 2:
A positioning structure or fixture acts as an intermediary between the flexible shield braid and the shield terminal. This intermediary component provides stable positioning and support for the braid, enabling precise laser welding without requiring complex jigs while maintaining joining accuracy
2Reliability
If the overlapping portion of the shield braid and conductive member is laser-welded, then joining can be achieved, but heat energy is transmitted to the periphery causing low welding efficiency
Solution Approach 1:
The laser welding process is segmented into multiple localized welding points along the overlapping portion of the shield braid and conductive member. By dividing the continuous welding into discrete segments, heat energy is concentrated at each welding point rather than being dispersed, reducing heat transmission to the periphery and improving welding efficiency while maintaining connection reliability
Solution Approach 2:
The welding strategy applies local quality by concentrating laser energy only at the specific welding points where the shield braid overlaps with the conductive member, rather than heating the entire overlapping region. This localized heating approach minimizes heat transmission to surrounding areas, reducing energy loss and improving welding efficiency
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
This configuration enables high-reliability connections with reduced takt time and cost by improving positioning accuracy and minimizing heat energy escape, allowing efficient laser welding without increasing irradiation time or power, thereby enhancing the connection process.
Implementation Method 1
the welded portion is laser-welded onto the braid
Data Source
AI summary
A braided part connection structure includes a conductive braid and a conductive member electrically connected and fixed to the braid and made of a conductive plate material. The conductive member includes a braid joining portion. The braid joining portion includes, at a part of the conductive member in a longitudinal direction of the conductive member, a plurality of openings formed at intervals with each other along a direction intersecting the longitudinal direction and a welded portion defined by two adjacent openings of the plurality of openings. The braid joining portion is provided on the braid in an overlapping manner and the welded portion is laser-welded onto the braid.