Broach Stripping Apparatus for Electrical Bar Conductors
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Solution Overview
Problem
Existing methods for stripping electrical bar conductors, such as abrasive grinding, suffer from poor processing accuracy, leading to incomplete removal of insulating material or excessive reduction of the conductor section, which can result in impaired welding and increased risk of conductor breakage during machine operation, and generate scrap that complicates cleaning.
Innovation Solution
A stripping apparatus comprising a first and second stripping station with broaches and calibrated plates that remove insulating coating from electrical bar conductors with precision, ensuring complete removal while minimizing deformation and scrap production, utilizing a combination of cantilevered and guided broaches with cutting edges and actuating mechanisms for controlled removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If abrasive grinding wheels are used to strip insulating material, then the stripping operation can be performed, but processing accuracy deteriorates leading to incomplete removal or excessive reduction of conductor section
Solution Approach 1:
The patent replaces the abrasive grinding mechanical system with a precision mechanical cutting system using broaches. The broaches have precisely positioned cutting edges that mechanically cut through the insulating coating without the material removal variability of grinding, thereby achieving consistent processing accuracy while preserving conductor integrity.
Solution Approach 2:
The patent changes the stripping mechanism from abrasive removal to precision cutting with controlled depth. The broach cutting edges are positioned at a precise depth relative to the conductor surface, controlling the amount of material removed to exactly match the insulating coating thickness, thus preventing both incomplete removal and excessive conductor section reduction.
2Manufacturing precision
If abrasive grinding is used for stripping, then insulating material can be removed, but conductor section is excessively reduced increasing breakage risk
Solution Approach 1:
The broach cutting edges are pre-positioned at a specific depth that corresponds exactly to the insulating coating thickness before the stripping operation begins. This preliminary positioning ensures that when the broach engages the conductor, the cutting edges automatically stop at the correct depth, preventing excessive removal of conductor material and preserving structural strength.
Solution Approach 2:
The patent transitions from an abrasive process with variable material removal to a precision cutting process with controlled depth parameter. The broach design incorporates fixed cutting edge positions that define the maximum depth of cut, ensuring consistent removal of only the insulating coating without encroaching on the conductor's resistive section.
3Manufacturing precision
If grinding is used for stripping, then insulating coating can be removed, but scrap projection is generated complicating cleaning
Solution Approach 1:
The patent replaces the abrasive grinding system that generates scattered scrap particles with a precision cutting system using broaches. The cutting edges cleanly sever the insulating coating, causing it to detach as controlled fragments rather than scattering as fine projection, thereby eliminating the cleaning complications associated with ground scrap.
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
The apparatus achieves high processing accuracy and rapid removal of insulating coating, ensuring complete stripping without residues and minimizing scrap, thereby enhancing the reliability of subsequent welding operations and maintaining a clean environment.
Implementation Method 1
a first pair of broaches (40), opposite to one another and arranged at opposite sides relative to the bar conductor (8), broaches (40) being axially movable relative to a cross working direction Y-Y perpendicular to the prevailing extension X-X and parallel to said longer sides (12), so as to remove by interference the insulating coating (20) on said longer sides (12) at the same time
Data Source
Figure 1
Figure 2~3a
Figure 3b
AI summary
Stripping apparatus (4) for an electrical bar conductor (8) having a metal core with two longer sides (12) and two shorter sides (16) coated with an electrically insulating coating (20). The apparatus (4) comprises a first stripping portion (24) that at least partly houses the conductor (8) arranged along a prevailing extension (X-X), so as to rest on one of said longer sides (12) cantilevered relative to a pair of supports (28). The first stripping station (24) houses a first pair of broaches (40), opposite to one another and arranged at opposite sides relative to the conductor (8), said broaches (40) being axially movable relative to a cross working direction (Y-Y) perpendicular to the prevailing extension (X-X). The broaches (40) are aligned with said stripping portion (36) relative to the prevailing extension (X-X), so as to carry out the removal of the insulating coating (20) at the stripping portion (36) comprised cantilevered between the supports (28).