Cable-to-Terminal Welding Fixture for Consistent Contact Height
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Solution Overview
Problem
Existing wiring systems face challenges in maintaining consistent vertical distance between contact surfaces across different batches of electric cables due to varying orientations of stranded wires, requiring frequent machine resets during production.
Innovation Solution
A method involving an electric cable with distinct sub-portions, where insulation is removed from one portion and remains on another, allowing for precise welding and compression to maintain consistent positioning, eliminating the need for machine resets by using a holding device to support the cable during welding, ensuring a defined distance and reliable sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the cable insulation is completely removed from the electric conductor, then the welding process can be performed, but the vertical distance between contact surfaces varies greatly across different batches, requiring frequent machine resets
Solution Approach 1:
The cable insulation is selectively removed only from the first sub-portion of the electric conductor that requires welding, while the second sub-portion retains its insulation. This localized approach allows the welding area to have different properties (exposed conductor) from the sealing area (insulated conductor), resolving the contradiction between welding accessibility and positioning precision.
Solution Approach 2:
The holding device acts as an intermediary element that clamps onto the insulated second sub-portion of the cable. This intermediary provides a stable reference point for positioning, ensuring that the vertical distance between contact surfaces remains consistent across different cable batches without requiring machine resets.
2Manufacturing precision
If the cable is held fixed during welding, then the position of the second sub-portion is maintained, but additional device complexity is introduced
Solution Approach 1:
The holding device utilizes the cable's own insulated second sub-portion as part of its clamping mechanism. By designing the holding device to clamp onto the insulated portion, the cable itself becomes part of the positioning system, reducing the need for additional complex external positioning mechanisms.
3Reliability
If the first sub-portion is compressed during welding, then reliable electrical connection is achieved, but the cable structure may be deformed
Solution Approach 1:
Compression is applied only to the first sub-portion during welding, while the holding device maintains the shape and position of the second sub-portion. This localized compression ensures reliable electrical connection at the welding point without deforming the overall cable structure or the sealed second sub-portion.
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 method allows for consistent and cost-effective manufacturing of wiring systems without the need for frequent machine adjustments, ensuring reliable electrical and mechanical connections even under high vibrations, and maintaining a precise distance between contact surfaces.
Implementation Method 1
U.S. Pat. No. 6,854,637 B2 discloses a wiring system in which the electric conductor is in each case ultrasonically welded on both sides of a contact surface
Data Source
AI summary
A method for manufacturing a wiring system includes providing an electric cable having an electric conductor and a contact element with a termination portion, and removing a cable insulation in a first sub-portion of the electric cable. The cable insulation remains on the electric conductor in a second sub-portion of the electric cable offset from the first sub-portion. The electric conductor is welded at the first sub-portion to a termination surface of the termination portion. The first sub-portion is pressed against the termination portion and compressed during welding. A holding device encompasses the second sub-portion at least partially. The holding device supports the second sub-portion at least during the welding and compressing of the first sub-portion and maintains a position of the second sub-portion.