Electrical Conductor Strand Welding With Axial Offset Joints
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Solution Overview
Problem
Welding electrical conductors in a raised edge configuration results in welds with small current flow sections, making them difficult to penetrate, and increasing welding energy can lead to conductor destruction.
Innovation Solution
The method involves axially offsetting the free ends of electrical conductors and melting them without adding material, creating a layer of melted material with a variable thickness to increase the current flow section and ensure effective welding without damaging the conductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If welding energy is increased to increase penetration of the weld, then the current flow section increases, but the electrical conductors are destroyed by accumulation of energy
Solution Approach 1:
The free ends of adjacent strands are axially offset by a non-zero distance d before welding, creating a stepped configuration. This preliminary arrangement allows the welding energy to be distributed more effectively, enabling sufficient penetration and current flow section without excessive energy accumulation that would destroy the conductors
Solution Approach 2:
The axial offset distance d is controlled within specific ranges (5%-120% of strand thickness, preferably 10%-100%, better still 15%-80%). By optimizing this geometric parameter, the weld penetration and current flow section are maximized while preventing conductor destruction from energy accumulation
2Ease of manufacture
If welding is performed in raised edge configuration, then the welding process is simplified, but the welds have small current flow sections and are difficult to penetrate
Solution Approach 1:
Instead of welding strands at the same height (symmetric raised edge configuration), the free ends of adjacent strands are axially offset by a non-zero distance d, creating an asymmetric stepped configuration. This asymmetry increases the weld penetration area and current flow section while maintaining process simplicity
Solution Approach 2:
The strands are arranged with axial offset along the elongation axis, adding a dimensional variation to the weld configuration. This axial dimensioning creates overlapping weld zones that increase the effective current flow section without complicating the welding process
3Area of stationary object
If material is added to increase current flow section, then the electrical conductivity improves, but high energy levels destroy the assembly
Solution Approach 1:
The strands themselves provide the material for the weld through their axial offset arrangement. The excess material from the offset configuration is melted to form the weld, eliminating the need for additional filler material and the associated high energy levels that would destroy the assembly
Solution Approach 2:
The axial offset distance d is optimized to provide sufficient excess material for welding without requiring additional material addition. This parameter control enables adequate current flow section while maintaining energy levels that prevent assembly destruction
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 approach allows for efficient welding of electrical conductors without additional material, reducing the risk of conductor destruction and ensuring good electrical conductivity by increasing the area of the current flow section.
Implementation Method 1
melting the free ends of the strands thus arranged in order to weld them without addition of material
Data Source
AI summary
A method for welding a plurality of strands of one or more electrical conductors comprises at least the following steps: (a) preparing the strands to be welded such that at least the free ends of adjacent strands are axially offset by a non-zero distance d; and (b) melting the free ends of the strands thus arranged in order to weld them without addition of material.