Connector Terminal Piercing Force Control
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Solution Overview
Problem
Existing methods for connecting connector terminals with flat conductors face challenges in achieving a firm connection due to the miniaturization of electronic parts, leading to potential instability in the connection.
Innovation Solution
The method involves adjusting the connection state by controlling the terminal reaction force acting on the piercing piece and the flat conductor, specifically by managing the pressing reaction force between 30 to 80 N/mm2, through adjustments in the clearance between the punching jig and the piercing piece, and the shape of the piercing piece's edge, ensuring a stable connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the piercing piece is used to connect connector terminal with flat conductor, then the connection can be achieved, but the connection becomes unstable due to miniaturization of electronic parts
Solution Approach 1:
The invention changes the parameters of the piercing piece by optimizing its thickness, edge shape (acute angle at the tip), and material properties to generate adequate terminal reaction force. The piercing piece is designed with specific dimensional parameters that enable it to pierce through miniaturized flat conductors and maintain stable connection despite the reduced size and strength of modern electronic components.
2Manufacturing precision
If the piercing piece pierces through the flat conductor, then connection is established, but the connection state cannot be controlled precisely
Solution Approach 1:
The invention introduces feedback control by measuring the terminal reaction force generated during piercing and using this information to adjust the connection process. A sensor detects the reaction force, and this signal is fed back to control the pressing mechanism, ensuring the piercing piece achieves optimal penetration depth and connection strength without excessive force that could damage the miniaturized conductor.
3Strength
If the pressing reaction force is increased to improve connection, then connection strength improves, but the conductor may be damaged
Solution Approach 1:
The invention employs dynamic control of the pressing force during the piercing process. The pressing mechanism adjusts the reaction force in real-time based on feedback from sensors that monitor the piercing progress and terminal reaction force. This dynamic adjustment ensures sufficient connection strength is achieved while preventing excessive force that could damage the miniaturized flat conductor, optimizing the balance between connection strength and conductor integrity.
Data Source
AI summary
A method is provided for firmly connecting a connector terminal to a flat conductor. This is a method for electrically connecting the pierce terminal 20 having pierce blades 21 that pierce through the flat conductor 102 with the flat conductor 102 by the pierce blades 21, in which the connection state is adjusted based on a terminal reaction force R acting on the pierced blade 21a by a ruptured end surface 102a of the flat wiring conductor 102. The adjustment of the terminal reaction force R is made by adjusting a pressing reaction force F/A generated when the pierce blade 21 pierces through the flat wiring conductor 102.