Contact Strip Forming for Precise Weld Stud Geometry
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Solution Overview
Problem
Existing methods for producing contact elements from endless contact strips are inflexible, costly, and lack precision, requiring different supply rolls for varying contact element types and offering no pre- or post-processing options to improve welding and geometric dimensional accuracy.
Innovation Solution
A method using a uniform endless belt that can be cut and formed into various configurations, allowing for quick and cost-effective production of contact elements with adjustable cross-section, shape, and welding geometry, using interchangeable cutting-embossing tools and a joining film for efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If different supply rolls with type-specific contact strips are used for different contact element types, then the contact elements can be produced with correct geometry, but the device complexity and production flexibility deteriorate
Solution Approach 1:
The patent uses a single universal supply roll containing contact strip with a basic geometry that can be formed into different target geometries. This replaces multiple type-specific supply rolls, reducing device complexity while maintaining manufacturing precision through the forming process that adapts the basic geometry to various contact element requirements.
Solution Approach 2:
The patent separates the contact strip production into two independent stages: (1) production of a basic geometry contact strip from a universal supply roll, and (2) forming of the basic geometry into target geometries using forming devices. This segmentation allows the supply roll to remain simple and universal while achieving diverse contact element geometries through the forming stage.
2Manufacturing precision
If type-specific supply rolls are used for different contact element types, then the contact elements can be produced with correct welding lug geometry, but the adaptability and production flexibility deteriorate
Solution Approach 1:
The universal supply roll contains contact strip that can be formed into various target geometries including different welding lug configurations. This single supply roll replaces multiple type-specific rolls, enhancing adaptability while maintaining welding lug geometry precision through the forming process that creates the specific welding lug patterns from the basic geometry.
Solution Approach 2:
The patent introduces dynamic adaptability by using forming devices that can be adjusted or replaced to create different target geometries from the same basic geometry contact strip. This allows the production system to adapt to different contact element types without changing the supply roll, improving versatility while maintaining geometric precision.
3Device complexity
If a uniform basic geometry contact strip is used for all contact element types, then the device complexity is reduced, but the manufacturing precision of target geometry deteriorates
Solution Approach 1:
The patent segments the geometry creation process into two independent functions: the supply roll provides the basic geometry, and the forming devices create the target geometry. This segmentation allows the supply roll to remain simple and uniform, reducing device complexity, while the forming stage ensures high manufacturing precision of the target geometry through dedicated forming operations.
Solution Approach 2:
The patent performs preliminary preparation by producing contact strip with a basic geometry that is optimized for the forming process. This basic geometry serves as a versatile precursor that can be efficiently transformed into various target geometries, ensuring that the simplification of the supply roll does not compromise the final manufacturing precision through proper preliminary configuration.
4Manufacturing precision
If multiple type-specific supply rolls are maintained for different contact elements, then the geometric accuracy is maintained, but the loss of time for changing supply rolls increases
Solution Approach 1:
The universal supply roll eliminates the need to change between multiple type-specific rolls when producing different contact element types. A single supply roll can produce various contact element geometries through the forming process, completely eliminating supply roll change time while maintaining geometric accuracy through the forming operations that create precise target geometries from the basic geometry.
Solution Approach 2:
By separating the geometry specification function (handled by the universal supply roll with basic geometry) from the geometry transformation function (handled by the forming devices), the patent eliminates the need to change supply rolls for different contact element types. The forming devices are adjusted or replaced instead, which takes significantly less time, thereby eliminating supply roll change downtime while maintaining manufacturing precision.
Data Source
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Figure 2
Figure 3A~5E
AI summary
A method for manufacturing contact elements for electrical contacts from an endless contact strip, which contact elements (15) have a target cross-section, target shape and/or target weld stud geometry, comprises the following process steps: - providing an endless strip (11) with a basic shape deviating from the target cross-section, target shape and/or target weld stud geometry, - cutting a strip piece forming the contact element (15) from the endless strip (11) and forming the strip piece into the contact element (15) with the target cross-section, target shape and/or target weld stud geometry, and - applying the contact element (15) to a carrier strip (21).