Electrical Contact System Self-Positioning Welding
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Solution Overview
Problem
Existing contact systems require auxiliary devices for precise positioning and holding during welding, leading to complex and costly production processes, especially in applications like the automotive and aeronautical sectors where high accuracy and reproducibility are crucial, and there is a need for material-efficient and weldable connections without the need for external fixation.
Innovation Solution
A mechanical pre-fixing process is employed where one contact element is slidably mounted on another, using a fixing element with U-shaped arms to ensure precise alignment and a welding dome for targeted energy introduction, allowing for a material-locking connection without external devices, and the contact elements are produced in one piece through stamping and bending for efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If auxiliary devices are used for positioning and holding contact parts during welding, then positional accuracy and reliability are improved, but device complexity and production costs increase
Solution Approach 1:
The patent combines the positioning function and the contact part function into a single integrated component. The contact part itself is designed with geometric features (such as tapered sections, complementary shapes) that enable self-positioning and self-holding during the welding process, eliminating the need for separate auxiliary positioning devices and simplifying the production process.
Solution Approach 2:
The contact part is designed to perform its own positioning and holding functions through its inherent geometric structure. The self-positioning capability is achieved through features like tapered sections that guide alignment, and complementary shapes that provide automatic mechanical interlocking, allowing the component to secure itself without external assistance.
2Strength
If conventional welding methods are used for connecting contact parts, then material-locking connections are achieved, but the need for holding devices and positional control increases complexity
Solution Approach 1:
The patent merges the connection function and the positioning function into a single integrated design. The contact parts are shaped with complementary geometries that automatically align and hold each other in the correct position, allowing conventional welding methods to be applied directly without additional holding devices or complex positional control systems.
3Adaptability or versatility
If contact parts are produced as separate components requiring assembly, then flexibility in material selection is improved, but production complexity and costs increase
Solution Approach 1:
The patent segments the contact system into contact parts with standardized geometric features for self-positioning, while allowing flexibility in material selection for different applications. The segmented design with self-positioning capabilities enables efficient production through simplified assembly processes, resolving the conflict between material versatility and production efficiency.
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 eliminates the need for external fixation devices, ensuring high positional accuracy and reliability while optimizing material usage and weldability, resulting in a cost-effective and efficient production of electrical contact systems with secure connections.
Implementation Method 1
a fixing element (12) which preferably has two fixing arms (12a, 12b) and is more preferably bent in a U-shape, specifically for holding and fixing a holding section (22) of the second contact element (20) in a encompassing manner
Implementation Method 2
the first contact element (10), preferably a flat contact element, is, so to speak, slidably mounted on the second contact element (20) and encompasses it
Implementation Method 3
two welded connection sections (11, 21) which are designed in such a way that they can be brought into contact with one another and in order to be able to connect the contact elements (10, 20) to one another in a material-locking manner
Implementation Method 4
establishing a material connection on the two welded connection sections (11, 21) in each case for the permanent connection of the contact elements (10, 20) fixed to one another
Data Source
Figure 1~2
AI summary
The present invention relates to a contact system comprising an electrical welding contact element and a further contact part, and to a method for manufacturing the contact system comprising the electrical welding contact element and the further contact part, in particular a flat contact or a contact tongue of a flat contact grid.