Crimped Welded Joint for Stranded Wire Connection Reliability
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Solution Overview
Problem
Existing methods for connecting stranded wires with a large cross-section or numerous individual wires to connection elements are unreliable and prone to failure under high mechanical loads due to random wire alignment during welding, leading to inconsistent resistance and durability.
Innovation Solution
A method involving crimping the stranded wire into a cylindrical blind hole of the connection element followed by welding, ensuring consistent wire alignment and improved attachment strength, with ultrasonic welding for a secure and efficient bond.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If stranded wire is welded to a flat contact surface, then welding speed is improved, but connection reliability deteriorates due to random wire alignment
Solution Approach 1:
The stranded wire is inserted into the crimping recess before welding, pre-positioning the individual wires in a controlled manner against the side wall. This preliminary action ensures proper wire alignment is achieved before the welding process begins, resolving the random alignment issue while maintaining welding efficiency
Solution Approach 2:
The invention transitions from welding to a flat contact surface (2D plane) to welding against a side wall of a crimping recess (3D structure). This dimensional change allows the wires to be constrained in multiple directions, ensuring consistent alignment and contact during welding
2Strength
If crimping force is increased for large cross-section stranded cables, then connection strength is improved, but manufacturing complexity increases
Solution Approach 1:
The connection process is divided into two distinct stages: crimping followed by welding. The crimping stage provides initial mechanical holding, while the welding stage creates the final strong bond. This segmentation allows each process to be optimized independently, achieving high strength without excessive crimping complexity
Solution Approach 2:
The invention combines crimping and welding into a single integrated connection process. The crimping recess serves both as a positioning feature for the wires and as part of the final connection structure. This merging simplifies the overall manufacturing process while achieving the desired connection strength
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
The crimp-welded connection provides enhanced durability and reliability, reducing contact resistance and maintaining stability under high loads, with improved tensile strength and resistance to vibrations.
Implementation Method 1
a form-fitting connection which is produced in a first process step by crimping the end of the stranded wire received in the crimping recess with the connection element
Implementation Method 2
the end of the stranded wire received in the crimping recess is welded to the connection element in a second process step
Data Source
Figure 1
Figure 2a~3b
AI summary
The invention relates to a method for producing a permanent mechanical and electrical connection between a stranded wire and a connecting element, one end of the stranded wire being welded to the connecting element, the end of the stranded wire being introduced into a crimping recess of the connecting element prior to welding, and the connecting element being additionally crimped with the stranded wire. The invention further relates to crimped welded joints produced using said method.