Embedded-Wire Welding with Reentrance Shaping for Stable Joints
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Solution Overview
Problem
Conventional resistance welding techniques struggle to form high-quality, mechanically stable joints between electrical cables and wires with significant differences in cross-sections and materials, due to positional variance and disparate melting temperatures, leading to poor contact resistance and intermetallic compound formation.
Innovation Solution
A compact embedded-wire welding method involving pre-welding shaping of one wire to create a reentrance for precise positioning of the second wire, followed by a welding process that applies a welding potential difference along the wire's longitudinal length, ensuring homogeneous current distribution and improved contact surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional resistance welding is used to join wires of different cross-sections, then the welding process is simple and cost-effective, but the welding quality and mechanical strength are poor due to positional variance and poor contact
Solution Approach 1:
The patent applies preliminary action by pre-shaping one wire to create a reentrance geometry before welding. This pre-forming step ensures proper positioning and contact between wires of different cross-sections, eliminating positional variance issues during the welding process while maintaining the simplicity of the welding operation itself.
Solution Approach 2:
The patent applies local quality by creating a specific reentrance shape at the contact region of one wire. This localized geometric modification concentrates the contact area and improves current distribution at the critical welding interface, thereby enhancing welding quality without complicating the overall manufacturing process.
2Adaptability or versatility
If conventional resistance welding is used with significant cross-section differences, then the process can handle dissimilar materials, but intermetallic compound formation occurs due to poor contact surfaces
Solution Approach 1:
The patent applies local quality by creating a specific reentrance shape at the contact region of one wire. This localized geometric modification concentrates the contact area and improves current distribution at the critical welding interface, thereby enhancing welding quality without complicating the overall manufacturing process.
Solution Approach 2:
The patent applies parameter changes by modifying the geometric parameters of the wire contact surface through pre-shaping. The reentrance geometry changes the contact pressure distribution and current density parameters, ensuring reliable welding of dissimilar materials by optimizing the thermal and mechanical conditions at the interface.
3Force
If conventional resistance welding is used, then the welding electrodes can apply compression, but the peel force is low due to poor encirclement of the interconnected wires
Solution Approach 1:
The patent applies preliminary action by pre-shaping one wire to create a reentrance geometry before welding. This pre-forming step ensures proper positioning and contact between wires of different cross-sections, eliminating positional variance issues during the welding process while maintaining the simplicity of the welding operation itself.
Solution Approach 2:
The patent applies local quality by creating a specific reentrance shape at the contact region of one wire. This localized geometric modification concentrates the contact area and improves current distribution at the critical welding interface, thereby enhancing welding quality without complicating the overall manufacturing process.
4Productivity
If welding is performed on segments with poor positioning, then the process is fast, but longer welding segments are required to increase mechanical stability
Solution Approach 1:
The patent applies preliminary action by pre-shaping one wire to create a reentrance geometry before welding. This pre-forming step ensures proper positioning and contact between wires of different cross-sections, eliminating positional variance issues during the welding process while maintaining the simplicity of the welding operation itself.
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 enhances the quality and mechanical stability of welded joints by achieving consistent heat generation and intermetallic compound formation, reducing the negative effects of positional variance and material discrepancies.
Implementation Method 1
two electrical cables and/or wires are disposed in an overlapping manner between welding electrodes which will apply a welding current sufficient to generate heat at the overlapping region
Implementation Method 2
the welding electrodes may apply a slight compression to the wires to be welded for reducing the contact resistance at the overlapping surfaces during the welding process
Data Source
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AI summary
A device for compact embedded-wire welding of electrical wires is provided having a set of pre-welding electrodes 100 to pre-shape a cross-section of a first wire segment 110, via compression, with a pre-welding shape which includes a reentrance 115 for accommodating a second wire segment 120 to be welded. In addition, the device also includes a set of welding electrodes 200 for loading the pre-shaped first segment 110 and the second wire segment 120 positioned in the reentrance, and which allow changing the pre-shaped cross-section of the first segment 110 into a welding shape suitable for applying a welding current for welding the first and second segments and achieve an homogenous distribution of welding current densities at the contact surfaces between the first and second segments. A method for compact embedded-wire welding using the sets of pre-welding electrodes 100 and/or welding electrodes 200 is also provided.