Hot-Crimp Welding Segment Control for Stable Wire Connections
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for producing hot-crimp connections between metals are hindered by inaccuracies in measuring control parameters like resistance, current, temperature, pressing force, and sinking path, leading to fluctuations in quality and instability in the connection process, especially due to the inability to directly monitor the connection zone and compensate for material properties and electrode variations.
Innovation Solution
The method divides the hot-crimp connection process into multiple segments with specific parameter sets for each stage, using switch-off heights and energy/charge as criteria to control the process, allowing for precise adjustment of current and pressing force, and incorporating a pre-crimp phase for optimal metallurgical bonding, thereby ensuring a stable and strong connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional single-stage hot-crimp process is used, then production speed is maintained, but connection quality fluctuates and stability is poor
Solution Approach 1:
The hot-crimp connection process is divided into multiple segments (first segment, second segment, third segment) with distinct parameter sets for each. The first segment uses initial pressing force and current for heating, the second segment adjusts parameters for metallurgical bonding, and the third segment applies final pressing for cooling and stabilization. This segmentation enables precise control of connection quality at each stage while maintaining overall process efficiency.
2Measurement precision
If monitoring of connection zone is attempted, then quality control improves, but measurement accuracy is insufficient
Solution Approach 1:
The patent uses measurable intermediary parameters (pressing force, current, temperature, sinking path) that can be accurately monitored externally to indirectly assess the connection zone state. By controlling and monitoring these intermediary variables, the system achieves precise quality control without requiring direct measurement of the inaccessible connection zone, thereby resolving the measurement accuracy problem.
3Reliability
If material variations are compensated, then connection stability improves, but process complexity increases
Solution Approach 1:
The patent applies different parameter sets tailored to specific stages of the connection process. Each segment (heating, bonding, cooling) has optimized pressing force, current, and time parameters that account for material behavior at that particular stage. This localized parameter optimization compensates for material variations without requiring complex real-time adjustment mechanisms, as each segment is designed to handle specific material states.
4Manufacturing precision
If multi-stage process with parameter adjustment is implemented, then connection quality improves, but production time increases
Solution Approach 1:
The multi-stage hot-crimp process is designed as a continuous operation where the workpiece transitions seamlessly from the first segment through the second segment to the third segment without interruption. The pressing force and current are continuously adjusted according to the stage, but the process flow remains uninterrupted. This continuous operation maintains high production speed while achieving precise quality control through staged parameter optimization.
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 multi-stage process ensures a long-term stable, materially bonded connection with improved reproducibility and quality, compensating for material and dimensional variations, and enabling traceability and process optimization by monitoring heat equalization and energy input in each segment.
Implementation Method 1
a hot-crimp connection (17) between a shaped part (1) and at least one wire (2) and/or at least one strand (3) with at least two wires (2) made of metals
Implementation Method 2
The curve is calculated from the quotient of the measured voltage and the measured current. Since a direct measurement of the voltage in the connection zone is not technically feasible, the measured voltage values are falsified by the contact resistances of the components and electrodes and by the material resistances of the components and electrodes
Data Source
AI summary
A method for producing a hot-crimp connection includes the following metallurgically different steps that are run through sequentially: Segment 1: Producing a first connection between the shaped part and the outer layer of the wires and/or stranded wires by a complete and/or partial eutectic melting process of the outer wires which have been freed by the concurrently proceeding compaction and/or predeformation of an insulating layer, Segment 2: Producing a diffusion bond and/or an at least partial fusion bond between the inner wires of the strand which have been freed from the insulating layer by the compaction, Segment 3: Currentless cooling of the hot-crimped bond, a switchover taking place between at least two successive segments after a segment-specific height position has been reached and/or energy/charge has been fed in.