Integrated Electrical Wiring Assembly Laser Cutting Process
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Solution Overview
Problem
Traditional electrical wiring assembly manufacturing processes require managing large inventories of various terminals and cables, leading to inefficiencies and increased costs due to the need for multiple terminal and cable types, and the complexity of attaching them manually.
Innovation Solution
A process involving laser cutting of a copper-based metal sheet to form a forked split blade terminal by cutting an elongate strip, creating a mesial slit and distal projections, and optionally forming an insulative covering, cutting to shape, folding, and bending, which eliminates the need for separate terminals and cables by integrating these functions into a single sheet of material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional processes use separate terminals and cables for electrical wiring assemblies, then functional requirements are met, but inventory management complexity and costs increase significantly
Solution Approach 1:
The patent combines separate terminals and cables into a single integrated electrical wiring assembly. The terminal body, conductive elements, and insulating components are merged into one unified structure that can be produced as a single piece, eliminating the need to manage inventories of multiple separate terminal types and cable varieties.
Solution Approach 2:
The integrated electrical wiring assembly is designed to perform multiple functions within a single component. It provides both terminal connection functionality and cable routing capabilities, replacing the need for separate terminal blocks and cable management components, thereby reducing inventory complexity while maintaining versatility.
2Reliability
If traditional processes use multiple terminal and cable types, then specific electrical requirements are satisfied, but manufacturing time and labor costs increase
Solution Approach 1:
The integrated terminal is designed with modular segments that can be configured to meet different electrical requirements. By segmenting the single piece terminal into functional zones (conductive areas, insulating areas, mounting areas), the design maintains the ability to satisfy specific electrical requirements while streamlining manufacturing to a single-piece process.
Solution Approach 2:
The patent varies parameters such as conductor thickness, terminal dimensions, and material composition within the single-piece terminal design to meet different electrical requirements. This allows customization of electrical characteristics without requiring separate terminal types, thereby reducing manufacturing complexity and time.
3Reliability
If separate terminals are crimped onto cable ends using automatic machines, then connection reliability is achieved, but process complexity and equipment requirements increase
Solution Approach 1:
The terminal body and cable attachment features are merged into a single integrated component. The crimping features, contact elements, and insulating structures are all part of one piece that is formed in a single manufacturing process, eliminating the need for separate crimping operations and reducing process complexity while maintaining connection reliability.
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 process reduces inventory management, simplifies the manufacturing process, and allows for customizable current carrying capabilities by varying the strip width, thereby streamlining the production of electrical wiring assemblies and reducing labor and time costs.
Implementation Method 1
The process includes the steps of cutting an elongate strip from a sheet of metal and cutting a mesial slit in an end of the strip, thereby forming a pair of distal projections flanking the mesial slit. In an example implementation having one or more features of the process of the previous paragraph, the steps of the process are performed using a laser cutting process.
Data Source
AI summary
A process of manufacturing an electrical wiring assembly includes the steps of cutting an elongate strip from a sheet of metal and cutting a mesial slit in an end of the uninsulated segment, thereby forming a pair of distal projections flanking the mesial slit. The mesial slit and the pair of distal projections form a forked split blade terminal.