Lamella Contact Manufacturing via Parallel Slot Formation
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Solution Overview
Problem
The production of lamellar contacts is associated with high costs and limited production capacity due to the need for multiple work stations on rotary transfer machines, which burdens further production steps and design options.
Innovation Solution
A method for manufacturing lamellar contacts with at least six elementary slots, where the first and second through-slots are parallel and the third through-slot is central or at right angles, reducing the number of stations required on rotary transfer machines by optimizing the sequence of slot formation and rotation, thereby saving time and effort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple through-slots are introduced to form lamellae in the plug-in area, then the electrical connection reliability is improved, but the number of work stations on rotary transfer machines increases and production cost rises
Solution Approach 1:
The invention divides the slot formation process into two segments: first forming two parallel through-slots that extend completely through the contact piece, then forming a third through-slot that connects to these parallel slots. This segmentation allows the lamellae to be formed in a systematic way that ensures reliable electrical connection while optimizing the number of required work stations.
Solution Approach 2:
The two parallel through-slots are formed in advance before the third connecting slot is created. This preliminary action ensures that the basic lamellar structure is already in place, providing a stable foundation for the final slot formation and enabling efficient production planning on rotary transfer machines.
2Manufacturing precision
If multiple work stations are used for slot formation, then the lamellar contact can be produced with proper elasticity, but the production time and effort increase
Solution Approach 1:
The invention merges the formation of multiple slots into a coordinated sequence where two parallel through-slots are formed first, then a third slot connects them. This merging of slot formation operations into an integrated process reduces the total number of separate work stations needed on rotary transfer machines, thereby reducing production time while maintaining proper lamella elasticity.
3Ease of manufacture
If the number of stations on rotary transfer machines is increased to accommodate all work steps, then complete lamella formation is achieved, but further production steps and design options are burdened
Solution Approach 1:
The invention introduces a spatial optimization by arranging two through-slots parallel to each other and a third slot perpendicular to them, forming a three-dimensional slot pattern. This dimensional arrangement ensures complete lamella formation with fewer work stations, reducing production system complexity while maintaining manufacturing completeness.
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 approach significantly reduces production time and effort, allowing for the potential to process two contacts simultaneously, thereby doubling production capacity and reducing overall production costs.
Implementation Method 1
a lamellar contact (2) consisting of an at least slightly elastically deformable metal
Data Source
Figure 1a~1c
Figure 2a~2c
AI summary
In order to produce the single lamellar contact (2) with as little effort as possible, it is proposed to introduce two through slots (D1, D2) parallel to each other and in particular perpendicular to a third through slot (D3) into its hollow cylindrical plugging area (21) to generate the lamellae (22, 22', 22", 22"', 22"",22''''''.