Laser Compaction Welding of Stranded Conductor Ends

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Solution Overview

Problem

Conventional methods for preparing stranded conductors for laser welding require multiple steps and tools, leading to increased costs and inefficiencies due to the need for deburring and achieving a flat front face.

Innovation Solution

A method and device that use a laser beam source to compact and weld the strands of a stranded conductor, eliminating the need for separate tools and steps by using gripping jaws to compress the strands and then weld them together using the same laser beam source.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If multiple separate tools and steps are used to prepare the conductor end (stripping, compacting, deburring), then a flat front face suitable for welding is achieved, but the process complexity and manufacturing costs increase significantly

Engineering Contradiction:

Improveflatness of front faceVSAvoidnumber of tools and process steps

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent combines multiple separate preparation steps (stripping, compacting, and deburring) into a single integrated laser processing step. The laser beam performs all three functions sequentially on the conductor end without requiring separate mechanical tools, thereby reducing device complexity while maintaining the required flatness for welding.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The laser beam source is used to perform multiple functions: stripping the insulation, compacting the strands through controlled melting and resolidification, and deburring the front face. This multi-functional approach eliminates the need for multiple specialized tools, resolving the contradiction between achieving precise flatness and reducing process complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Quantity of substance

If conventional mechanical compacting is used to compress strands, then strand gaps are reduced, but the front face becomes uneven and requires additional deburring steps

Engineering Contradiction:

Improvestrand compaction densityVSAvoidflatness of front face

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The patent replaces the mechanical compacting process with a laser-based process. The laser beam selectively melts and resolidifies the strand ends, causing them to fuse and compact into a dense, flat structure in a single step. This substitution eliminates the uneven front face problem associated with mechanical compacting while achieving the required compaction density.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If the conductor end is prepared with minimal processing, then process time and costs are reduced, but insufficient contact surface area results in poor welding quality and increased contact resistance

Engineering Contradiction:

Improvepreparation process speedVSAvoidwelding quality and electrical contact

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The laser processing performs preliminary actions (stripping, compacting, and deburring) in a single integrated step before welding. This preliminary preparation creates the optimal surface condition for welding, ensuring sufficient contact surface area and low contact resistance while maintaining high productivity through the efficiency of the single-step process.

Inventive Principle:

Principle #10Preliminary action

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 reduces the number of work steps, minimizes material waste, and lowers costs by enabling the preparation and welding of stranded conductors in a single, unified process using a single tool.

Implementation Method 1

a laser beam source (12) is provided for laser welding

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

the strands (8) are at least partially melted by the laser beam source (12)

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 3

the gripping jaws (10) are moved towards each other so that the strands (8) between the gripping jaws (10) are mechanically compressed in a radial direction

Methodology Applied

Scientific EffectMechanical compression: Compression

Data Source

PatentUS12330234B2Method and apparatus for processing an electrical conductor

Publication Date: 2025.06.17 AUTO KABEL MANAGEMENT GMBH

AI summary

Method for processing an electrical conductor, in which a bare conductor end of a stranded conductor is provided, the strands of the bare conductor end are gripped at least partially circumferentially by gripping jaws, the strands are at least partially compacted in the region of the conductor end by the gripping jaws, and the compacted strands are welded to one another with the aid of a laser beam source in the region of the gripping jaws, through the gripping jaws.