Laser Welding Conductors With Bead Preforming for Zero-Gap Contact
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Solution Overview
Problem
The existing welding processes for conductors on workpieces require significant force to maintain contact due to insulation, leading to inefficient mechanical contact and potential gaps during laser welding, which can compromise the quality of the weld.
Innovation Solution
A bead is formed in the stripped region of the conductor to reduce the distance between the conductor and workpiece, allowing for initial mechanical contact and subsequent deformation during laser welding to achieve a secure, zero-gap connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the conductor is held down with significant force to overcome the insulation distance, then mechanical contact is achieved, but the holding-down devices become complex and the process becomes less efficient
Solution Approach 1:
A bead is formed in the stripped region of the conductor before welding to preliminarily reduce the distance between the conductor and workpiece. This preliminary deformation ensures that during holding down, the conductor makes contact with the workpiece more easily, reducing the complexity requirements of holding-down devices while maintaining reliable mechanical contact
2Reliability
If the conductor is held down with significant force to overcome the insulation distance, then mechanical contact is achieved, but the necessary holding force increases
Solution Approach 1:
The bead is formed in advance in the stripped region to preliminarily bridge the gap created by insulation. This reduces the distance that needs to be overcome during holding down, thereby reducing the necessary holding force while still achieving reliable mechanical contact for welding
3Reliability
If the conductor is held down firmly to ensure contact, then welding quality improves, but the process time increases due to higher holding forces required
Solution Approach 1:
The bead formation preliminarily positions the conductor closer to the workpiece surface in the stripped region. This reduces the holding force needed to maintain contact during welding, allowing for faster cycle times and improved productivity while maintaining weld quality through reliable mechanical contact
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 welding process by reducing the necessary force for holding down the conductor, ensuring direct contact and improving the quality of the weld through thermal expansion, resulting in a more secure and efficient connection.
Implementation Method 1
a bead is created in a stripped region of the conductor... the conductor is displaced in the direction of the workpiece... the necessary deforming of the conductor already taking place during the forming of the bead
Implementation Method 2
a laser welding of the conductor onto the workpiece takes place in the welding region
Implementation Method 3
The thermal expansion of the conductor during the laser welding in the welding region has the effect that the conductor is deformed in such a way that the conductor subsequently lies in contact with the further welding region
Data Source
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AI summary
The present invention relates to a welding method in which a conductor is welded to a workpiece. The conductor comprises a first metal and the workpiece comprises a second metal. At first, an isolation of the conductor is removed at a predetermined length. Subsequently thereto, a bead is formed in a stripped region of the conductor. Subsequently, the conductor is held down on the workpiece wherein a mechanical contact with the welding region between the conductor and the workpiece is formed by the process of holding down. The welding region is in this context arranged in the area of the bead. Subsequently, the conductor is welded to the workpiece in the welding region by means of laser welding.