Modular Backshell Housing Friction Welding
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Solution Overview
Problem
The production of backshell housings with varying sizes and shapes requires different dies or molds, increasing production costs due to the need for multiple tooling setups.
Innovation Solution
A backshell housing composed of two housing parts friction welded together, allowing for customizable orientations and configurations without additional components like adhesives, which can be manufactured using standardized parts and reduced tooling, enabling various designs without the need for multiple dies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different dies or molds are used for every variation of backshell housing, then customization of size and shape is achieved, but production costs increase
Solution Approach 1:
The backshell housing is divided into multiple standardized segments or modules that can be assembled in different configurations. This segmentation allows customization of size and shape by combining different numbers and types of modules, while each module itself is manufactured using a single standardized die or mold, thereby reducing tooling costs.
Solution Approach 2:
A universal base module is designed that can serve multiple functions and be configured in various arrangements to create different backshell housing variations. This universal module is manufactured using a single die or mold, and through different assembly configurations, multiple customized housing designs are achieved without requiring separate tooling for each variation.
2Ease of manufacture
If a single die or mold is used for all backshell housing variations, then production costs decrease, but customization of size and shape is limited
Solution Approach 1:
The housing is segmented into standardized components that can be mixed and matched. Each segment is produced using the same die or mold, keeping manufacturing simple and costs low, while the segments can be combined in various ways to achieve customized sizes and shapes for different applications.
Solution Approach 2:
The design incorporates adjustable or reconfigurable elements within the standardized modules, allowing the effective dimensions and configuration of the backshell housing to be dynamically adapted for different applications while maintaining the same basic manufacturing tooling.
3Ease of operation
If adhesive components are used to join housing parts, then assembly is simplified, but joint strength and reliability decrease
Solution Approach 1:
The patent replaces chemical bonding (adhesives) with mechanical bonding methods such as friction welding, ultrasonic welding, or interference-fit mechanical joints. These mechanical connection methods provide superior joint strength and reliability while maintaining assembly simplicity through standardized joining features integrated into the modular components.
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 manufacturing costs and enables the production of diverse backshell housing configurations with enhanced strength and reliability, as the friction welding method provides a strong and gap-free joint, suitable for different applications.
Implementation Method 1
a first housing part and a second housing part friction welded to one another
Data Source
AI summary
A backshell housing includes a pair of housing parts including a first housing part and a second housing part friction welded to one another. A cable passage of the first housing part is continuous with a cable passage of the second housing part.