Ultrasonic Compression of Braided Conductors Using Polygonal Chamber
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Solution Overview
Problem
The existing ultrasonic compaction methods for strands result in a rectangular cross-section that is often too large for circular contact terminals, making it difficult to install cables safely and efficiently due to the diagonal diameter being larger than the circular mount.
Innovation Solution
The use of a compression chamber with a polygonal shape, specifically octagonal, in the sonotrode and anvil, which approximates a circular cross-section, allowing for easier insertion and contact, along with a corrugated structure for efficient vibration transmission and counter-pressure, and varying cross-sectional areas for uniform compaction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a rectangular compression chamber is used for ultrasonic compaction, then the compaction process is simple and effective, but the resulting strand cross-section has a large diagonal diameter that does not fit well in circular contact terminals
Solution Approach 1:
The compression chamber cross-section is changed from rectangular to polygonal (e.g., hexagonal or octagonal), which approximates a circular shape. This allows the compacted strands to have a smaller maximum diameter that fits better in circular contact terminals, while still maintaining straight counter surfaces for effective compression.
2Shape
If the compression chamber cross-section is changed to polygonal shape, then the strand diameter is reduced for better fitting, but the complexity of the anvil and sonotrode increases
Solution Approach 1:
The anvil is divided into multiple segment pieces that can be assembled together to form the polygonal compression chamber. This segmentation allows the complex polygonal shape to be constructed from simpler modular components, reducing manufacturing complexity while maintaining the desired cross-section shape.
3Ease of operation
If strands are inserted into narrow circular receptacles, then connection is achieved, but the flexible individual wires bend and fray during insertion
Solution Approach 1:
The strands are pre-compacted into a polygonal cross-section before insertion, which reduces their maximum diameter and creates a more rigid structure. This preliminary shaping prevents the individual wires from bending and fraying during the insertion process into narrow circular receptacles.
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 solution simplifies and secures the insertion of compacted strands into contact terminals by reducing the maximum diameter to a circular shape, ensuring safer and quicker cable installation by adapting the cross-section to fit conventional receptacles.
Implementation Method 1
The vibrations of the sonotrode are transmitted to the strands via a corrugated structure of the wall of the compression chamber
Implementation Method 2
This high-frequency oscillation causes sufficient heat to be generated between the individual wires of a strand of a cable due to the friction process and contact pressure
Implementation Method 3
This high-frequency oscillation causes sufficient heat to be generated between the individual wires of a strand of a cable due to the friction process and contact pressure, so that the individual wires are cold-pressed together
Data Source
Figure 1~2
Figure 3~6
AI summary
Cables or conductors (16) with strands (14), manufactured in an arrangement (1) for ultrasonic compaction of strands (14) with an anvil (2) and a sonotrode (4), wherein the anvil (2) and the sonotrode (4) each have a chamber section (8a, 8b) which is configured such that the chamber sections (8a, 8b) of the anvil (2) and the sonotrode (4) form a common compaction chamber (6) for receiving the strands (14) during ultrasonic compaction, are intended to enable particularly easy and therefore also quick and safe installation in terminal blocks or other cable receptacles. For this purpose, the compaction chamber (6) has a cross-section essentially n-gonal with n>4.