Power Distribution Wire with Non-Circular Cross-Section for Bending Accuracy
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Solution Overview
Problem
Existing methods for manufacturing power distribution components using round metallic wires face challenges in achieving precise dimensional accuracy and form accuracy due to additional processing required for forming non-circular cross-sections, which can lead to inferior bending angles and positional inaccuracies, and difficulties in preventing rotation and displacement during assembly.
Innovation Solution
A method involving linear correction, cross-section non-circular portion formation, bending, and integral resin attachment, where the wire is processed to include flat surfaces for improved surface contact and reduced rotation, allowing for precise three-dimensional shaping without additional processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a round metallic wire is used as a power line, then flexibility and ease of bending are improved, but rotation and displacement occur during fastening to terminals
Solution Approach 1:
The patent applies asymmetry by changing the cross-sectional shape of the power line from circular to non-circular (such as D-shaped or flattened). This asymmetric shape prevents rotation during fastening to terminals while maintaining the flexibility advantages of the round wire. The non-circular cross section ensures that the wire can only be inserted in one orientation, eliminating the rotation problem that occurs with circular cross sections.
2Reliability
If a jig crushes a predetermined portion of the power line to form a non-circular cross section, then rotation is suppressed, but dimensional accuracy and form accuracy deteriorate
Solution Approach 1:
The patent applies preliminary action by forming the non-circular cross section at the very beginning of the wire drawing process, before any subsequent processing or assembly steps. The wire is drawn through a non-circular die to create the asymmetric cross section inherently, rather than attempting to deform an already-formed circular wire. This preliminary formation ensures that the wire maintains its specified dimensional accuracy and form throughout subsequent handling and assembly operations.
3Reliability
If additional processing is performed to form non-circular cross-section, then rotation is prevented, but manufacturing complexity increases
Solution Approach 1:
The patent applies merging by combining the cross-section formation and the rotation prevention function into a single integrated process step. The non-circular cross section is formed inherently during the wire drawing operation itself, merging the shaping function with the rotation prevention function. This eliminates the need for separate crushing or deformation steps that would otherwise be required to create the non-circular shape, thereby reducing manufacturing complexity while achieving rotation prevention.
Data Source
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Figure 3
AI summary
There is provided a three-dimensionally shaped round metallic wire having a cross-section non-circular portion in a predetermined portion without performing additional processing and having specified dimensional accuracy and accuracy of form. In an intermediate step in which the round metallic wire is processed in a predetermined three-dimensional shape, a cross-section non-circular portion forming machine 20 which forms the cross-section non-circular portion having a non-circular cross-sectional shape in at least one position is included. At the time of bending, the cross-section non-circular portion is held by a wire holding portion of a bending machine 30, and the bending is performed in the predetermined three-dimensional shape. Holding the cross-section non-circular portion causes relative rotation between the cross-section non-circular portion and the wire holding portion to be suppressed as compared with a case of the cross-section circular shape. Accordingly, bending accuracy in the three-dimensional shape for the round metallic wire is improved.