Two-Step Resistance Welding for Sensor Terminal Wire Connection
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Solution Overview
Problem
Conventional techniques for joining terminal wires to lead wires in temperature sensors face challenges with controlling welding current, leading to issues such as conductor fusion or separation, and require repetitive welding operations, which are time-consuming and inefficient.
Innovation Solution
A method involving two welding steps: first, fusing multiple conductors to form a thicker electricity conduction wire, and second, connecting the terminal wire to this unified wire, allowing for proper welding current settings and reducing the number of welding operations required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding current is increased to ensure adequate welding, then welding strength is improved, but conductors may fuse and break
Solution Approach 1:
The welding process is divided into two distinct stages: first welding to unite conductors, and second welding to connect the terminal wire to the electricity conduction wire. This segmentation allows each welding operation to be optimized independently, with the first welding using parameters suitable for bonding multiple conductors and the second welding using parameters optimized for connecting the terminal wire, thereby preventing both conductor damage and ensuring adequate welding strength
Solution Approach 2:
The first welding operation is performed in advance to unite the multiple conductors into a unified electricity conduction wire structure. This preliminary action creates a more robust conductor assembly that can better withstand the welding current applied during the second welding operation, preventing conductor fusion and breakage while ensuring adequate connection strength
2Reliability
If welding current is decreased to prevent conductor fusion, then conductor integrity is maintained, but welding is not performed adequately and welded portion may separate
Solution Approach 1:
The welding process is divided into two distinct stages: first welding to unite conductors, and second welding to connect the terminal wire to the electricity conduction wire. This segmentation allows each welding operation to be optimized independently, with the first welding using parameters suitable for bonding multiple conductors and the second welding using parameters optimized for connecting the terminal wire, thereby preventing both conductor damage and ensuring adequate welding strength
Solution Approach 2:
The first welding operation is performed in advance to unite the multiple conductors into a unified electricity conduction wire structure. This preliminary action creates a more robust conductor assembly that can better withstand the welding current applied during the second welding operation, preventing conductor fusion and breakage while ensuring adequate connection strength
3Reliability
If multiple welding operations are performed to reliably weld loose conductors, then welding reliability is improved, but manufacturing time increases
Solution Approach 1:
The welding process is divided into two distinct stages: first welding to unite conductors, and second welding to connect the terminal wire to the electricity conduction wire. This segmentation allows each welding operation to be optimized independently, reducing the total number of welding operations required compared to conventional methods that would require multiple welding attempts on loose conductors
Solution Approach 2:
The first welding operation is performed in advance to unite the multiple conductors into a unified electricity conduction wire structure. This preliminary action creates a more robust conductor assembly that facilitates a single reliable welding operation in the second step, thereby improving welding reliability while minimizing the total number of welding operations and reducing manufacturing time
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 enables easy and reliable connection of terminal wires to lead wires, preventing conductor fusion or separation, and significantly improves working efficiency by minimizing the number of welding operations needed.
Implementation Method 1
joining each terminal wire extending from a thermistor element with a plurality of conductors projecting from an end of an insulated wire through use of solder
Implementation Method 2
the plurality of conductors, which constitute the electricity conduction wire, are fused and joined together for unification by the first welding
Data Source
AI summary
A sensor and method of manufacturing the same. A plurality of conductors (33) constituting an electricity conduction wire (37) are fused and joined for unification by a first resistance welding operation. Subsequently, a terminal wire (20) and the electricity conduction wire (37) are caused to overlap in the axial direction and connected by a second resistance welding operation.