Shield Wire Earthing Terminal Curvature Optimization
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Solution Overview
Problem
Existing methods for fixing an earthing metal fitting to a shield wire face challenges in achieving a balance between holding force and reducing the load on the braided conductor or covered wire, often resulting in either insufficient holding force or risk of damage due to excessive stress.
Innovation Solution
A method involving a shield wire production process where a tubular first terminal and second terminal are clamped and press-deformed into a damping shape using a mold with a protruding portion, allowing the covered wire and shield body to be inserted and folded radially, creating a groove-shaped portion that reduces stress on the shield wire while maintaining a strong holding force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a protruding portion in hemispherical shape is used to form a dent that deeply bites into the braided conductor or covered wire, then the holding force of the earthing metal fitting is improved, but the stress generated at the bite position becomes excessively large, risking damage to the braided conductor or covered wire
Solution Approach 1:
The invention changes the curvature radius of the protruding portion from a small hemispherical shape to a larger curvature radius that is smaller than the outer diameter of the shield wire. This modified curvature distributes the biting stress over a larger area, reducing peak stress concentration while still forming an effective dent for holding the earthing metal fitting securely
Solution Approach 2:
The invention modifies the geometric parameters of the protruding portion, specifically setting its curvature radius within a defined range (smaller than the shield wire's outer diameter but larger than a hemispherical shape). This parameter optimization allows the protruding portion to bite into the shield wire effectively for holding force while distributing stress to prevent damage
2Stress or pressure
If the bite of the dent is made shallow to reduce stress, then the load on the braided conductor or covered wire is reduced, but a sufficient holding force for fixing the earthing metal fitting cannot be obtained, resulting in positional deviation
Solution Approach 1:
By optimizing the curvature radius of the protruding portion to be smaller than the shield wire's outer diameter, the invention creates a dent with sufficient depth and biting force to secure the earthing metal fitting, while the controlled curvature ensures stress is distributed appropriately to maintain adequate holding force without excessive concentration
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 effectively increases the holding force for the earthing member while minimizing the load on the shield wire, preventing damage and positional deviations, thus achieving a balanced clamping solution.
Implementation Method 1
press-deforming the first terminal and the second terminal into a damping shape by sandwiching the first terminal and the second terminal with a mold
Data Source
AI summary
A method for producing a shield wire includes: disposing the first terminal at an opening end portion of the shield body in a state where the covered wire and the shield body are inserted into the first terminal; folding the opening end portion of the shield body to an outer side and disposing the second terminal to sandwich the folded opening end portion; and press-deforming the first terminal and the second terminal into a clamping shape. A mold surface of the mold has a protruding portion protruding toward the axis, and a protruding end surface of the protruding portion has a radius of curvature smaller than a radius of an outer peripheral surface of the second terminal before clamping and larger than a radius of an outer peripheral surface of the covered wire before clamping.