Shielding Unit Press-Fit Assembly for High-Voltage Cables
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Solution Overview
Problem
Conventional methods for fixing a shielding member to a shielding shell in high-voltage electric vehicle or hybrid electric vehicle shielding cables are cumbersome and prone to exposing the end of the shielding member, making it difficult to visually confirm and securely attach the crimp ring or internal/external cylinder connection, leading to potential exposure and operational inefficiencies.
Innovation Solution
A shielding unit with a cylindrical shielding member and a shielding shell, where the end of the shielding member is folded back from the outer to the inner surface of a shielding ring and then wound around it, allowing the cylindrical portion to be press-fitted, ensuring the end is not exposed and providing a secure, locked connection with excellent electrical conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a crimp ring is used to fix the shielding member to the shielding shell, then the shielding member can be securely attached, but the crimp ring blocks the operator's field of vision making positioning difficult and time-consuming
Solution Approach 1:
The shielding member end is folded back to the inner circumferential surface side before the crimp ring is installed, so the folding action is performed in advance to enable visual confirmation and easier positioning during the crimping operation
Solution Approach 2:
Instead of crimping the shielding member from the outer circumferential surface, the end is folded back inward and then crimped from the inner side, reversing the conventional crimping direction to improve operability
2Ease of manufacture
If the shielding member end is not folded back, then the attachment operation is simpler, but the end portion becomes exposed and may ravel or obstruct subsequent operations
Solution Approach 1:
The end of the shielding member is folded back to the inner circumferential surface side before the crimp ring is installed, so the folding action is performed in advance to prevent exposure and ravelling during subsequent operations
3Reliability
If the end of the shielding member is folded back and wound around the shielding ring, then the end is securely locked and cannot be exposed, but the attachment process becomes more complex
Solution Approach 1:
The shielding member end is divided into multiple sections: the folded-back portion that contacts the inner circumferential surface, the wound-around portion that loops around the shielding ring, and the secured portion that is crimped between the shielding ring and cylindrical portion, with each segment serving a specific functional purpose
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
Facilitates easy and secure attachment of the shielding member to the shell, preventing exposure and ensuring reliable electrical conductivity and positional stability, even under tensile forces, while maintaining a sufficient contact area.
Implementation Method 1
the shielding member is electrically conducted to the shielding case through the shielding shell, and the bundle of wires covered with the shielding member functions as a shielding cable having a shielding property against high frequency noises
Implementation Method 2
the end of the shielding member fitted on a cylindrical portion of the shielding shell is crimped from its outside by the crimp ring, thereby fixing the shielding member to the cylindrical portion
Implementation Method 3
The end portion of the shielding member is sandwiched between the cylindrical portion and the shielding ring
Data Source
AI summary
A shielding unit is formed by press-fitting a small diameter portion of a shielding shell into a shielding ring around which an end portion of a shielding member is wrapped, such that the end portion of the shielding member is sandwiched by the shielding ring and the small diameter portion. By having the end portion of the shielding member be folded over to the inside of the shielding ring when press-fitting the small diameter portion of the shielding shell into the shielding ring, even if the position of an opening is unknown, it is possible to reliably position the opening inside the shielding member, unexposed to the outside, after the press-fitting. This easily allows the end portion of the shielding member to be mounted and secured to the shielding shell so as not to be exposed to the outside.