Single-Piece Cable Lug Crimping for Waterproof Ground Connections
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Solution Overview
Problem
Existing cable lugs for grounding vehicle wiring harnesses are difficult to integrate into automated manufacturing processes due to their complex construction, require time-consuming manual sealing with heat-shrink tubing, and often have less robust designs.
Innovation Solution
A single-piece cable lug is manufactured from a metal strip, featuring a section for connecting to the vehicle body and a crimping section with a cavity, produced through deep drawing and bending, allowing for automated production and standard crimping methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cable lugs are made from two separate pieces (multi-part construction), then sealing against water ingress is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent merges the sealing function into the single-piece cable lug structure itself, eliminating the need for separate sealing components. The cable lug is designed with an integrated sealing mechanism that prevents water ingress while maintaining a simple one-piece construction, thus improving reliability without increasing device complexity.
2Reliability
If cable lugs are made from two separate pieces, then sealing is improved, but ease of manufacture decreases
Solution Approach 1:
The invention combines the sealing function directly into the single-piece cable lug body, eliminating the need for separate sealing components and assembly steps. This integrated approach maintains effective water ingress prevention while significantly simplifying the manufacturing process, allowing for more straightforward production.
3Strength
If cable lugs are made as individual separate pieces, then structural robustness is improved, but ease of operation in automated manufacturing decreases
Solution Approach 1:
The patent merges multiple cable lugs into a single strip structure, maintaining the robustness of individual cable lug designs while enabling automated manufacturing processes. The strip configuration allows multiple cable lugs to be produced and handled as one continuous piece, facilitating integration into automated wiring harness manufacturing systems.
4Reliability
If manual sealing with heat shrink tubing is used, then sealing reliability is improved, but productivity decreases
Solution Approach 1:
The cable lug is designed with self-service sealing capability, where the sealing function is integrated directly into the cable lug structure itself. This eliminates the need for separate manual heat shrink tubing application steps, allowing the sealing to be achieved as part of the standard crimping process, thereby maintaining sealing reliability while significantly improving manufacturing productivity.
5Strength
If individual cable lugs are used instead of strip-connected lugs, then structural integrity is improved, but device complexity in automated processing increases
Solution Approach 1:
The patent merges multiple cable lugs into a single strip structure that maintains the structural integrity of individual lugs. The strip configuration allows automated processing equipment to handle and process multiple cable lugs simultaneously as one continuous piece, reducing processing complexity while preserving the structural strength needed for reliable electrical connections.
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
The solution enables robust, efficient, and cost-effective integration of cable lugs into automated vehicle wiring harness manufacturing, eliminating manual sealing and ensuring a reliable, waterproof connection.
Implementation Method 1
it comprises the step of deep drawing the section for crimping the cable from the segment to shape the section for crimping the cable by applying force with a tool in a direction perpendicular to the segment surface
Data Source
Figure 1a~1b
Figure 1c~1d
Figure 1e~1f
AI summary
The invention relates to the method for producing a cable lug (1), comprising the following successive steps: providing a metal strip and cutting the blank (2) from a metal strip. The blank (2) is in the form of a compact individual part and comprises a portion (3) for the connection of the cable lug (1) to the vehicle body and a segment (4a) for forming a portion (4) for the pressing of the cable (7), which are interconnected by a connecting portion (5). The portion (3) for the connection of the cable lug (1) to the vehicle body comprises a connection hole (3a). The method for producing the cable lug (1) also comprises the step of deep-drawing the portion (4) for the pressing of the cable (7) from the segment (4a) for forming the portion (4) for the pressing of the cable (7), the resulting portion (4) for the pressing of the cable (7) comprising a cavity (9) for the insertion of the cable (7). The invention also relates to a cable lug (1), which is in the form of a compact individual part and the connecting portion (5) of which has at least one leg (6) extending around the portion (4) for the pressing of the cable (7).