Spring-Contact Splice Terminal for Automated Cable Shoe Assembly
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Solution Overview
Problem
Existing splice solutions for unshielded electric lines in vehicles require manual labor, leading to high production costs and bulky designs, especially for thin low-voltage lines that need to share electrical potential, with no automated machine-based connection methods available.
Innovation Solution
A splice arrangement featuring a connection bolt with spring contacts and cable shoes, allowing for automated assembly, reducing manual intervention and space requirements, utilizing a method that includes a shrinking hood for insulation and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual work is used to connect conductors to a contact piece, then connection reliability is improved, but production cost increases and automation is not available
Solution Approach 1:
The cable shoe automatically performs the connection function by receiving the connection bolt and establishing electrical contact through its own structural features (through hole, contact surfaces), eliminating the need for manual conductor attachment operations while maintaining reliable connections
Solution Approach 2:
The cable shoe serves multiple functions: it provides mechanical support for the conductor, establishes electrical contact through the through hole, and enables automated assembly by receiving the connection bolt directly, replacing multiple manual operations with a single multi-functional component
2Reliability
If manual work is used to connect conductors to a contact piece, then connection quality is maintained, but productivity decreases
Solution Approach 1:
The cable shoe is pre-prepared with the through hole and contact surfaces during manufacturing, so that during assembly it only needs to receive the connection bolt without requiring any manual conductor attachment operations, enabling automated high-speed assembly while maintaining connection quality
3Reliability
If a splice for shielded lines with screen connection is used, then electrical potential sharing is improved, but installation space increases
Solution Approach 1:
The screen connection function is extracted and eliminated from the design since unshielded lines do not have screens, leaving only the essential conductor connection functionality, which significantly reduces the required installation space while maintaining electrical potential sharing among the three lines
4Area of stationary object
If simpler types of contacts are used for unshielded lines, then installation space is reduced, but manual work is still required
Solution Approach 1:
The cable shoe with its through hole and contact surfaces serves itself by directly receiving the connection bolt and establishing electrical contact without requiring any additional manual conductor attachment operations, enabling automated assembly of the compact design
Solution Approach 2:
The cable shoe integrates multiple functions (mechanical support, electrical contact, automated assembly interface) into a single component, enabling the compact splice design to be manufactured automatically without manual intervention
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
Enables cost-effective, automated manufacturing of compact splice arrangements for unshielded electric lines, reducing production costs and installation space while ensuring reliable electrical connections.
Implementation Method 1
at least one spring contact fixed to the shaft for engaging with one or several of the cable shoes to establish an electrical connection
Implementation Method 2
a method that includes a shrinking hood for insulation and protection
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A splice arrangement for a plurality of electric lines (301) is a suggested. Each electric line comprises a conductor, an insulating sheath, and a cable shoe fixed to one end of the respective conductor of each line. The splice arrangement (300) comprises a connection bolt composed of a shaft and a head (113) and is provided with at least one spring contact fixed to the shaft for engaging with one or several of the cable shoes to establish an electrical connection between the plurality of electric lines. Furthermore, a method for manufacturing the splice arrangement is proposed.