Stranded Conductor End Welding With Integrated Compacting Jaws
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for preparing stranded conductor ends for laser welding are multi-step processes involving various tools, leading to increased costs and inefficiencies, particularly due to the need for separate tools for compacting and deburring, which results in suboptimal weld quality and mechanical stability.
Innovation Solution
A method and device utilizing gripping jaws integrated with a laser welding system to compact and weld stranded conductor ends in a single step, using the laser beam to both compress the strands and create a flat, uniform surface for welding, thereby eliminating the need for additional tools and improving the weld quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional multi-step processes are used to prepare conductor ends (compacting with one tool, deburring with another), then the end face can be prepared for welding, but the process complexity and cost increase significantly
Solution Approach 1:
The patent combines multiple functions (compacting, deburring, and welding) into a single integrated tool head that processes the conductor end in one positioning step, eliminating the need for separate compacting and deburring tools while maintaining precise end face preparation
Solution Approach 2:
The integrated tool head performs multiple operations universally on the conductor end - it can compact strands, deburr the end face, and position for welding, all within a single tool that serves multiple purposes rather than requiring specialized tools for each function
2Stability of the object's composition
If strands are compacted mechanically before welding, then gaps between strands are reduced, but the end face becomes uneven requiring additional deburring steps
Solution Approach 1:
The compacting and deburring functions are merged into a single integrated operation where the tool head simultaneously compresses strands against the anvil surface and creates a flat end face, achieving both compactness and flatness in one step rather than sequentially
3Reliability
If only some strands protrude far enough to contact the connecting part, then contact areas are small and discontinuous, but this results in insufficient material for continuous weld seams and increased contact resistance
Solution Approach 1:
The integrated tool head performs preliminary compacting and end face preparation before welding, ensuring all strands are properly positioned and compressed against the anvil surface in advance, so that when welding occurs, continuous material availability is guaranteed without requiring post-compacting adjustments
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 reduces the number of processing steps, enhances the mechanical stability and electrical contact resistance of the weld, and allows for a continuous, large-area weld seam with improved long-term performance.
Implementation Method 1
A laser beam source is used to weld the strands together through the gripping jaws
Implementation Method 2
there is increased Joule losses and thus increased heat input
Implementation Method 3
the end face must be as flat as possible to ensure a butt weld
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3a~3b
AI summary
The invention relates to a method for processing an electrical conductor, in which a bare conductor end of a stranded conductor is provided, the strands of the bare conductor end are gripped at least partially circumferentially by gripping jaws, the strands are at least partially compacted in the region of the conductor end by the gripping jaws, and the compacted strands are welded to one another with the aid of a laser beam source in the region of the gripping jaws, through the gripping jaws.