Stranded Wire Coating Removal via Angled Laser Scanning
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Solution Overview
Problem
Existing methods for processing stranded wire units are not time-efficient and precise, particularly when it comes to removing coatings from multiple wire elements while ensuring minimal damage and maintaining electrical conductivity.
Innovation Solution
A method involving the use of a laser to heat and remove a partial area of the coating on stranded wire units, allowing for precise and flexible removal without damaging the wire elements, while maintaining alignment and contact capabilities for efficient electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional methods are used to remove coating from stranded wire units, then processing can be completed, but the process is time-consuming and lacks precision
Solution Approach 1:
The patent replaces conventional mechanical coating removal methods (such as stripping or cutting tools) with a laser-based thermal processing system. The laser beam delivers concentrated energy to the coating material, vaporizing or carbonizing it rapidly without mechanical contact. This substitution enables both high processing speed and precise control over the removal depth and location, resolving the contradiction between productivity and manufacturing precision.
Solution Approach 2:
The patent utilizes controllable laser parameters (power, pulse duration, scanning speed, beam diameter) to precisely regulate the coating removal process. By adjusting these parameters, the system can adapt to different wire types, coating materials, and removal requirements, achieving both rapid processing and high precision. The ability to dynamically change processing parameters allows optimization for each specific application scenario.
2Reliability
If coating is removed aggressively to ensure complete exposure, then electrical contact is achieved, but wire elements may be damaged
Solution Approach 1:
The laser processing system applies energy locally and selectively to the coating material only, with precise spatial control of the beam. The processing parameters are optimized to affect only the coating layer without transmitting excessive heat to the underlying wire elements. This localized processing ensures reliable electrical contact by completely removing the coating barrier while preventing thermal damage to the conductive cores, thus resolving the contradiction between contact reliability and wire integrity.
Solution Approach 2:
The patent employs pulsed laser operation with carefully controlled pulse durations and repetition rates. The periodic application of thermal energy allows brief intervals for heat dissipation, preventing cumulative thermal buildup that could damage the wire elements. This pulsed approach maintains effective coating removal while protecting the electrical conductors from overheating, addressing the contradiction between reliable contact and wire element protection.
3Manufacturing precision
If multiple wire elements are processed individually, then precision is maintained, but processing time increases significantly
Solution Approach 1:
The patent merges the processing of multiple wire elements into a single coordinated laser operation. The laser beam is scanned simultaneously across multiple adjacent wire elements, removing coating from each element in sequence or in parallel depending on beam configuration. This combined approach maintains individual element precision through controlled scanning while dramatically reducing total processing time compared to handling and processing each element separately, thus resolving the contradiction between precision and productivity.
Solution Approach 2:
The laser processing system operates continuously with uninterrupted beam delivery across all wire elements. The scanning mechanism ensures continuous coverage without idle transitions or repositioning delays between elements. This continuous useful action maximizes processing efficiency while maintaining precision through consistent parameter control throughout the entire multi-element processing sequence, addressing the contradiction between individual precision and overall processing speed.
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 rapid, precise processing of stranded wire units with low production costs, ensuring functional integrity and high reproducibility by removing coatings in a controlled manner, thus facilitating efficient electrical connections.
Implementation Method 1
at least a portion of the coating being removed by heat generated by a laser
Implementation Method 2
The partial area of the coating is heated directly by means of the laser
Implementation Method 3
a precise and flexible removal of the coating in the partial area can advantageously be achieved by the heat generated by the laser
Data Source
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AI summary
The method for processing a stranded wire unit (10) extended with two stranded wire elements (12) each having a coating (14), which extends over a large part of a longitudinal extension of the wire elements, is claimed. A portion (16) of the coating is removed by a heat generated by laser, where the portion is directly heated by the laser. The portion forms an end region (20) of the respective wire elements. A scanning direction, in which the laser is moved over the portion of the coating, is aligned at an angle of 45[deg] relative to the longitudinal extension of each of the wire elements. The method for processing a stranded wire unit (10) extended with two stranded wire elements (12) each having a coating (14), which extends over a large part of a longitudinal extension of the wire elements, is claimed. A portion (16) of the coating is removed by a heat generated by laser, where the portion is directly heated by the laser. The portion forms an end region (20) of the respective wire elements. The wire elements are arranged next to each other before processing. A scanning direction, in which the laser is moved over the portion of the coating, is aligned at an angle of 45[deg] relative to the longitudinal extension of each of the wire elements. An independent claim is included for a stranded wire unit.