Terminal-Equipped Electric Wire Bonded Portion Shape
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Solution Overview
Problem
Conventional methods for manufacturing terminal-equipped electric wires result in non-uniform right and left biting portions of the wire barrel portion, leading to deteriorated crimping performance due to inconsistent shapes of the bonded portion.
Innovation Solution
A method is developed to form a bonded portion on the conductor with a sectional shape that allows a variable distance between its geometric center and the wire barrel portion to fall within a specific range, ensuring uniform engagement and crimping by shaping the bonded portion in a circular or regular polygonal form before terminal fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the bonded portion is formed in a rectangular parallelepiped shape, then the manufacturing process is simple, but the right and left biting portions of the wire barrel portion become non-uniform, deteriorating crimping performance
Solution Approach 1:
The bonded portion is formed with a circular cross-section instead of a rectangular parallelepiped shape. This curvature ensures that when the wire barrel portion crimps the bonded portion, the biting portions on the right and left sides become uniform, thereby improving crimping performance while maintaining manufacturing simplicity through the bonding process
2Ease of manufacture
If the bonded portion is formed with a non-circular cross-section, then the strands can be easily bonded, but the distance between the geometric center and wire barrel portion varies during rotation, causing non-uniform biting
Solution Approach 1:
The bonded portion is formed with a circular cross-section where the distance from the geometric center to the circumference remains constant regardless of rotation angle. This ensures that when the wire barrel portion engages with the bonded portion during crimping, the biting portions remain uniform even if the bonded portion rotates, thereby maintaining engagement consistency
Solution Approach 2:
The cross-sectional shape parameter is changed from rectangular to circular. This parameter change ensures that the geometric properties (constant radius from center) remain stable during rotation, preventing variation in the distance between the geometric center and the wire barrel portion, thus maintaining consistent engagement
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 prevents non-uniform biting and stabilizes the crimping performance by ensuring consistent mechanical and electrical bonding between the wire and terminal, enhancing the overall quality of the terminal-equipped electric wire.
Implementation Method 1
the distal end portion of the conductor 305, including a plurality of strands 311, is bonded by ultrasonically bonding the respective strands 311, thereby forming a bonded portion 309
Data Source
AI summary
A method for manufacturing a terminal-equipped electric wire includes forming, in an electric wire, a bonded portion in which strands of a conductor exposed due to absence of a sheath are bonded to each other. A terminal including a wire barrel portion is fixed to the electric wire such that the wire barrel portion covers at least a part of the bonded portion. A sectional shape of the bonded portion before the fixing of the terminal is formed in such a shape that a variable range of a value of a distance between a geometric center of a cross section of the bonded portion and the wire barrel portion falls within a range of 0.71 to 1.29 when rotating the bonded portion by an arbitrary angle while engaging the bonded portion with the wire barrel portion within the wire barrel portion.