Wiring Harness Termination Welding With Insulated Cable Support
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Solution Overview
Problem
The variation in vertical distance between contact surfaces of electric cables due to different orientations of stranded wires requires frequent resetting of production machines, leading to inefficiencies in manufacturing wiring systems for motor vehicles and charging stations.
Innovation Solution
A method involving a stranded electric conductor with defined sub-portions, where one sub-portion is welded to a termination surface with a holding means supporting the other sub-portion during welding, maintaining its position and ensuring precise alignment and sealing, thereby allowing for consistent manufacturing without machine reconfiguration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cable insulation is completely removed for welding, then the welding contact is improved, but the sealing capability is compromised
Solution Approach 1:
The electric cable is divided into two distinct sub-portions: a first sub-portion where the cable insulation is removed for welding, and a second sub-portion where the cable insulation remains for sealing. This segmentation allows the welding region to have direct contact with the termination surface while the sealed region maintains fluid-tight protection, resolving the contradiction between welding reliability and sealing capability.
2Manufacturing precision
If the machine is reset for each batch of electric cable, then the manufacturing precision is maintained, but the productivity decreases
Solution Approach 1:
The cable insulation is removed only in the first sub-portion that will be welded, while the second sub-portion retains its insulation for sealing. This preliminary preparation allows the welding process to proceed with consistent positioning without requiring machine resets for different cable batches, thereby maintaining manufacturing precision while improving productivity.
3Device complexity
If the second sub-portion is not supported during welding, then the device complexity is reduced, but the manufacturing precision deteriorates
Solution Approach 1:
A holding means is introduced as an intermediary component to support the second sub-portion during the welding process. This holding means maintains the position of the second sub-portion, preventing unwanted deformation and ensuring consistent alignment between the first and second sub-portions, thereby achieving manufacturing precision without excessive device complexity.
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 method ensures precise alignment and sealing, preventing deformation and damage, and allows for cost-effective, reliable production of wiring systems with high fatigue strength and fluid-tight connections, eliminating the need for batch-specific machine adjustments.
Implementation Method 1
the first sub-portion is ultrasonically welded to the termination portion
Data Source
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AI summary
The invention relates to a method for manufacturing a wiring system (10) for transmitting electrical power in an electric vehicle or a charging station of an electric vehicle, and to a wiring system (10), there being provided an electric cable (20) that has at least one stranded electric conductor (30), and a contact element (80) that has a termination portion (85), a cable insulation (25) being removed in a first sub-portion (50) of the electric cable (20), and the cable insulation (25) remaining on the electric conductor (30) in a second sub-portion (55) of the electric cable (20) arranged so as to be offset from the first sub-portion (50), the electric conductor (30) being welded, by the first sub-portion (50), to a termination surface (95) of the termination portion (85), during welding, the first sub-portion (50) being pressed against the termination portion (85). A holding means (320) encompasses the second sub-portion (55) at least partially, preferably over its full circumference, the holding means (320) supporting the second sub-portion (55) at least during the compressing and welding of the first sub-portion (50) and maintaining a position of the second sub-portion (55).