Test Cable V-Shaped Junction Ultrasonic Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing test cables require extensive double soldering at each connection point, leading to bulkiness, high production costs, and reduced flexibility, while prior methods fail to efficiently connect multiple strands separately and ensure reliable contact.
Innovation Solution
A V-shaped design for the intermediate cable with offset spot welds and ultrasonic welding ensures a flexible, slim test cable with reduced material usage, using thinner strands for voltage measurement and heat-shrink tubing for insulation, maintaining elasticity and secure connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If double soldering is used at each connection point to connect strands, then reliable contact is achieved, but the pin housing becomes bulky and production becomes complex
Solution Approach 1:
The patent divides the connection structure into separate segments: the intermediate cable with its stranded wires and the pin housing with contact points. Instead of complex double soldering at each point, the patent uses individual contact points that press against the stranded wires, simplifying the connection method while maintaining reliability.
Solution Approach 2:
The patent replaces the soldering process (thermal/chemical connection method) with a mechanical pressing connection. The contact points mechanically press against the stranded wires to establish electrical contact, eliminating the need for double soldering and reducing pin housing complexity.
2Reliability
If double soldering is performed at each connection point, then strands are firmly grasped, but production time and effort increase significantly
Solution Approach 1:
The patent prepares the intermediate cable with stranded wires in advance, with the wires already positioned and ready for connection. The contact points are pre-formed with appropriate pressing force, eliminating the need for time-consuming double soldering operations during final assembly.
Solution Approach 2:
The patent replaces the labor-intensive soldering process with a simple mechanical pressing operation. The contact points are designed to automatically press against the stranded wires with sufficient force to ensure reliable electrical contact, dramatically reducing production time and effort.
3Reliability
If many double solder joints are created, then connections are secure, but the pin housing requires more space and becomes bulky
Solution Approach 1:
The patent segments the connection function into individual contact points rather than requiring multiple solder joints per connection. Each contact point independently establishes electrical contact with the stranded wires, reducing the overall space required in the pin housing.
Solution Approach 2:
The patent replaces the space-consuming double solder joint structure with compact mechanical contact points. These contact points require minimal space within the pin housing while providing secure electrical connections through mechanical pressing force.
4Reliability
If the test cable uses traditional connection methods, then contacts are reliable, but the cable becomes less flexible and more rigid
Solution Approach 1:
The patent uses stranded wires instead of solid conductors, dividing the conductor into multiple flexible strands. This segmentation maintains electrical reliability while significantly improving cable flexibility and bendability.
Solution Approach 2:
The patent replaces rigid soldered connections with flexible mechanical contact points that can accommodate cable movement and bending. The contact points are designed to maintain reliable electrical contact even when the cable flexes, preserving both reliability and flexibility.
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
The solution results in a cost-effective, flexible, and reliable test cable that maintains ease of use with existing connectors, ensuring accurate contact transmission and minimizing mechanical stress and material usage.
Implementation Method 1
Only the three ends 6, 8 of the strands 3, 7 are joined together, the ultrasonic welding, which is marked with the black dot 10 takes place.
Data Source
Figure 1~3
AI summary
The test cable (1) has a bundle of multiple isolated strands (3), where an isolated measuring strand (7) is branched from each isolated strand in a contact manner and is combined into a bundle. An intermediate cable (2) with its isolated strand is separated to a half length, where stripped ends of the intermediate cable are combined in a V-shape or stripped to the half length by a short piece, and are bent in a V-shape. The measuring strand in an extension is attached at the V-intersection (9) of each of the strands (3) in a contact manner.