Tilting Jaw Wire Fixing for Precise Multi-Core Cable Joining
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In high-voltage wiring harness production, the existing rigid mold cavities for fixing individual wires in multi-core electrical sheathed cables are cumbersome, leading to difficulties in secure insertion, precise positioning, and laborious removal, resulting in potential insertion errors and tool breakage, as well as increased costs and waste due to the need for multiple mold variants.
Innovation Solution
A device with a movable and tiltable jaw mechanism and an inner web with concave contours is used to securely fix and position individual wires, allowing for adjustable clamping forces to accommodate different wire diameters, facilitating easier insertion and removal while ensuring precise geometric alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a rigid mold cavity is used to fix individual wires, then the wires can be positioned with geometric precision, but the wires cannot be securely fixed and are prone to slipping during insertion
Solution Approach 1:
The patent applies the dynamics principle by replacing the rigid, static mold cavity with a dynamic clamping system featuring movable jaw elements that can tilt and adjust. The jaw elements transition from an open position during insertion to a closed clamping position during welding, providing adaptive fixation that maintains both geometric precision and secure wire positioning throughout the process.
2Reliability
If a rigid mold cavity with high friction is used to hold multiple wires, then the wires are securely held during processing, but removing the finished connectors becomes laborious and requires considerable force
Solution Approach 1:
The clamping system dynamically adjusts the holding force through movable jaw elements that can be opened for easy removal. During processing, the jaws maintain strong clamping; after welding, the jaws can be opened to release the connectors with minimal force, eliminating the laborious removal process associated with high-friction rigid cavities.
Solution Approach 2:
The patent extracts the fixation function from a permanent rigid structure and implements it through removable, movable jaw elements. This allows the fixation mechanism to be temporarily applied during processing and then removed or opened for easy connector extraction, separating the holding function from the processing function.
3Adaptability or versatility
If multiple variants of rigid mold cavities are used to represent all product variants, then all wire configurations can be accommodated, but the effort and expense increase considerably
Solution Approach 1:
The patent implements universality through a single multi-functional clamping device with movable jaw elements that can accommodate multiple wire configurations. The adjustable and tiltable jaws can adapt to different wire diameters, positions, and orientations, replacing the need for multiple specialized rigid mold cavity variants while maintaining versatility across product variations.
Solution Approach 2:
The device utilizes parameter changes by allowing the jaw elements to adjust their position, angle, and clamping force to accommodate different wire configurations. This dynamic parameter adjustment enables a single device to handle multiple product variants that would otherwise require separate rigid mold cavities for each configuration.
4Manufacturing precision
If individual wires are force-fitted into a rigid mold cavity, then the wires are positioned correctly, but insertion errors and tool breakage occur due to improper positioning
Solution Approach 1:
The dynamic jaw elements provide adaptive positioning during insertion, allowing wires to be guided into the correct position without force-fitting. The movable jaws can adjust to accommodate slight variations in wire positioning, preventing insertion errors and tool breakage while maintaining geometric precision through controlled clamping after proper positioning is achieved.
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 significantly reduces the risk of non-compliance with product specifications, improves process stability, minimizes waste and downtime, and enhances working conditions by simplifying the handling and processing of high-voltage cables, allowing for efficient and precise joining of wires with varying diameters.
Implementation Method 1
The two jaw elements are preloaded in the second position by respective spring elements
Implementation Method 2
The connection is typically created by ultrasonic strand welding
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
The disclosure relates to a device (100) for fixing individual conductors (111, 112, 121, 122) of multi-core electrical sheathed cables (110, 120) for a subsequent joining process, wherein the device (100) comprises: two tiltable jaw elements (130, 140); and an inner element (150) arranged between the two jaw elements (130, 140), wherein each jaw element (130, 140) in a first tilting position (101) together with the inner element (150) forms a receptacle (131, 141) for inserting the individual wires (111, 112, 121, 122), and in a second tilting position (102) fixes the individual wires (111, 112, 121, 122) inserted into the receptacle (131, 141) for the subsequent joining process.