Ultrasonic Welding Device for Multi-Strand Cable Connection
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Solution Overview
Problem
Existing ultrasonic welding devices face difficulties in connecting cables with multiple strands, as existing connections or ends must be kept away from the compression space, making it challenging to ensure that only the intended conductors enter the welding area, especially when creating complex connections like Y- or X-nodes, which often requires lengthy stripping or twisting of cables to avoid electromagnetic interference.
Innovation Solution
A semi-automatic device with a protective hood and a retaining element that keeps non-welding strands away from the compression space, allowing for easy handling and reliable connection of cables with multiple strands by guiding them through the device while maintaining the protective hood's coverage, ensuring that only the necessary conductors are welded.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual loading is used to ensure non-welding conductors are kept away from the compression space, then operator control is maintained, but the protective hood prevents the operator from easily holding the conductors during welding
Solution Approach 1:
The patent introduces a retaining element as an intermediary component between the operator and the conductors. This retaining element automatically holds non-welding conductors away from the compression space during welding, eliminating the need for manual holding while maintaining reliability. The retaining element acts as a mediator that performs the retention function without requiring direct operator intervention during the welding process.
2Reliability
If the compression space is completely enclosed during welding, then safety is improved, but access for inserting and removing conductors becomes more difficult
Solution Approach 1:
The patent applies dynamics by making the protective hood movable rather than fixed. The protective hood can be opened to provide access for inserting and removing conductors, then closed during welding to ensure safety. This dynamic configuration allows the system to transition between different operational states (access mode and welding mode), resolving the contradiction between safety enclosure and operational access.
3Object-affected harmful factors
If lengthy stripping or twisting of cables is performed to avoid electromagnetic interference, then EMI protection is improved, but the complexity and time of the connection process increases
Solution Approach 1:
The patent extracts the non-welding conductors from the compression space using the retaining element, separating them from the welding operation. This extraction allows the welding process to focus only on the intended conductors without requiring extensive stripping or twisting of cable shields and twists, thereby reducing EMI protection measures while maintaining effectiveness and simplifying the overall connection process.
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 efficient and reliable ultrasonic connection of cables with multiple strands, reducing the need for extensive stripping or twisting, thus minimizing electromagnetic interference and simplifying the connection process for complex cable configurations like Y- or X-nodes.
Implementation Method 1
the sonotrode is excited by means of an ultrasonic converter, e.g. to longitudinal or torsional ultrasonic vibrations. The vibrations of the sonotrode are transmitted to the weld metal, for example the conductor ends, via the generally profiled working surface.
Data Source
Figure 1a~1b
Figure 1c~1d
Figure 2
AI summary
The invention relates to a device (1) and to a method for ultrasound connection of electrical conductors (2, 3). The device (1) comprises a compression space (4) for receiving the conductors (2, 3), the compression space (4) being delimited in a welding position by portions of delimiting faces (5, 6, 7, 8) arranged adjacently to one another, the delimiting faces comprising a working surface (5) of an ultrasound-transmitting sonotrode (15) and an anvil surface (6) arranged opposite the working surface (5). At least one retaining element (14) is provided for holding at least one strand (20), which is connected to at least part of the conductors (2, 3), away from the compression space (4).