Ultrasonic Terminal Wire Vibration Damping via Plate Clamping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing terminal-equipped electric wires using ultrasonic joining require complex post-welding operations to correct wire shape and effectively attenuate vibrations, leading to potential damage and quality issues.
Innovation Solution
A method involving clamping a predetermined length of an electric wire with a pair of plate bodies during ultrasonic joining, applying ultrasonic vibration to the conductor, and setting a clamping force weaker than the jacket's plastic deformation force to reduce vibration transmission and prevent damage, thereby eliminating the need for complex post-joining corrections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the electric wire is wound around a columnar jig and deformed to attenuate vibration, then the vibration transmitted to the terminal fitting is reduced, but the electric wire develops a curl requiring complicated post-welding correction operations
Solution Approach 1:
The vibration attenuating portion is formed by clamping the electric wire with a pair of plate bodies at a predetermined position before ultrasonic welding. This preliminary clamping creates a localized deformation that serves as a vibration damper during the subsequent welding process, eliminating the need for post-welding correction operations while effectively reducing vibration transmission to the terminal fitting
Solution Approach 2:
The invention extracts the vibration attenuation function from the overall welding process by creating a separate vibration attenuating portion through localized clamping deformation. This extracted component specifically addresses vibration issues without interfering with the welding operation or requiring additional correction steps
2Object-affected harmful factors
If the electric wire is clamped with a strong force to attenuate vibration, then the vibration transmission is reduced, but the jacket undergoes plastic deformation
Solution Approach 1:
The invention optimizes the clamping force parameter to a specific range that is sufficient to create effective vibration attenuation through localized deformation while remaining below the threshold that would cause unwanted plastic deformation of the jacket. This precise parameter control achieves vibration reduction without compromising jacket integrity
Solution Approach 2:
The clamping force is applied locally at a specific position on the electric wire rather than uniformly along its length. This localized application creates a controlled vibration attenuating portion with minimal deformation, concentrating the vibration-damping effect where needed while preserving the overall quality and integrity of the jacket
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 effectively attenuates vibrations transmitted to the terminal fitting, reducing the risk of damage and product defects while producing high-quality terminal-equipped electric wires without the need for complicated post-welding operations.
Implementation Method 1
the vibration transmitted through the conductor of the electric wire is attenuated at the intermediate portion of the electric wire clamped with the pair of plate bodies
Implementation Method 2
performing an ultrasonic joining processing by applying an ultrasonic vibration to the conductor exposed at the other end of the electric wire
Implementation Method 3
a friction of the jacket against the conductor is increased
Data Source
AI summary
A method of manufacturing a terminal-equipped electric wire, includes: connecting a terminal fitting to one end of an electric wire in which a conductor is covered with a jacket; clamping a range of a predetermined length in a length direction at an intermediate portion of the electric wire with a pair of plate bodies; and performing an ultrasonic joining processing by applying an ultrasonic vibration to the conductor exposed at the other end of the electric wire.