Wire-Terminal Connection Sealing via 3D Nozzle Movement
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Solution Overview
Problem
Existing methods for manufacturing terminals with electric wires face challenges in forming a sufficient anticorrosion portion, particularly due to uneven application of sealing materials, which can lead to air pockets and loss of sealing function when cured.
Innovation Solution
A method involving the movement of a nozzle in X-, Y-, and Z-directions during the supply of sealing material to the wire-terminal connection portion, ensuring fine motions and precise coverage of the connection area to prevent air pockets and ensure even application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If sealing material is supplied from a stationary nozzle position, then the manufacturing process is simple, but the sealing material application becomes uneven and air pockets are formed
Solution Approach 1:
The nozzle is transformed from a stationary component to a dynamic one that can move in X, Y, and Z directions. This allows the nozzle to adapt its position continuously during sealing material supply, ensuring uniform application across the wire-terminal connection portion and preventing air pocket formation while maintaining electrical connection integrity
Solution Approach 2:
A control system serves as an intermediary between the nozzle movement mechanism and the sealing material supply process. This intermediary coordinates the nozzle's three-dimensional movements with the sealing material flow rate, ensuring precise application uniformity and resolving the contradiction between manufacturing precision and device complexity
2Reliability
If high compression rate crimping is applied to aluminum conductor, then contact resistance is reduced, but electric corrosion occurs when water reaches the crimping part
Solution Approach 1:
The high compression rate crimping is applied preliminarily to break the oxide film and reduce contact resistance before the sealing process. Subsequently, the sealing material is supplied to prevent water from reaching the crimping part, thereby counteracting the potential electric corrosion issue before it can occur
Solution Approach 2:
The solution combines two different approaches: mechanical crimping (physical method) to reduce contact resistance, and chemical sealing material application to prevent corrosion. This composite approach addresses both the electrical connection requirement and the corrosion protection requirement simultaneously
Data Source
AI summary
A method for manufacturing a terminal with an electric wire includes: forming a conductor exposed portion by removing a resin coating of an electric wire; forming a wire-terminal connection portion by connecting a terminal fitting to a position of the conductor exposed portion; and supplying a sealing material from a nozzle to the wire-terminal connection portion. During supply of the sealing material, the nozzle is moved in X-, Y- and Z-directions or a relative position between the wire-terminal connection portion and the nozzle is changed in the X-, Y- and Z-directions.