Joining quality of stranded wire is desired to be improved

Suggestion to compact stranded wires to prevent loosening of the wires

Challenge: Welding quality of stranded wires is desired to be improved,
and loosening of wires is desired to be eliminated.

Background

  • In the case of welding stranded wires, contact status of wires between each other tends to vary leading to unstable welding strength.
  • Loosened wires may cause shorting.
  • Loosening of wires may cause less contact surfaces leading to possibility of high resistance value (heat generation).

Background

Avio's Solution: The problem may be solved by applying force, heating and
compacting the terminal of the stranded wire.

The joining condition becomes stable and the welding strength is improved.
It also helps to prevent occurrence of shirt circuit.

Point

By compacting and forming the stranded wire, connection reliability in the next process can be improved.


Fabrication method 1 (AWG20x5 wires)

Fabrication method 1 (AWG20x5 wires)


Fabrication method 2 (AWG4)

Fabrication method 2 (AWG4)

Important point for selection of the fabrication method between resistance welding and ultrasonic welding.

Point

1. Resistance welding

Joining by fusion. Less possibility for disconnection. Applicable to fine wire diameter.

2. Ultrasonic welding

Solid phase joining. Less possibility for thermal impact. Applicable to thick wire diameter.

Important point for selection of the fabrication method between resistance welding and ultrasonic welding

<Reference: Cable standard: Wire diameter>

SQ
(JIS)
0.2 2 8 14 22 38 60 100
AWG
(UL)
24 14 8 6 4 1 1/0 4/0
Cross sectional area
(mm²)
0.205 2.08 8.37 13.3 21.15 42.41 53.49 107.2

Applicable models

Related products

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