Optimization of the Process Reliability of the Ultrasonic Crimping Process by Evaluating the Mounting Conditions for Tubular Cable Lugs

Abstract:

Article Preview

One of the major and at the same time most critical process step in the production of electric drives is the contacting process. The purpose of this contacting process is to join the stator windings mechanically and electrically with a contact element. An innovative and energy-efficient process is the ultrasonic crimping process, which combines the two process steps of stripping and contacting in one single process. This process is characterized by the transformation of oscillation energy into thermal energy caused by damping. Due to the direct heat generation within the cable lug and the oscillation coupled in, it shows major potentials relating to process stability, the contacting of high-frequency litz wires and anodized conductors. However, some disadvantages like the occasional occurrence of fatigue fractures in the tubular cable lugs and unclear dependencies reducing process reliability have to be investigated. The following paper presents possibilities to further optimize the ultrasonic crimping process and increase the process reliability. In this context, the mounting conditions of the tubular cable lugs are considered. In order to evaluate the obtained results, the electrical and mechanical connection quality of the samples is determined.

Info:

Periodical:

Edited by:

Jörg Franke, Michael Scholz and Annika Höft

Pages:

119-126

Citation:

J. Seefried et al., "Optimization of the Process Reliability of the Ultrasonic Crimping Process by Evaluating the Mounting Conditions for Tubular Cable Lugs", Applied Mechanics and Materials, Vol. 882, pp. 119-126, 2018

Online since:

July 2018

Export:

Price:

$41.00

[1] Golde, H.-D.: Ultraschall-Metallschweissen. Funktionsweise und Anwendung einer hochwertigen Verbindungstechnik. Landsberg/Lech (1995).

[2] Matthes, K.-J.; Schneider, W.: Schweißtechnik. Schweißen von metallischen Konstruktionswerkstoffen, 1. Aufl. s.l. (2012).

DOI: https://doi.org/10.3139/9783446428324

[3] Deutscher Verband für Schweißtechnik / Fachgruppe Schweißtechnische Ingenieurausbildung: Fügetechnik, Schweißtechnik, 7., aktualisierte Auflage. Düsseldorf (2007).

[4] Wodara, J.; Herold, H.: Fachbuchreihe Schweißtechnik Band 151: Ultraschallfügen und -trennen. Düsseldorf: Verl. für Schweißen und Verwandte Verfahren, DVS-Verl., 2004 (151).

DOI: https://doi.org/10.1002/maco.19950460913

[5] Spreng, S.; Gläßel, T. ; Franke, J.: Adaption of the Ultrasonic Welding Technique to the Process of Joining Insulated Copper Wires with Standardized Tubular Cable Lugs. In: 2015 IEEE 61st Holm Conference on Electrical Contacts (Holm) (2015).

DOI: https://doi.org/10.1109/holm.2015.7355088

[6] Weißgerber, W.: Elektrotechnik für Ingenieure - Formelsammlung. Bd. 5, (2015).

[7] DIN EN 60352-2: Lötfreie Verbindungen – Teil 2: Crimpverbindungen – Allgemeine Anforderungen, Prüfverfahren und Anwendungshinweise. Beuth Verlag, Berlin, (2006).