US3728781A - Method of producing a stranded wire assembly by friction welding - Google Patents

Method of producing a stranded wire assembly by friction welding Download PDF

Info

Publication number
US3728781A
US3728781A US00137258A US3728781DA US3728781A US 3728781 A US3728781 A US 3728781A US 00137258 A US00137258 A US 00137258A US 3728781D A US3728781D A US 3728781DA US 3728781 A US3728781 A US 3728781A
Authority
US
United States
Prior art keywords
sleeve
cable
connector
wire
friction welding
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
US00137258A
Other languages
English (en)
Inventor
R Curtis
G English
J Hense
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Production Technology Inc
Original Assignee
Production Technology Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Production Technology Inc filed Critical Production Technology Inc
Application granted granted Critical
Publication of US3728781A publication Critical patent/US3728781A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

Links

Images

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/02—Soldered or welded connections
    • H01R4/029—Welded connections
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
    • B23K20/129—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding specially adapted for particular articles or workpieces
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/02—Soldered or welded connections
    • H01R4/023—Soldered or welded connections between cables or wires and terminals

Definitions

  • the present invention relates to a method of producing a stranded wire cable assembly wherein the stranded cable is permanently bonded to a connector and the cable and connector are a honogeneous structure. The end of the cable is sufficiently restrained to allow friction welding of the cable-to the connector. This produces a true metallurgical bond between cable and connector. Friction welding of the conventional or inertia type may be used.
  • lt is another object to produce a stranded cable assembly having mechanical and electrical conduction properties superior to presently known assemblies.
  • FIG. 1 is a side elevation view illustrating one ernbodiment of a friction welding machine which may be used to practice the method of the present invention
  • FIG. 2 is a side view, partially in section, of a stranded wire assembly produced by one of the Prior Art methods',
  • FIG. 3 is a side view, partially in section of the individual components used in producing an assembly by the instant invention
  • FIG. 4 is a side view, partially in section, of a completed assembly produced by the method of the present invention.
  • a friction welding machine constructed in accordance with one exemplary embodiment of the present invention is indicated generally by the reference numeral 11 in FIG. 1.
  • the machine comprises a frame or housing structure generally denoted at 12 for housing the various elements of the machine.
  • the two parts to be welded, workpieces WP- 1 and WP-2 are mounted within chucks 14 and 16.
  • the chuck 16 does not rotate and is mounted on a tailstock fixture 18.
  • the fixture 18 is mounted for axial movement on the machine frame 12 under the control 'of a load cylinder 20.
  • a pressure control circuit not shown, regulates the pressure in the load cylinder, and thus determines the force with which the parts WP-l and WP-2 are engaged.
  • the chuck 14 is mounted on a spindle 22, and the v chuck and spindle are mounted for rotation within the frame l2.
  • the rotary spindle 22 is adapted to receive flywheels 24 which may be of various size and mass depending upon the particular application of the machine.
  • An electric motor 26 rotates the spindle through a hydrostatic transmission generally indicated by the reference numeral 28.
  • the hydrostatic transmission includes a hydraulic pump 30, a hydraulic motor 32, and a manifold 34 between the pump and motor.
  • the drive ratio between the motor and the spindle 22 can be varied by changing the cam angles in either the pump 30 or the motor 32, and the motor and pump can be used to effectively disconnect the motor 26 from the spindle 22 by moving the cam of the pump 30 to a position in which the pump 30 does not displace any hydraulic fluid to the motor 32.
  • the flywheel weights 24 are mounted on the spindle 22 so that the welding machine ll can be operated as an inertia welding machine as described in U.S. Pat. No. 3,273,233 and as described in further detail below.
  • a welding operation to join a first workpiece, such as an electrical connector designated as WP-l to a second workpiece such as an electrical cable designated as WP-2, for example, can be performed by operating the machine in the following general manner.
  • the first workpiece WP-l is firmly clamped in the rotatable chuck 14 located on the spindle 22.
  • the second workpiece WP-2 is firmly clamped in the non-rotatable chuck 16 which is located on the tailstock portion 18 of the machine.
  • FIG. 2 A stranded wire connector assembly produced by one of the presently known methods is illustrated in FIG. 2.
  • This assembly 40 is an electrical cable connector assembly and comprises a connector member 42 and a length of cable 44.
  • the connector member 42 contains a solid threaded portion 46 on theone end and a hollow bored portion 48 on the other end.
  • the threaded portion 46 is for connecting the assembly 40 to a terminal (not shown), and the hollow bored portion 48 is for receiving an end of the cable 44.
  • a protective insulative coating 50 surrounds the cable 44 except for the end portion 52 which is inserted into' the bored portion 48 of connector 42.
  • the connector 42 and cable 44 are joined into the assembly 40 by inserting the bare end portion 52 of the cable into the bore 48 of connector 42, and applying a circumferential pressure to the outside surface of the hollow bored portion 48 which causes the portion 48 to collapse on to the cable 44 and become mechanically attached to the cable.
  • the walls 54 of bored portion 48 can contain one or more longitudinal slots to facilitate collapsing of the connector on to the cable.
  • an electrical connector assembly such as 40
  • electrical current is conducted from the cable 44 to the connector 42 by means of the external cable strands only. This is duel to the nature of the mechanical joint between the connector 42 and the cable 44 wherein only the external strands of cable 44 are in intimate contact with the connector 42. Since current is transmitted from the cable 44 to the connector 42 mainly by the external strands of the cable 44, a larger cable is required to transmit a given amount of current from the cable to the connector. In such an electrical connector assembly, the more expensive copper cable must be used, as opposed to the less expensive aluminum cable, in view of the poor electrical conduction across the mechanicaljoint. v
  • the friction welded stranded wire cable assembly 60 ofthe present invention comprises a connector member 62, a hollow circular sleeve member 64, and a length of stranded wire cable 66.
  • assembly 60 ⁇ is an electrical conductor assembly, similar to assembly 40 of FIG. 2.
  • Connector 62 is a solid member containing a threaded portion 68 on one end and a shoulder portion 70 on the other end.
  • the sleeve 64 contains a through bore 72, a first end 74 for receiving the stranded wire cable 66, and a second end portion 76 for mating with the shoulder portion of connector 62.
  • Sleeve 64 contains a longitudinal slot 82 cut through the wall of the sleeve and running the entire length of the sleeve. Although the slot 82 is shown as running parallel to the axis of the sleeve, it could also be cut at a-n angle to the longitudinal axis of the sleeve or in a spiral patternaround the sleeve.
  • a protective coating 78 surrounds the stranded cable 66 except for the end portion 80 which is inserted into the bore 72 of sleeve 64.
  • the individual components are permanently joined into an assembly in the following manner.
  • the end portion 80 of cable 66 is inserted into the bore 72 of sleeve 64 until the end surface 84 of the cable is flush with the end surface 76 of the sleeve 64.
  • a radially inward compressive force is then applied to the circumferential surface 86 of sleeve 64 which causes the sleeve to collapse on to the cable 66 and thereby mechanically lock the sleeve 64 to the cable 66.
  • End surface 84 of cable 66 and end surface 76 of sleeve 64 now form a common coplanar surface.
  • the locked together sleeve and cable assembly is then clamped or fastened in a non-rotatable chuck or holding fixture on the tailstock portion of a friction welding machine.
  • the connector member 62 is then clamped in a rotatable chuck or holding fixture on the spindle of the same machine.
  • a friction welding operation as previously described, is then performed and the common coplanar surface of the sleeve and cable is welded to the shoulder portion 70 of the Vconnector member 62.
  • the finished friction welded assembly 60 then consists of the sleeve and cable unit friction welded to the connector member at interface88.
  • a true metallurgical bond now exists between the cable 66 and the connector 62.
  • the material of the cable 66 and of the connector 62 are then a homogeneous structure and there is absolutely no hinderance of electrical current flow between the two. Due to the metallurgical bond between the cable and the connector, and the fact that the materials are a homogeneous structure, in the embodiment of an electrical connector assembly, the less expensive aluminum cable can be used to replace ⁇ the more expensive copper cable, since full electrical current flow is now available between cable and connectot'. v
  • the flash 90 produced during the weld operation can be machined away to produce a smooth exterior surface. Once the flash 90 has been removed, there is no external evidence that a weld joint exists between the cable, sleeve and connector.
  • a method of joining a stranded wire cable to a connector comprising the steps of:

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Manufacturing Of Electrical Connectors (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)
  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
US00137258A 1971-04-26 1971-04-26 Method of producing a stranded wire assembly by friction welding Expired - Lifetime US3728781A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US13725871A 1971-04-26 1971-04-26

Publications (1)

Publication Number Publication Date
US3728781A true US3728781A (en) 1973-04-24

Family

ID=22476524

Family Applications (1)

Application Number Title Priority Date Filing Date
US00137258A Expired - Lifetime US3728781A (en) 1971-04-26 1971-04-26 Method of producing a stranded wire assembly by friction welding

Country Status (7)

Country Link
US (1) US3728781A (enrdf_load_stackoverflow)
JP (1) JPS4848985A (enrdf_load_stackoverflow)
CA (1) CA954012A (enrdf_load_stackoverflow)
DE (1) DE2218049A1 (enrdf_load_stackoverflow)
FR (1) FR2136682A5 (enrdf_load_stackoverflow)
GB (1) GB1331037A (enrdf_load_stackoverflow)
IT (1) IT952749B (enrdf_load_stackoverflow)

Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3876280A (en) * 1973-10-02 1975-04-08 Coatings Inc Electric terminator comprising one-piece bimetallic connector and method for making such connector
US3916518A (en) * 1973-10-02 1975-11-04 Coatings Inc Method for making one-piece bimetallic connector
US3949466A (en) * 1974-05-28 1976-04-13 Arthur D. Little Inc. Process for forming an aluminum electrical conducting wire junction end piece
EP1032077A3 (de) * 1999-02-24 2001-06-27 Auto Kabel Managementgesellschaft mbH Verbindung eines elektrischen Aluminiumkabels mit einem aus Kupfer oder dergleichen Metall bestehenden Anschlussteil
US20030102353A1 (en) * 2001-08-06 2003-06-05 Honda Giken Kogyo Kabushiki Kaisha Joined structure of different metals and friction welding method thereof
WO2012071083A1 (en) * 2010-11-22 2012-05-31 Andrew Llc Cylindrical surface spin weld apparatus and method of use
WO2012139793A1 (de) * 2011-04-14 2012-10-18 Auto-Kabel Managementgesellschaft Mbh Herstellung eines elektrischen kabels sowie verfahren zur herstellung einer verbindung
US20130025121A1 (en) * 2010-11-22 2013-01-31 Andrew Corporation Friction weld coaxial connector and interconnection method
US20130203303A1 (en) * 2010-10-13 2013-08-08 Gebauer & Griller Kabelwerke Gesellschaft M.B.H. Connection element for an electrical conductor
US20170033473A1 (en) * 2012-11-23 2017-02-02 Nexans Method for electrically conductively connecting a contact piece to an electrical conductor, and corresponding arrangement
CN110832713A (zh) * 2017-07-05 2020-02-21 利萨·德雷克塞迈尔有限责任公司 用于制造电线路装置的方法
US11394163B2 (en) * 2017-10-13 2022-07-19 Lisa Dräxlmaier GmbH Electric line assembly with direct contacting and method for producing same
US11437766B2 (en) 2010-11-22 2022-09-06 Commscope Technologies Llc Connector and coaxial cable with molecular bond interconnection
US11462843B2 (en) 2010-11-22 2022-10-04 Commscope Technologies Llc Ultrasonic weld interconnection coaxial connector and interconnection with coaxial cable
CN117913614A (zh) * 2024-03-19 2024-04-19 西安誉丰通号科技有限公司 一种铁路钢轨引、连接线的制备方法

Families Citing this family (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2410612A1 (de) 2010-07-22 2012-01-25 Nexans Verfahren zur Herstellung von Kabeln mit Aluminiumleiter
DE102010044241A1 (de) 2010-09-02 2012-03-08 Auto-Kabel Managementgesellschaft Mbh Verbindung und Verfahren zum Verbinden eines Aluminiumkabels mit Anschlussteilen
DE102010053768B4 (de) 2010-12-08 2013-11-07 Auto-Kabel Management Gmbh Verfahren zum Verbinden eines Aluminiumkabels mit einem Anschlussteil
DE102011011409B4 (de) 2011-02-16 2013-10-31 Auto-Kabel Management Gmbh Anschlussteil und Verbindung für elektrische Anlagen
DE102011017071A1 (de) 2011-04-14 2012-10-18 Auto-Kabel Managementgesellschaft Mbh Anschlussteil für elektrische Anlagen
DE102011018353A1 (de) * 2011-04-20 2012-10-25 Auto-Kabel Managementgesellschaft Mbh Schweißhülse mit Kontaktteil
DE102014216833A1 (de) * 2014-08-25 2016-02-25 Kuka Systems Gmbh Kabelverbindung zum Anschluss eines elektrischen Kabels
ES2880282T3 (es) 2017-07-26 2021-11-24 Nordex Energy Se & Co Kg Conector para un cable que conduce corriente de gran amperaje y un procedimiento para la fabricación de un conector semejante

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US463134A (en) * 1891-11-17 bevington
US1363355A (en) * 1920-05-10 1920-12-28 Thomson Electric Welding Compa Method of uniting cable ends
US1977846A (en) * 1931-11-06 1934-10-23 American Steel & Wire Co Butt welded end fitting
US3576067A (en) * 1968-02-28 1971-04-27 Caterpillar Tractor Co Friction welding irregularly shaped objects
US3626363A (en) * 1969-07-29 1971-12-07 Itt Roll-formed contact and crimping device therefor

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US463134A (en) * 1891-11-17 bevington
US1363355A (en) * 1920-05-10 1920-12-28 Thomson Electric Welding Compa Method of uniting cable ends
US1977846A (en) * 1931-11-06 1934-10-23 American Steel & Wire Co Butt welded end fitting
US3576067A (en) * 1968-02-28 1971-04-27 Caterpillar Tractor Co Friction welding irregularly shaped objects
US3626363A (en) * 1969-07-29 1971-12-07 Itt Roll-formed contact and crimping device therefor

Cited By (31)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3876280A (en) * 1973-10-02 1975-04-08 Coatings Inc Electric terminator comprising one-piece bimetallic connector and method for making such connector
US3916518A (en) * 1973-10-02 1975-11-04 Coatings Inc Method for making one-piece bimetallic connector
US3949466A (en) * 1974-05-28 1976-04-13 Arthur D. Little Inc. Process for forming an aluminum electrical conducting wire junction end piece
EP1032077A3 (de) * 1999-02-24 2001-06-27 Auto Kabel Managementgesellschaft mbH Verbindung eines elektrischen Aluminiumkabels mit einem aus Kupfer oder dergleichen Metall bestehenden Anschlussteil
US6538203B1 (en) * 1999-02-24 2003-03-25 Auto Kabel Managementgesellschaft Mbh Connection of an electrical aluminum cable with a connection piece of copper or similar material
US20030102353A1 (en) * 2001-08-06 2003-06-05 Honda Giken Kogyo Kabushiki Kaisha Joined structure of different metals and friction welding method thereof
US6828038B2 (en) * 2001-08-06 2004-12-07 Honda Giken Kogyo Kabushiki Kaisha Joined structure of different metals and friction welding method thereof
US20050087583A1 (en) * 2001-08-06 2005-04-28 Honda Giken Kogyo Kabushiki Kaisha Joined structure of different metals and friction welding method thereof
US7441690B2 (en) 2001-08-06 2008-10-28 Honda Giken Kogyo Kabushiki Kaisha Joined structure of different metals and friction welding method thereof
US9225076B2 (en) * 2010-10-13 2015-12-29 Gebauer & Griller Kabelwerke Gesellschaft M.B.H. Connection element for an electrical conductor
US20130203303A1 (en) * 2010-10-13 2013-08-08 Gebauer & Griller Kabelwerke Gesellschaft M.B.H. Connection element for an electrical conductor
US12113317B2 (en) 2010-11-22 2024-10-08 Outdoor Wireless Networks LLC Connector and coaxial cable with molecular bond interconnection
US20130025121A1 (en) * 2010-11-22 2013-01-31 Andrew Corporation Friction weld coaxial connector and interconnection method
US8479383B2 (en) * 2010-11-22 2013-07-09 Andrew Llc Friction weld coaxial connector and interconnection method
WO2012071083A1 (en) * 2010-11-22 2012-05-31 Andrew Llc Cylindrical surface spin weld apparatus and method of use
US11437766B2 (en) 2010-11-22 2022-09-06 Commscope Technologies Llc Connector and coaxial cable with molecular bond interconnection
US12100925B2 (en) 2010-11-22 2024-09-24 Outdoor Wireless Networks LLC Ultrasonic weld interconnection coaxial connector and interconnection with coaxial cable
US9768574B2 (en) 2010-11-22 2017-09-19 Commscope Technologies Llc Cylindrical surface spin weld apparatus
US11757212B2 (en) 2010-11-22 2023-09-12 Commscope Technologies Llc Ultrasonic weld interconnection coaxial connector and interconnection with coaxial cable
US11735874B2 (en) 2010-11-22 2023-08-22 Commscope Technologies Llc Connector and coaxial cable with molecular bond interconnection
US11462843B2 (en) 2010-11-22 2022-10-04 Commscope Technologies Llc Ultrasonic weld interconnection coaxial connector and interconnection with coaxial cable
US11437767B2 (en) 2010-11-22 2022-09-06 Commscope Technologies Llc Connector and coaxial cable with molecular bond interconnection
US8840437B2 (en) 2011-04-14 2014-09-23 Auto Kabel Managementgesellschaft Mbh Production of an electrical cable and method for producing a connection
WO2012139793A1 (de) * 2011-04-14 2012-10-18 Auto-Kabel Managementgesellschaft Mbh Herstellung eines elektrischen kabels sowie verfahren zur herstellung einer verbindung
US10404025B2 (en) * 2012-11-23 2019-09-03 Nexans Arrangement for electrically conductively connecting a contact piece to an electrical connector
US20170033473A1 (en) * 2012-11-23 2017-02-02 Nexans Method for electrically conductively connecting a contact piece to an electrical conductor, and corresponding arrangement
US11158961B2 (en) * 2017-07-05 2021-10-26 Lisa Draexlmaier Gmbh Method for producing an electrical line arrangement
CN110832713A (zh) * 2017-07-05 2020-02-21 利萨·德雷克塞迈尔有限责任公司 用于制造电线路装置的方法
US11394163B2 (en) * 2017-10-13 2022-07-19 Lisa Dräxlmaier GmbH Electric line assembly with direct contacting and method for producing same
CN117913614A (zh) * 2024-03-19 2024-04-19 西安誉丰通号科技有限公司 一种铁路钢轨引、连接线的制备方法
CN117913614B (zh) * 2024-03-19 2024-06-04 西安誉丰通号科技有限公司 一种铁路钢轨引、连接线的制备方法

Also Published As

Publication number Publication date
CA954012A (en) 1974-09-03
GB1331037A (en) 1973-09-19
DE2218049A1 (enrdf_load_stackoverflow) 1972-11-02
JPS4848985A (enrdf_load_stackoverflow) 1973-07-11
IT952749B (it) 1973-07-30
FR2136682A5 (enrdf_load_stackoverflow) 1972-12-22

Similar Documents

Publication Publication Date Title
US3728781A (en) Method of producing a stranded wire assembly by friction welding
US2795039A (en) Method of frictionally welding a tube to a metal object
US5845384A (en) Joining system and method of detachably and securely joining two members
US4331280A (en) Method of jointing pipes by friction welding
US3134278A (en) Friction welding
US3618196A (en) Flash trap for friction welding
US3269002A (en) Friction welding
US20180219345A1 (en) Sonotrode, device and method for producing a join
GB1063229A (en) Friction welding
CN109968037B (zh) 一种机床及利用该机床进行摩擦焊接的方法
US3512792A (en) Collet chuck for inertia welders
US3452421A (en) Friction welding of dissimilar materials
US3504425A (en) Method of friction welding
US3314583A (en) Friction welding devices for joining lengths of wire
US3234646A (en) Friction welding
US3478411A (en) Friction welding stellite facings to valve seats
US3599857A (en) Wide range friction welder
US3613982A (en) Friction welder
US3831459A (en) Cluster gear assembly produced by friction welding
US3234645A (en) Friction welding
US3606968A (en) Friction welding chuck assembly
US3485143A (en) Friction welded internally cooled piston
US3452914A (en) Apparatus for controlling flash during friction bonding
US3750263A (en) Method for producing an assembly by friction welding
US4033501A (en) Friction welding machine