Project Overview:
The project investigated the wire connections and multi-strand wires with insulation and insulated structures. The research aimed to determine the best materials for crimping and welding using different materials and procedures. The process consisted of three unique steps: crimping, welding, and measurements, while navigating challenges such as connecting two different kinds of wires.
St. Clair College partnered with industry leaders known for their expertise in welding. This partnership allowed student researchers to conduct hands-on analysis and redefine the developments in crimping/welding automation. Industry leaders’ technologies were used to enable research on Tungsten, Tapered Tip Copper, and Larger Tip Diameter.
Purpose and Objectives:
The project aimed to find the best materials for crimping and welding, as well as appropriate values for welding parameters to prevent any loss in strands and maintain the conductivity of the wires. This involved developing a two-stage crimping/soldering process for connecting the wires without reducing finished part quality. The team focused on identifying high-demand combinations and difficult configurations, using parametric studies, analysis of total wire gauge influence, and testing the proposed crimping/welding operations to examine quality.
Key Innovations:
- Tungsten: An electrode used for fusing very small workpieces like wires or ribbons together.
- Tapered Tip Copper: Used when the distance between tips isn’t as critical, focusing energy more fully and penetrating deeper.
- Larger Tip Diameter: Solves the concern of connection cross-section while eliminating the tripping and twisting of wires.
- Welding Machine: A key component for conducting resistance and bulk resistance tests.
- Semi-Automated Crimping Machine: A flywheel-based drive design using a 1/3HP, 110V, 230V, single-phase electric motor to produce uniform crimps.
Impact & Benefits:
- Researchers Collaboration: 2 researchers led the project by focusing on determining the best materials suitable for crimping and welding.
- Student Researcher Contribution: 1 student researcher supported by utilizing sustainable values for welding parameters to meet high-volume production targets required by automotive OEMs.
Deliverables & Technologies:
- Automated Robotic Measurement System
- CAD Integration for Automated Guidance
- Advanced Sensor Implementation
- Robot Programming
- Sensor Technology
- CAD Software
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