Task

ProEVTM cable, produced by Promark Electronics, a Division of Electrical Components International, welded to Stäubli compact PerforMore two-pole connector for electric drive systems. The ProEVTM 95 mm2 cable with 3,000 flexible, fine 0.2 mm diameter wires is used for the Stäubli plug contact. The ProEVTM cable was used in this application for its high flexibility. However, the Stäubli plug contact only has a maximum welding width of 18 mm, in contrast to the 22 mm required for 95mm2. This poses the challenge of achieving the required compaction without damaging the fine wires in the weld transition area.

Solution

The torsional PowerWheel® welding system was utilized to achieve a good quality weld between the ProEVTM 95 mm2 flexible cable and the 18 mm wide PerforMore connector. The tooling design and configuration had to be arranged so that we could allow sufficient welding energy to achieve a quality weld without affecting the finer wires in the transitional area.

Advantages of this configuration

The PowerWheel® system allows a higher clamping force for the Stäubli plug contact, which is an advantage when welding a large cable in a smaller area. The weld nugget height in such a case is higher than in a normal scenario. Since the torsional welding amplitude is at its peak at the center of the weld nugget, one can apply the additional energy required for the thicker height with minimal chance of affecting the wires in the weld transition area. The quality control variables such as final weld height, welding time, and power are monitored and controlled for every weld while production data is recorded for traceability.