Wiring Harness News Sep-Oct 2022 - Page 29


Processing Electric Vehicle Heavy Cables

Continued from page 27 ____________ gree of compression force over the core ’ s peripheral area . This compression force thus plays a significant role in the difficulty dislodging the insulation slug , given the inherent coefficient of friction between the insulation material and the subjacent core metal . This would be especially apparent on longer slugs .
Sleeve compression factor of elastic material .
So how would you measure or at least have an idea of how difficult it can be to dislodge an elastic insulation slug ? One method I devised is to compare the circumference dimension between the mounted sleeve
how tightly the insulation is wrapping the underlying layer . I have tried this method with a few wire samples which I know were problematic to process . I found that this “ compression factor ” fluctuated between 6 % to 14 %. The common denominator between these samples was that they all had problems being dislodged by means of a rotary blade “ pushing ” them off . It was most problematic trying to dislodge them using bayonet or tangent type slicing blades . Peripheral slicing blades were more successful but would fail when there was variation of concentricity between different lots of the same wire being processed .


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Figure 7 . Caculating the compression ratio between stretched ( mounted ) insulation and removed and flattened insulation slug .
and the dislodged sleeve ( Figure 7 ). The assumption would be that the mounted sleeve material is being
The formula for calculating this compression ratio ( CR ) is stretched around the underlying core periphery . As such , it is under tension , but this tension force is not enough to break the polymer chains . When you remove the slug off the core ( or underlying layer ), the molecules relax and shrink the sleeve to their natural at-rest circumference length . Comparing the at-rest length to the mounted peripheral length , gives you a percentage factor which suggests
More successful and routine automatic processing of these types of wires is in the near future as improvements in the individual lateral process modules of modern equipment are implemented by the OEMS as a result of real time experience in the manufacturing floor . Meanwhile , the alternate solution is to apply manual labor or bench processes to these problematic issues .
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