A robotic wire termination system for efficiently connecting a plurality of wires to an electrical connector. The robotic wire termination system generally includes a frame, a connector support attached to the frame, a robot manipulator having at least one arm, a heating device attached to the at least one arm and a control unit in communication with the robot manipulator to control the operation of the robot manipulator. The arm of the robot manipulator is adapted to move the heating device so that the heating device can apply heat to a selected connector pin of the electrical connector.

A solder sleeve for connecting a wire to another wire or to a terminal device is formed from an alloy comprised of 42 percent tin and 58 percent bismuth that has a eutectic melt point of approximately 138° C. The wire receiving portion, at least one side of the solder sleeve is in the form of a hollow tubular member that is extruded so as to lack a longitudinal seam, the opposing side may be in one of many forms. A thermochromic dye is mixed in with a flux layer located on a portion of the outer surface of the solder sleeve, the dye designed to change from a first color to a second color at the same temperature as the melting point of the alloy. The solder sleeve may be held within a heat shrink tube.

A method of joining electrical connections together includes evaluating at least one weld joint between at least two substrates, determining a mismatch between the at least two substrates, and welding the at least two substrates together with a multi-step welding process. The multi-step welding process includes compensating for the mismatch between the at least two substrates by welding on both sides but not overlapping a joint line between the at least two substrate with a first welding step and increasing melt volume and penetration depth of a weld between the at least two substrates with a second welding step.

In a high-temperature superconducting (HTS) wire connection assembly in which HTS wires each including a HTS layer are connected to each other, a first HTS wire and a second HTS wire that face each other are connected to each other at a plurality of joint portions separated from each other along a longitudinal direction of the first HTS wire and the second HTS wire. Each of the plurality of joint portions may preferably have any one of a rectangle shape, a rounded rectangle shape, and an ellipse shape, and it is preferable to satisfy 0.1<L/W<1.5, and is more preferable to satisfy 0.25<L/W<0.75 when a length in the longitudinal direction of the HTS wire is taken as L and a length in a width direction of the HTS wire is taken as W. It is also preferable that W and/or L monotonously increase from upstream side toward downstream side along the longitudinal direction of the wire.

An ultrasonic welding apparatus joins metal pieces, such as wires, which are placed in a weldment zone where the metal pieces are subjected to pressure through a compressive height anvil and an adjustable width anvil, and intimate contact is made with a sonotrode of an ultrasonic stack. A first electric motor actuates movement of the height anvil to develop a compressive force for ultrasonic welding of the metal pieces. A second electric motor can position the width anvil before and during welding. A sensor, such as a load cell, measures the compressive force developed. The sensor directly can measure the load on the height anvil independent of the ultrasonic stack. A software algorithm can compensate for deflection of the load cell sensor and lost motion in the first electric motor actuating movement.

An apparatus that melts and monitors sleeves for installation onto shielded cables. The apparatus includes a heat source for melting the sleeve, cable supports for supporting the cable during the melting process, a sensor system that is configured to measure a dimension of the sleeve during melting, and a computer that is connected to receive sensor data from the sensor system and send heater control signals to the heat source. The computer is configured to receive dimensional data from the sensor system, monitor that dimensional data by performing a dimensional analysis, and then deactivate or remove the heat source in response to dimensional analysis results indicating that the sleeve is fully melted (in the case of a solder sleeve) or only fully shrunken (in the case of a dead end sleeve) onto the cable.

An electrical cable having at least one consolidated end may be made of a multi-stranded conductor or a plurality of conductive leaves. At least one end of the multi-stranded conductor or plurality of conductive leaves is ultrasonically welded together. The end of the multi-stranded conductor or plurality of conductive leaves ultrasonically welded together may further include a sleeve or cap substantially enclosing the end of the multi-stranded conductor or plurality of conductive leaves.

A robotic wire termination system for efficiently connecting a plurality of wires to an electrical connector. The robotic wire termination system generally includes a frame, a connector support attached to the frame, a robot manipulator having at least one arm, a heating device attached to the at least one arm and a control unit in communication with the robot manipulator to control the operation of the robot manipulator. The arm of the robot manipulator is adapted to move the heating device so that the heating device can apply heat to a selected connector pin of the electrical connector.

A terminal includes: a tubular box portion to receive a mating terminal; a spring portion extending in a beam shape from a front end portion of the box portion; and a pressing piece configured to restrict a bending range of the spring portion. A free end of the spring portion is inside the box portion, and the spring portion has a contact point with the mating terminal. The pressing piece is placed at a pressing position located inside the box portion and away from the contact point in the bending direction. The pressing piece is configured to restrict the bending range of the spring portion to achieve at least part of the spring portion closer to the free end than the contact point is located on the bending direction side with respect to the pressing position.

An ultrasonic metal welding device for welding electrical conductors using a compression chamber that is adjustable at least n height and that is delimited on opposite sides by a section of a sonotrode as a first delimiting surface and by at least one section of a counter electrode (156) as a second delimiting surface, wherein for welding, the counter electrode and the sonotrode are displaced relative to one another. The counter electrode used is one that comprises sections (152, 154) of geometrically different working surfaces or is composed of at least two sections that are displaceable relative to one another.