A wire terminating apparatus and method which allows for determining the quality of a wire termination. The method includes terminating the wire, monitoring the thermal properties of the termination with one or more thermal sensors and comparing the monitored thermal properties to stored thermal properties to determine if the termination is defective. If the termination is defective, the termination is discarded. The apparatus includes a wire termination zone. A thermal sensor is mounted on the wire terminating apparatus proximate the wire termination zone. The thermal sensor monitors the thermal properties of the termination to determine if the termination is defective.

A method for connecting an electrical cable having at least one wire made of aluminum or an aluminum alloy to a connector element includes the following steps: Inserting a stripped portion at an end of the electrical cable into a tube of the connector element. Crimping the tube where an end portion of the electrical cable is arranged so that a relative motion between the tube and the electrical cable is prevented. Crimping the tube where a second portion of the electrical cable is arranged, the second portion being further from the end of the electrical cable than the end portion, such that a change of the cross section and an elongation of the least one wire at the second portion of the electrical cable is caused. Resistance welding the tube to the at least one wire at the second portion of the electrical cable.

A conductive cell frame for connecting a plurality of battery cells is disclosed. The conductive cell frame includes a first conductive portion and a plurality of second conductive portions, and the upper surface of each second conductive portion is connected to the first conductive portion through a eutectic portion. The lower surface of each second conductive portion is provided with at least one protruding welding portion, wherein the second conductive portion is connected to the housing of the battery cell through the protruding welding portion. The first conductive portion and the second conductive portion are made of different materials, wherein the resistance of the second conductive portion is greater than the resistance of the first conductive portion. Thus, a small current can be used to connect to the conductive cell frame and the battery cell, which not only reduces the consumption of energy, but also avoids damage of the battery cell during the electric welding process

A resistance soldering device configured for use with an electrical terminal having a first surface and a second surface opposite the first surface on which a layer of a solder composition is disposed includes an electrode having a first electrical conductor configured to be connected to a positive pole of an electrical power supply, a second electrical conductor configured to be connected to a negative pole of the electrical power supply and an electrically resistive bridge interconnecting the first and second electrical conductors. A method of using such a device is also presented herein.

A method for forming a connection between a wire and a pin includes placing a fixturing element over the pin, capturing the wire between an upper surface and a lower surface of the fixturing element, compressing the fixturing element to hold the wire around the pin and forming a fixed connection between the wire and the pin. A system for forming an electrical connection includes a pin, a fixturing element disposed around the pin, and a wire placed around pin and sandwiched between an upper surface and a lower surface of the fixturing element.

A wire terminating apparatus and method which allows for determining the quality of a wire termination. The method includes terminating the wire, monitoring the thermal properties of the termination with one or more thermal sensors and comparing the monitored thermal properties to stored thermal properties to determine if the termination is defective. If the termination is defective, the termination is discarded. The apparatus includes a wire termination zone. A thermal sensor is mounted on the wire terminating apparatus proximate the wire termination zone. The thermal sensor monitors the thermal properties of the termination to determine if the termination is defective.

The invention relates to a cable assembly comprising at least three electric cables which have electric conductors that are electrically and mechanically connected together. Each of the electric conductors is free of an insulation material and is plate-shaped in a contact point. One of the cables is designed as a support cable, and the electric conductor of the support cable is formed as a support plate at the contact point in order to attach the contact points of the other electric conductors. Multiple contact points of the other electric conductors are secured to a surface of the support plate next to one another.

Method for establishing a connection between an electrical connecting element for a motor vehicle on-board network and a cable of the motor vehicle on-board network in which the cable (2) is provided with a metallic stranded conductor (4), firstly the metallic stranded conductor is mechanically compacted in such a way that a flat area is formed, whereby during the compacting, a material bond is formed between strands of the stranded conductor (4), and subsequently, the connecting element is connected to the flat region in a material bond.

A method for fusing an electrical conductor to a film pad circuit including the steps of: providing an electrically inert substrate having a first surface and an opposing second surface; applying an electrically conductive film to the second surface of the electrically inert substrate; applying an electrically conductive member to the electrically conductive film; placing an electrical conductor on the first surface of the electrically inert substrate; and fusing the electrical conductor to the conductive member.

An apparatus and method for fastening dissimilar materials like steel, plastic and aluminum. A resistance welding fastener having multiple layers may be used with or without a sealant. The fastener may be used to form an aluminum covered steel laminate via a hemming pattern of attachment. The fastener may have a solid shaft or have an extended reach and have features for interacting with the welding electrode. A variety of electrode tips may be employed to cooperate with the fastener.