"Novel welding system technology for simple and process-reliable contacting of high-frequency stranded wires in electrical engineering"

High-frequency stranded wires and enamel-insulated wires have become an indispensable part of our everyday lives. They now play a decisive role in almost all areas of daily life. This starts with applications at home, such as induction hobs, and continues with classic applications in industry and electrical engineering, such as transformers and chokes as well as power electronics components, through to high-tech solutions in healthcare. They are also of crucial importance as a key technology for electro-mobility, for example in electric motors and inductive charging technology.

High-frequency stranded wires consist of a large number of thin single insulated wires. The safe and efficient contacting of the wires poses a challenge in terms of production technology. In the application, the level of power dissipation is not only influenced by the strand structure, but is also significantly determined by the quality of the connection between the strand and the connecting element.

The development team of the Institute of Welding and Joining Technology at RWTH Aachen University sees great potential in friction welding connector technology, a novel process developed to market maturity for contacting aluminum stranded wires with conductor cross sections ≥ 4 mm².

Whithin the "Start-up Transfer.NRW" funding program, which is financed by the European Regional Development Fund (Europäischen Fonds für Regionale Entwicklung, EFRE) and the state of North Rhine-Westphalia, the "HFconnect" project aims to further develop the RSV technology and provide proof of concept for use in contacting high-frequency stranded wires. The existing welding system concept, which is ready for serial production, will be expanded for the new application and preparations will be made for the establishment of a company as a technology supplier planned for 2022.

Description of the efre research project