Method and system for preparing a terminal for an insulated wire conductor

A method for preparing a wire conductor, the method comprising:

• inserting a portion of the wire conductor into a fixture, wherein the wire conductor is an elongated conductive element encased in an insulative material, and has a rectangular cross-section including a first pair of opposed faces and a second pair of opposed faces, and wherein a plurality of square edges are disposed at adjacent ones of the first pair of opposed faces and a second pair of opposed faces;
• executing, via a mechanical device, a mechanical ablation process to remove the insulative material from an outer surface of the plurality of square edges along a predefined length of the portion of the wire conductor;
• executing, via the mechanical device, the mechanical ablation process to remove the insulative material from the first pair of opposed faces along the predefined length of the portion of the wire conductor;
• and
• executing, via a laser tool, a laser ablation process to remove the insulative material from the second pair of opposed faces along the predefined length of the portion of the wire conductor,
• wherein the insulative material is removed from the outer surface of the plurality of square edges and from the first pair of opposed faces, via the mechanical ablation process, and the insulative material is removed from the second pair of opposed faces, via the laser ablation process, simultaneously within one process step.

A wire conductor, comprising:

• an elongated conductive element encased in enamel;
• wherein the elongated conductive element has a rectangular cross-section including a first pair of opposed faces and a second pair of opposed faces;
• wherein a plurality of square edges are disposed at adjacent ones of the first pair of opposed faces and a second pair of opposed faces;
• wherein a portion of the elongated conductive element is subjected to a mechanical ablation process to remove the enamel from an outer surface of the plurality of square edges along a predefined length of the portion of the elongated conductive element;
• wherein a portion of the first pair of opposed faces along the predefined length of the portion of the elongated conductive element is subjected to a laser ablation process to remove the enamel;
• and wherein a portion of the second pair of opposed faces along the predefined length of the portion of the elongated conductive element is subjected to the laser ablation process to remove the enamel,
• wherein the insulative material is removed from the outer surface of the plurality of square edges, via the mechanical ablation process, and the insulative material is removed from the first pair of opposed faces and the second pair of opposed faces, via the laser ablation process, simultaneously within one process step.