A cable end crimper

Abstract

This invention relates to the field of cable crimping technology, and more particularly to a cable end crimping device for crimping cable assemblies. The cable assembly includes a terminal block, a metal inner sleeve, and a cable conductor. The inner core of the cable conductor passes through the metal inner sleeve and is then folded in the opposite direction and wrapped around the outer wall of the metal inner sleeve. The terminal block is sleeved on the outside of the metal inner sleeve that wraps the inner core. The cable end crimping device includes a chassis, a power unit, and a crimping connector, which is connected to the power unit. The crimping connector includes a support component and a crimping component. This invention, through a unique "pre-treatment folding-crimping wrapping" process path, combined with an M-shaped punch and a precise cavity design with two steps, completely and tightly compacts and permanently seals the inner core of the cable within the cavity formed by the metal inner sleeve and the terminal block during the crimping process. This solves the "burr" problem of exposed copper wires in the inner core in traditional processes and eliminates the risk of short circuits to ground or between phases that may be caused by exposed conductor tips.

Description

Technical Field

[0001] This invention relates to the field of cable crimping technology, and more particularly to a cable end crimping device. Background Technology

[0002] Cable conductor crimpers are core specialized tools used in power, telecommunications, rail transportation, and industrial automation fields to achieve permanent, highly reliable electrical connections between cables and terminals (or electrical connectors). Their principle involves applying significant mechanical pressure to induce controlled plastic deformation in the metal sleeve of the terminal, thereby tightly wrapping and engaging the inserted cable conductor (inner core). In high-performance electrical connections, a three-layer composite structure of "cable conductor-metal inner sleeve-terminal" is commonly used to enhance the mechanical strength and electrical reliability of the connection. However, this structure faces three interconnected and difficult-to-solve core technical problems in actual crimping processes, severely limiting the ultimate performance of the crimped connection.

[0003] First, when crimping multi-strand stranded wires, improper pretreatment or poor mold design can easily cause some conductor wires to stick up or be exposed from the terminal port. The exposed conductor tips can easily cause short circuits to ground or between phases, resulting in equipment failure or even fire.

[0004] Secondly, the angular structure of traditional crimping dies can create stress concentration points on the terminal surface during the crimping process. When energized, the current lines contract, causing an abnormal increase in local contact resistance, which leads to a vicious cycle of overheating and accelerated oxidation at the connection point, ultimately resulting in connection failure.

[0005] Finally, existing crimping processes largely rely on the operator's visual inspection and touch to place and support the cable assembly. At the moment of crimping, even slight tilting, sliding, or rotation of the cable assembly can cause the crimping position to shift or the angle to be incorrect. This directly results in a reduction in the contact area of ​​the crimping surface and uneven pressure distribution, making it difficult to accurately control the crimping height (compression amount).

[0006] Therefore, the present invention provides a cable end crimper that can fundamentally prevent the inner core from being exposed, guide the uniform flow of materials to avoid stress concentration, achieve coordinated deformation of composite structures, have adaptive precision positioning capabilities, and form an anti-loosening mechanical interlock. Summary of the Invention

[0007] To address the aforementioned problems, the present invention provides a cable end crimper, which solves the problems mentioned in the background art.

[0008] To achieve the above objectives, the embodiments of this application provide the following technical solution: This invention provides a cable end crimper for crimping cable assemblies; the cable assembly includes a terminal block, a metal inner sleeve, and a cable conductor; the inner core of the cable conductor passes through the metal inner sleeve and is folded in the opposite direction, wrapping around the outer wall of the metal inner sleeve; the terminal block is sleeved outside the metal inner sleeve containing the inner core; the cable end crimper includes a chassis, a power unit, and a crimping connector; a power switch is provided on the outer wall of the chassis, and a power module and a control unit are integrated inside the chassis; the power unit is located inside the chassis and is electrically connected to the power module, control unit, and power switch; the crimping connector is located on the side wall of the chassis and is connected to the power unit; the crimping connector includes a support component and a crimping component.

[0009] The supporting component includes a lower support mold, the upper end of which has at least one U-shaped through groove for receiving cable assemblies along its length direction; the crimping component includes a movable frame and an upper pressing mold disposed below it, the lower end of which has an M-shaped punch corresponding to the U-shaped through groove, and the middle protrusion of the M-shaped punch is configured as a two-stage stepped section.

[0010] According to an advantageous embodiment, the dimensions of the plurality of U-shaped through slots on the lower mold gradually decrease along its length.

[0011] According to an advantageous embodiment, a guide groove is provided at the bottom of the U-shaped through groove, and a limiting member for limiting the cable assembly is provided in the guide groove.

[0012] The limiting component includes a U-shaped bracket slidably disposed in the guide groove, a base slidably disposed inside the U-shaped bracket, and a threaded rod passing through the interior of both the U-shaped bracket and the base. The threaded rod is threadedly connected to the U-shaped bracket, the base is slidably sleeved on the outer wall of the threaded rod, and a movable spring is sleeved on the outer wall of the threaded rod located inside the U-shaped bracket. The two ends of the movable spring respectively abut against the side wall of the base and the inner wall of the U-shaped bracket.

[0013] The upper end face of the base is threaded with two limiting rods, and trapezoidal wedges are slidably mounted on both limiting rods. The outer wall of each limiting rod is fitted with a return spring.

[0014] According to an advantageous embodiment, the lower support mold is provided with symmetrical slots on both sides of the guide groove for the vertical side of the M-shaped punch to pass through.

[0015] According to an advantageous embodiment, the power unit is a hydraulic cylinder or an electric push rod, and the output end of the power unit is rigidly connected to the movable frame.

[0016] According to an advantageous embodiment, the inner wall of the terminal block is uniformly provided with toothed protrusions along the circumferential direction.

[0017] According to an advantageous embodiment, the toothed protrusions on the inner wall of the terminal block are embedded in the outer wall of the inner metal sleeve to form an interlocking structure, and the inner core of the cable conductor is sealed within the cavity formed by the terminal block and the inner metal sleeve.

[0018] According to an advantageous embodiment, the present invention also provides a method for crimping cable ends, specifically including the following steps;

[0019] Step 1: Pass the inner core of the cable conductor through the metal inner sleeve, then fold the inner core of the cable conductor in the opposite direction and wrap it around the outer wall of the metal inner sleeve.

[0020] Step 2: Fit the terminal block onto the outside of the metal inner sleeve containing the inner core to form a cable assembly;

[0021] Step 3: Place the cable assembly into the U-shaped channel of the support assembly and limit its position using the limiting device;

[0022] Step 4: Drive the crimping assembly with the power unit to press down the cable assembly, and remove it after it is formed.

[0023] Compared with the prior art, the cable end crimper provided in this embodiment of the invention has the following beneficial effects:

[0024] 1. This invention uses a unique “pre-processing folding-pressing and wrapping” process path, combined with the precise cavity design of M-shaped punch and two-stage steps, to completely and tightly compress and permanently seal the inner core of the cable within the cavity formed by the metal inner sleeve and the terminal during the pressing process. This solves the “burr” problem of exposed copper wires in the inner core in traditional processes and eliminates the risk of short circuits to ground or between phases that may be caused by exposed conductor tips.

[0025] 2. During the crimping process, this invention guides the terminal block and the inner metal sleeve to undergo uniform and smooth plastic deformation along an optimized streamline path, effectively avoiding sharp stress concentrations and internal material folding defects at corners. This results in a smooth and flat outer surface of the crimping area and a smooth transition of the cross-section. It significantly improves the fatigue and vibration resistance of the joint after crimping. Furthermore, the smooth and flat contact surface maximizes the contact area between the terminal block and the external connector and ensures uniform pressure distribution, significantly reducing and stabilizing contact resistance. This reduces Joule heating during operation and prevents the formation of local hot spots.

[0026] 3. The present invention has two steps in the middle of the M-shaped punch. The higher first step acts first to act on and compress the terminal body. As the stroke goes deeper, the slightly lower second step then intervenes and compresses the metal inner sleeve. The step-by-step but time-overlapping pressing method actively adapts to the yield characteristics of different components, ensuring that at the end of the pressing, the three layers of materials achieve synchronous and sufficient plastic deformation and tight bonding, forming an ideal connector with high mechanical strength and consistent conductive path.

[0027] 4. The semi-enclosed structure of the U-shaped through groove in this invention provides initial centering; together with the limiting component, it can automatically complete the position correction and apply a flexible and continuous lateral locking force during placement according to the outer diameter and length of the terminal, so as to firmly and accurately fix the terminal in the preset crimping position, eliminating errors such as skewing and sliding caused by unstable manual support, ensuring that the angle of each crimping is vertical and the position is accurate, thereby controlling the crimping height within the ideal range.

[0028] 5. In the final stage of crimping, the toothed protrusions on the inner wall of the terminal block of this invention are embedded into the outer wall of the plastically deformed metal inner sleeve, forming a microscopic, continuous interlocking structure at the interface between the two. This interlocking structure not only provides mechanical tensile and torsional strength far exceeding that of traditional friction, but also creates numerous parallel microscopic current channels through a large number of interlocking points, significantly reducing and stabilizing the contact resistance. It can also effectively resist the microscopic slippage and stress relaxation of the interface that are prone to occur under dynamic loads such as vibration and thermal cycling, thereby ensuring the long-term stability of the contact pressure at the connection point. Attached Figure Description

[0029] Figure 1 This is a three-dimensional structural diagram of the cable crimper.

[0030] Figure 2 This is a three-dimensional view of the first position of the cable crimper during operation.

[0031] Figure 3 This is a three-dimensional view of the second position of the cable crimper during operation.

[0032] Figure 4 This is a plan view of the cable conductor being pressed down by the crimping assembly in this cable end crimper.

[0033] Figure 5 This is a planar sectional view of the crimping assembly in the cable end crimper.

[0034] Figure 6 For the present invention Figure 5 A magnified view of section A in the image.

[0035] Figure 7 This is a diagram showing the state of the cable conductor portion after it passes through the metal inner sleeve in this invention.

[0036] Figure 8 for Figure 7 A diagram showing the initial state of the through-terminals in the middle structure.

[0037] Figure 9 This is a cross-sectional view of the cable conductor of the present invention after being crimped together with terminals and a metal inner sleeve.

[0038] The attached diagram shows the following reference numerals: 1. Chassis; 2. Power unit; 3. Crimping connector; 31. Support assembly; 32. Crimping assembly; 33. Limiting component; 311. Lower support mold; 312. U-shaped through groove; 313. Guide groove; 314. Slot; 331. U-shaped bracket; 332. Base; 333. Threaded rod; 334. Movable spring; 335. Limiting rod; 336. Trapezoidal wedge; 337. Return spring; 321. Movable frame; 322. Upper pressing mold; 323. M-shaped punch; 101. Terminal block; 102. Metal inner sleeve; 103. Cable conductor. Detailed Implementation

[0039] The following is in conjunction with the appendix Figure 1 -Appendix Figure 9 This application will be described in further detail.

[0040] Please refer to the following: Figure 1 and Figure 2 A cable end crimper is disclosed for crimping cable assemblies. The cable assembly includes a terminal block 101, a metal inner sleeve 102, and a cable conductor 103. The cable end crimper includes a housing 1, a power unit 2, and a crimp connector 3. A power switch is provided on the outer wall of the housing 1, and a power module and a control unit are integrated inside the housing 1. The power unit 2 is located inside the housing 1 and is electrically connected to the power module, the control unit, and the power switch. The crimp connector 3 is located on the side wall of the housing 1 and is connected to the power unit 2. The crimp connector 3 consists of a support component 31 and a crimping component 32.

[0041] Specifically, before crimping the terminal block 101 to the cable conductor 103, the inner core of the cable conductor 103 is first passed through the inner metal sleeve 102, keeping the boundary between the inner core and the insulation layer within the inner metal sleeve 102, while ensuring that the inner core of the cable conductor 103 completely penetrates the inner metal sleeve 102 (see...). Figure 7 Then, the cable conductor 103 passes through the inner core portion of the metal inner sleeve 102 and is folded in the opposite direction, so that the folded inner core is evenly distributed on the outer periphery of the metal inner sleeve 102. After completing the above operation, the terminal block 101 is then installed (see...). Figure 8 and Figure 9 Then, the entire cable conductor 103 with the terminal block 101 (i.e., the cable assembly) is placed inside the support assembly 31, and the cable assembly is kept in a limited position. Then, the power switch is pressed, and the power unit 2 is controlled by the control unit to drive the crimping assembly 32 to move down, thus completing the crimping of the cable assembly. After the crimping is completed, the crimped cable assembly can be removed. After the crimping is formed, the inner core of the cable conductor 103 is tightly closed, and the inner core of the cable conductor 103 is housed between the metal inner sleeve 102 and the terminal block 101, so there will be no problem of short circuit due to the inner core being exposed.

[0042] It should be noted that the process of the power unit 2 driving the pressing assembly 32 to move downward is usually achieved by direct drive of a hydraulic cylinder or an electric push rod. In this embodiment, a hydraulic cylinder is preferred. The output end of the hydraulic cylinder is rigidly connected to the pressing assembly 32. When pressing is required, controlling the operation of the hydraulic cylinder can stably drive the pressing assembly 32 to move downward.

[0043] See Figure 3 The supporting component 31 includes a lower support mold 311. The upper end of the lower support mold 311 has U-shaped through grooves 312 that extend along its width direction evenly along its length direction, and the size of the U-shaped through grooves 312 gradually decreases along its length direction. The purpose of the U-shaped through grooves 312 gradually decreasing along its length direction is to enable crimping of different types of cable conductors 103, greatly improving the applicability of crimping. Furthermore, the semi-enclosed structure of the U-shaped through grooves 312 provides an automatic centering effect for the terminal block 101 placed therein in the radial direction, forcing the axis of the terminal block 101 to be parallel to the crimping direction.

[0044] See Figure 5 and Figure 6 The bottom of the U-shaped through groove 312 is provided with a guide groove 313, and a limiting member 33 for limiting the cable is provided in the guide groove 313. The limiting member 33 can limit the cable assembly in the corresponding U-shaped through groove 312, so as to prevent the cable assembly from being tilted or falling off during the crimping process, thereby affecting the crimping quality.

[0045] See Figure 5 and Figure 6 The limiting member 33 includes a U-shaped bracket 331 slidably disposed in the guide groove 313, a base 332 slidably disposed inside the U-shaped bracket 331, and a threaded rod 333 passing through the interior of the U-shaped bracket 331 and the base 332. The threaded rod 333 is threadedly connected to the U-shaped bracket 331. The base 332 is slidably sleeved on the outer wall of the threaded rod 333. A movable spring 334 is sleeved on the outer wall of the threaded rod 333 located inside the U-shaped bracket 331. One end of the movable spring 334 abuts against the side wall of the base 332, and the other end abuts against the inner wall of the U-shaped bracket 331. Two limiting rods 335 are threadedly connected to the upper end face of the base 332. A trapezoidal wedge block 336 is slidably disposed on both limiting rods 335, and a return spring 337 is sleeved on the outer wall of each limiting rod 335.

[0046] When limiting the cable assembly, first adjust the position of the trapezoidal wedge 336 according to the length of the terminal block 101. Specifically, this adjustment is achieved by rotating the threaded rod 333. The rotation of the threaded rod 333 causes the U-shaped bracket 331, which is threadedly connected to it, to move inside the guide groove 313, thereby completing the position adjustment. Then, place the cable assembly in the U-shaped through groove 312 in an inclined downward pressing manner. In the final stage of the placement process, after the side wall of the terminal block 101 is in contact with the upper end of the trapezoidal wedge 336, continue to press the cable assembly down until the trapezoidal wedge 336 is fully engaged. 36 moves along the limit rod 335 to the limit state. At this time, the reset spring 337 is also fully compressed and in the limit state. During the continued pressing process, the side wall of the cable conductor 103 will pass over the upper inclined surface of the trapezoidal wedge 336 until it abuts against the side wall of the trapezoidal wedge 336. At this time, the movable spring 334 is compressed, and the position of the base 332 inside the U-shaped bracket 331 is adjusted accordingly. Through the elastic action of the movable spring 334, the side wall of the trapezoidal wedge 336 abuts against the side wall of the cable conductor 103, completing the limiting work of the cable assembly.

[0047] The limiting member 33 can adaptively tighten terminals 101 of different lengths, ensuring that the crimping point of terminals 101 of different lengths is always in the optimal position after being limited and fixed. During the process of crimping the cable conductor 103 with the terminal 101, the stability of the cable assembly is effectively guaranteed. Thus, during the crimping process, the crimping angle is perpendicular to the angle of the cable assembly, and the contact area will not be reduced due to the crimping angle being skewed. At the same time, after the limiting member 33 limits and tightens the terminal 101, there is no need for manual support of the cable assembly. It can effectively maintain the uniformity of the overall force on the crimping surface, so that the crimping height after crimping is in an ideal state. It will not cause insufficient contact area due to insufficient crimping height in some areas and insufficient deformation of the terminal 101 and the metal inner sleeve 102 in the cable assembly. Nor will it cause excessive crimping height, causing the terminal 101 and the metal inner sleeve 102 to be over-compressed, resulting in a decrease in mechanical strength or breakage.

[0048] See Figure 3 , Figure 4 and Figure 5 The pressing assembly 32 includes a movable frame 321, which is connected to the power unit 2. An upper pressing mold 322 is provided inside the movable frame 321 by bolts. M-shaped punches 323 that mate with U-shaped through slots 312 are evenly provided at the lower end of the upper pressing mold 322 along its length. The lower support mold 311 is also symmetrically provided with slots 314 on both sides of the guide groove 313 for the vertical side of the M-shaped punches 323 to pass through.

[0049] During the specific crimping of the cable assembly, the power unit 2 drives the movable frame 321 to move downwards, while the upper crimping die 322 moves downwards synchronously with the movable frame 321, gradually approaching the wiring terminal 101 inside the U-shaped through groove 312. The opening of the U-shaped through groove 312 guides the downward movement of the M-shaped punch 323, maintaining crimping accuracy, and the slot 314 simultaneously limits the downward movement path of the M-shaped punch 323. Through the action of the M-shaped punch 323, the crimping of the cable assembly is gradually completed. After crimping, the exposed inner core end of the cable conductor 103 is folded and stored between the wiring terminal 101 and the metal inner sleeve 102, effectively avoiding the exposure of the inner core in the traditional crimping process. This reduces the risk of short circuits. It should be noted that the M-shaped punch 323 has a continuously varying curvature. During the crimping process, this shape guides the metal material of the terminal 101 and the inner metal sleeve 102 to undergo more uniform and smooth plastic deformation, avoiding the severe stress concentration and material folding risks associated with traditional crimping at the corners. This results in a smooth and flat outer surface of the crimping area and a smooth cross-sectional transition. The smooth and flat crimping surface maximizes the contact area between the terminal 101 and the external connector or busbar, and ensures uniform contact pressure distribution. According to electrical contact theory, this effectively reduces and stabilizes contact resistance, thereby reducing Joule heating during operation and preventing localized overheating.

[0050] See Figure 5 The middle protrusion of the M-shaped punch 323 is configured as a two-stage stepped section. The two-stage stepped section allows the higher first-stage step to contact and compress the body of the terminal 101 first during the pressing process of the M-shaped punch 323. As the pressing stroke deepens, the slightly lower second-stage step begins to contact and compress the inner metal sleeve 102. This staged but overlapping compression sequence ensures that the terminal 101 and the inner metal sleeve 102, which may have different hardness and thickness, can achieve coordinated plastic deformation. This allows both of them, as well as the inner core of the cable conductor 103 sandwiched between them, to achieve ideal density and bonding strength at the end of the pressing process, preventing loose internal structure or uneven stress caused by asynchronous deformation.

[0051] To further improve the connection strength of the cable assembly after crimping, refer to... Figure 8 and Figure 9 The inner wall of the terminal 101 is uniformly provided with toothed protrusions along its circumference. First, when the terminal 101 is put into the metal inner sleeve 102 with the folded inner core, these toothed protrusions can mechanically comb the scattered inner core copper wires, making them straighter and more evenly wrapped around the metal inner sleeve 102, laying the foundation for subsequent uniform crimping.

[0052] During the crimping deformation stage, the toothed protrusions on the inner wall of the terminal 101 will embed into the outer wall of the plastically deformed metal inner sleeve 102 under pressure, forming a microscopic interlocking structure that significantly increases the mechanical bonding strength between the two.

[0053] Finally, this concave-convex interlocking structure greatly increases the effective contact area between the terminal block 101 and the metal inner sleeve 102, forming more parallel micro-contact points. The more parallel micro-contact points greatly increase the current path, thereby further reducing and stabilizing the contact resistance at the connection, ensuring uniform current distribution, and fundamentally avoiding the generation of local hot spots.

[0054] The specific working process of using the above-mentioned cable end crimper is as follows:

[0055] Step 1: Preprocessing:

[0056] 1. Inserting into the metal inner sleeve 102: Insert the exposed inner core of the cable conductor 103 to be crimped completely through the metal inner sleeve 102 from one end until the boundary between the inner core and the insulation layer is inside the metal inner sleeve 102.

[0057] 2. Fold the inner core: Fold the inner core of the cable that extends out of the other end of the metal inner sleeve 102 in the reverse direction along the original path, so that it is evenly wrapped around the outer circumference of the metal inner sleeve 102.

[0058] 3. Connecting the terminal block 101: Place the terminal block 101 over the metal inner sleeve 102 that has already wrapped the inner core; at this time, the toothed protrusions on the inner wall of the terminal block 101 will comb the folded inner core, making it more evenly distributed.

[0059] Step Two: Equipment Preparation and Positioning

[0060] 1. Select mold position: Select the U-shaped through groove 312 on the lower mold 311 of the supporting component 31 according to the cable diameter.

[0061] 2. Pre-adjustment limit: Based on the length of the terminal block 101, rotate the threaded rod 333 of the limit member 33 to drive the U-shaped bracket 331 and the trapezoidal wedge 336 above it to move along the guide groove 313 and preset them to the corresponding position of the crimping termination.

[0062] Step 3: Clamping and self-adaptive locking:

[0063] 1. Tilt insertion: Place the pre-processed cable assembly into the selected U-shaped through groove 312 at a tilt angle.

[0064] 2. Trigger wedge: When the cable assembly is lowered, the outer wall of the terminal 101 contacts and presses down the upper inclined surface of the trapezoidal wedge 336, causing it to slide down along the limit rod 335 and compress the reset spring 337.

[0065] 3. Locking complete: Continue pressing down on the cable assembly until it is fully seated at the bottom of the U-shaped groove 312. During this process, the sidewall of the cable conductor 103 passes over the top of the trapezoidal wedge 336 and contacts its vertical sidewall, pushing the base 332 to compress the movable spring 334. After being placed in position, the rebound force of the movable spring 334 applies a continuous lateral clamping force to the cable assembly through the vertical sidewall of the trapezoidal wedge 336, firmly limiting it in the U-shaped groove 312, ensuring that the crimping point is accurately positioned and the axis is parallel to the crimping direction.

[0066] Step 4: Perform crimping:

[0067] 1. Start crimping: Press the power switch, and the control unit commands the power unit 2 to work.

[0068] 2. Powered downward movement: The power unit 2 drives the movable frame 321 and upper die 322 of the crimping assembly 32 to move steadily downward in the vertical direction. The opening of the U-shaped through groove 312 and the slot 314 together guide and ultimately limit the downward path of the M-shaped punch 323. Finally, the crimping work is completed. During the crimping process, the higher first step of the M-shaped punch 323 first contacts and compresses the body of the terminal 101, causing it to undergo plastic deformation. As the stroke deepens, the slightly lower second step of the M-shaped punch 323 begins to contact and compress the inner metal sleeve 102. Under the guidance of the continuous curvature profile, the materials of the terminal 101 and the inner metal sleeve 102 flow evenly, achieving coordinated deformation. Under great pressure, the toothed protrusions on the inner wall of the terminal 101 embed into the deformed outer wall of the inner metal sleeve 102, forming a micro-mechanical interlock. At the same time, the inner core of the cable conductor 103 is completely and tightly compressed and sealed within the cavity formed by the terminal block 101 and the metal inner sleeve 102.

[0069] Step 5: Complete package pickup:

[0070] 1. Reset: After the crimping reaches the preset stroke or pressure, the power unit 2 drives the crimping assembly 32 to rise and reset.

[0071] 2. Remove the workpiece: Remove the crimped cable assembly from the U-shaped through groove 312; at this time, the crimping area of ​​the terminal 101 has a smooth M-shape appearance, with no exposed inner core, and a firm electrical and mechanical connection is formed inside.

[0072] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0073] Furthermore, the terms "first," "second," "number one," and "number two" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first," "second," "number one," or "number two" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0074] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0075] The embodiments described herein are preferred embodiments of the present invention and are not intended to limit the scope of protection of the present invention. Therefore, all equivalent changes made in accordance with the structure, shape, and principle of the present invention should be covered within the scope of protection of the present invention.

Claims

1. A cable end crimper for crimping cable assemblies; characterized in that, The cable assembly includes a terminal block, a metal inner sleeve, and a cable conductor. The inner core of the cable conductor passes through the metal inner sleeve, is folded back, and wraps around the outer wall of the metal inner sleeve. The terminal block is sleeved on the outside of the metal inner sleeve containing the inner core. The cable crimper includes: The chassis has a power switch on its outer wall and an integrated power module and control unit inside the chassis. The power unit is located inside the chassis and is electrically connected to the power module, control unit, and power switch. The crimp connector is located on the side wall of the chassis and connects to the power unit. The crimp connector includes a support assembly and a crimping assembly; The supporting component includes a lower support mold, and the upper end of the lower support mold has at least one U-shaped through groove for receiving the cable assembly along its length. The pressing assembly includes a movable frame and an upper pressing die disposed below it. The lower end of the upper pressing die is provided with an M-shaped punch corresponding to the U-shaped through groove. The middle protruding section of the M-shaped punch is configured as a two-stage stepped shape. The bottom of the U-shaped through groove is provided with a guide groove, and a limiting component for limiting the position of the cable assembly is provided in the guide groove; The limiting component includes a U-shaped bracket slidably disposed in the guide groove, a base slidably disposed inside the U-shaped bracket, and a threaded rod passing through the interior of the U-shaped bracket and the base. The threaded rod is threadedly connected to the U-shaped bracket, the base is slidably sleeved on the outer wall of the threaded rod, and a movable spring is sleeved on the outer wall of the threaded rod located inside the U-shaped bracket. The two ends of the movable spring respectively abut against the side wall of the base and the inner wall of the U-shaped bracket. The upper end face of the base is threaded with two limiting rods, and a trapezoidal wedge is slidably set on both limiting rods. The outer wall of each limiting rod is fitted with a reset spring. The lower support mold has symmetrical slots on both sides of the guide groove for the vertical side of the M-shaped punch to pass through.

2. The cable end crimper according to claim 1, characterized in that: The dimensions of the multiple U-shaped through slots on the lower mold gradually decrease along their length.

3. A cable end crimper according to any one of claims 1-2, characterized in that: The power unit is a hydraulic cylinder or an electric push rod, and the output end of the power unit is rigidly connected to the movable frame.

4. A cable end crimper according to claim 1, characterized in that: The inner wall of the terminal block is uniformly provided with tooth-shaped protrusions along the circumferential direction.

5. A cable end crimper according to claim 2, characterized in that: The toothed protrusions on the inner wall of the terminal block are embedded in the outer wall of the metal inner sleeve to form an interlocking structure, and the inner core of the cable conductor is sealed in the cavity formed by the terminal block and the metal inner sleeve.

6. A method for crimping cable ends, using a cable end crimper as described in any one of claims 1-5, characterized in that: Specifically, it includes the following steps; Step 1: Pass the inner core of the cable conductor through the metal inner sleeve, then fold the inner core of the cable conductor in the opposite direction and wrap it around the outer wall of the metal inner sleeve. Step 2: Fit the terminal block onto the outside of the metal inner sleeve containing the inner core to form a cable assembly; Step 3: Place the cable assembly into the U-shaped channel of the support assembly and limit its position using the limiting device; Step 4: Drive the crimping assembly with the power unit to press down the cable assembly, and remove it after it is formed.

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