IDC puncturing and crimping tool

Abstract

The utility model relates to the technical field of electrical element crimping, in particular to an IDC puncture crimping tool which comprises a supporting box, a plurality of stand columns are fixed at the top of the supporting box, a constraint frame is fixed at the top of each stand column, a crimping station is arranged at the bottom of an inner cavity of the constraint frame, an IDC connector is placed at the crimping station, and the IDC connector is fixed on the supporting box. A corresponding wire is inserted in the IDC connector, positioning clamping mechanisms are installed on the left side and the right side of the IDC connector respectively, a main pressure applying piece is installed on the portion, above the IDC connector, of the constraint frame, and the lower end of the main pressure applying piece is fixedly connected with the center of the top of a horizontal pressing plate. According to the utility model, the IDC connectors with different sizes and lengths are preliminarily fixed and clamped through the position adjusting and clamping mechanism, and under the cooperation or independent action of the main pressure applying piece and the auxiliary pressure applying piece, the rapid puncturing of the sheath of the lead and the pressing of the pricking needle in place are realized, and the conductive connectivity after the pricking needle abuts against the conductor is ensured.

Description

Technical Field

[0001] This utility model relates to the field of electrical component crimping technology, and in particular to IDC puncture crimping tooling. Background Technology

[0002] IDC piercing crimping fixtures are tools or devices used to achieve piercing connections in IDC (Insulation Piercing Connectors). In the field of electronic and electrical connections, they are widely used in consumer electronics, automotive wiring harnesses, and communication equipment industries due to their ability to achieve reliable electrical connections without pre-stripping the wire insulation.

[0003] Traditional IDC crimping technology uses tooling equipment to apply pressure to the metal spiked terminals of the IDC connector, causing them to penetrate the wire insulation layer and form a tight contact with the conductor, thereby completing electrical conduction.

[0004] Currently, the main technical problems with IDC piercing and crimping tools on the market are as follows:

[0005] The pressure control precision is insufficient. Existing tooling mostly uses simple cylinders to apply pressure, which makes it difficult to accurately control the crimping force. When the pressure is too high, it can easily cause the conductor to deform or even break. When the pressure is too low, it will increase the contact resistance between the terminal and the conductor, affecting the reliability of the electrical connection.

[0006] The existing press-fit structure has defects in the design of the positioning mechanism. The tooling effectively limits the positioning of the IDC connector and the wire. During the press-fit process, it is easy to deviate, which causes the piercing terminal to fail to accurately penetrate the center of the wire, resulting in poor contact.

[0007] The existing tooling requires frequent tooling component replacements when producing multiple product models on a mixed production line, resulting in a significant reduction in production efficiency.

[0008] Given the shortcomings of existing IDC piercing and crimping fixtures in terms of pressure control and positioning accuracy, there is a significant need to design a new type of IDC piercing and crimping fixture. Utility Model Content

[0009] To solve one of the aforementioned technical problems, the present invention employs the following technical solution: an IDC puncture crimping fixture, comprising a support box, several columns fixed on the top of the support box, a constraint frame fixed on the top of each column, a crimping station provided at the bottom of the inner cavity of the constraint frame, an IDC connector placed at the crimping station, a corresponding wire inserted inside the IDC connector, and adjustment clamping mechanisms installed on the left and right sides of the IDC connector respectively, the two adjustment clamping mechanisms cooperating to position the IDC connector, a main pressure component installed on the constraint frame above the IDC connector, the lower end of the main pressure component being fixedly connected to the top center of the horizontal pressure plate.

[0010] Based on any of the above technical solutions, a further optimization is made as follows: secondary pressure-applying components are symmetrically spaced on both sides of the main pressure-applying component, and the two secondary pressure-applying components and the main pressure-applying component are independent of each other in the working state.

[0011] Based on any of the above technical solutions, a further optimization is made as follows: the adjusting clamping mechanism includes a horizontally arranged adjusting screw, the inner end of which moves through a threaded hole on the lower outer side wall of the constraint frame and extends to the crimping station; a vertically arranged positioning plate is fixedly installed at the end of the adjusting screw, the inner end of which is used to abut against the corresponding end of the IDC connector; and a number of actuating rods are fixedly installed at even intervals along the circumference of the outer side wall of the adjusting screw.

[0012] Based on any of the above technical solutions, a further optimization is made as follows: the main pressure-applying component includes a vertically arranged central electric cylinder, the middle part of the cylinder barrel of the central electric cylinder is fixed on the constraint frame, and the bottom of the telescopic end of the central electric cylinder is fixed to the top center of the horizontal pressure plate.

[0013] Based on any of the above technical solutions, a further optimization is made as follows: the auxiliary pressure-applying component includes a vertically arranged side electric cylinder, the middle part of the cylinder barrel of the side electric cylinder is fixed on the constraint frame, and the bottom of the telescopic end of the side electric cylinder movably abuts against the top of one side of the horizontal pressure plate.

[0014] Based on any of the above technical solutions, a further optimization is made as follows: two guide columns are respectively arranged at intervals on both sides of the inner cavity of the constraint frame, and the top and bottom of each guide column are fixedly arranged. The horizontal pressure plate is movably sleeved on the outer wall of the guide column through the corresponding through holes at its four corners. Vertical springs are respectively sleeved on the outer wall of the guide column below the horizontal pressure plate, and the bottom of the vertical springs is fixedly connected to the constraint frame.

[0015] Based on any of the above technical solutions, a further optimization is made by spraying a protective coating on the inner end face of the positioning disk.

[0016] Based on any of the above technical solutions, a further optimization is made as follows: a pressure alarm is fixedly installed on the top of the horizontal pressure plate, and the top of the pressure alarm abuts against the bottom of the horizontal pressure plate.

[0017] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0018] 1. This utility model uses an adjustment clamping mechanism to initially fix and clamp IDC connectors of different sizes and lengths. With the cooperation or individual action of the main pressure component and the auxiliary pressure component, it can quickly pierce the outer sheath of the wire and press the needle into place, ensuring the conductivity after the needle and the conductor are pressed together, thus improving the convenience of crimping operation and the reliability of connection.

[0019] 2. In this utility model, the auxiliary pressure components symmetrically arranged on both sides of the main pressure component are independent of the main pressure component in the working state. They can be selected to apply pressure individually or in combination according to the length of the IDC connector, ensuring the balance and stability of the pressure application point. This solves the problem of uneven pressure distribution in traditional tooling and improves the consistency of crimping quality.

[0020] 3. The adjusting clamping mechanism of this utility model achieves precise positioning and rapid adjustment of IDC connectors through the cooperation of adjusting screw, positioning plate and toggle rod. It can adapt to connectors of different lengths without additional tools, shorten production changeover time and improve the versatility of tooling and production efficiency.

[0021] 4. This utility model sets guide columns and vertical springs in the inner cavity of the constraint frame. The guide columns limit the horizontal displacement of the horizontal pressure plate, and the vertical springs buffer the impact of pressing and assist the return stroke, ensuring the verticality and stability of the pressing process, while reducing equipment wear and extending the service life of the tooling. Attached Figure Description

[0022] To more clearly illustrate the specific embodiments of this utility model or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. In all the drawings, similar elements or components are generally identified by similar reference numerals. In the drawings, the elements or components are not necessarily drawn to scale.

[0023] Figure 1 This is a three-dimensional structural diagram of the present invention.

[0024] Figure 2 This is a schematic diagram of the main structure of this utility model.

[0025] Figure 3 This is a partially enlarged structural schematic diagram of the present invention.

[0026] In the diagram, 1. Support box; 2. Column; 3. Constraint frame; 4. IDC connector; 5. Wire; 6. Horizontal pressure plate; 7. Adjusting screw; 8. Positioning plate; 9. Actuating lever; 10. Central electric cylinder; 11. Side electric cylinder; 12. Guide column; 13. Vertical spring; 14. Pressure alarm. Detailed Implementation

[0027] The embodiments of the present utility model will now be described in detail with reference to the accompanying drawings. These embodiments are only used to more clearly illustrate the technical solution of the present utility model, and are therefore merely examples and should not be construed as limiting the scope of protection of the present utility model. The specific structure of the present utility model is as follows: Figures 1-3 As shown in the image.

[0028] Example 1: An IDC puncture crimping fixture includes a support box 1. Several columns 2 are fixed on the top of the support box 1. A constraint frame 3 is fixed on the top of each column 2. A crimping station is provided at the bottom of the inner cavity of the constraint frame 3. An IDC connector 4 is placed at the crimping station. A corresponding wire 5 is inserted into the IDC connector 4. Adjustment clamping mechanisms are installed on the left and right sides of the IDC connector 4 respectively. The two adjustment clamping mechanisms cooperate to position the IDC connector 4. A main pressure component is installed on the constraint frame 3 above the IDC connector 4. The lower end of the main pressure component is fixedly connected to the top center of the horizontal pressure plate 6.

[0029] The IDC piercing and crimping fixture of this utility model can use the adjustment and clamping mechanism to initially fix and clamp IDC connectors 4 of different sizes and lengths. At the same time, when piercing and crimping, it can quickly pierce the outer sheath of the wire 5 and press the piercing needle into place under the combined action of the main pressure component and the secondary pressure component or the action of the main pressure component alone. After the piercing needle is pressed against the conductor, the conductivity is guaranteed.

[0030] In specific operations, depending on the length of the current IDC connector 4, choose to use the main pressure component alone for crimping or use the main pressure component and the auxiliary pressure component together for pressure application to ensure the balance and stability of the pressure application points and the balance of force when pressing each needle.

[0031] During operation, the support box 1 forms a rigid structure by supporting the constraint frame 3 through the column 2, and the crimping station provides a positioning reference for the IDC connector 4. The adjustment and clamping mechanism fixes the IDC connector 4 in the center of the crimping station through mechanical abutment on the left and right sides; the main pressure component drives the horizontal pressure plate 6 to press down vertically, so that the piercing needle of the IDC connector 4 pierces the insulation layer of the wire 5 and makes contact with the conductor, thus realizing the electrical connection.

[0032] Based on any of the above technical solutions, a further optimization is made as follows: secondary pressure-applying components are symmetrically spaced on both sides of the main pressure-applying component, and the two secondary pressure-applying components and the main pressure-applying component are independent of each other in the working state.

[0033] The auxiliary pressure-applying components are symmetrically arranged side electric cylinders 11 on both sides of the main pressure-applying component, and the three are driven by an independent servo control system. When crimping IDC connectors 4 of different specifications, the main pressure-applying component applies the main crimping force from the top center, and the auxiliary pressure-applying components on both sides can independently adjust the output force according to parameters such as the distribution of the needles and the width of the connector, forming an asymmetrical pressure distribution.

[0034] The pressing stroke and holding time of each pressure-applying component can also be set individually. The parameters can be configured independently through PLC program or human-machine interface to ensure uniform force on the pressing surface.

[0035] Based on any of the above technical solutions, a further optimization is made as follows: the adjusting clamping mechanism includes a horizontally arranged adjusting screw 7, the inner end of which moves through a threaded hole on the lower outer side wall of the constraint frame 3 and extends to the crimping station; a vertically arranged positioning plate 8 is fixedly installed at the end of the adjusting screw 7, the inner end of which is used to abut against the corresponding end of the IDC connector 4; and a plurality of toggle levers 9 are fixedly installed at even intervals along the circumference of the outer side wall of the adjusting screw 7.

[0036] The main and auxiliary pressure components can independently adjust the pressure, pressing speed, and holding time, supporting three modes: center pressure, side pressure, and three-cylinder linkage, to adapt to different pressing process requirements.

[0037] Based on any of the above technical solutions, a further optimization is made as follows: the main pressure-applying component includes a vertically arranged central electric cylinder 10, the middle part of the cylinder of the central electric cylinder 10 is fixed on the constraint frame 3, and the bottom of the telescopic end of the central electric cylinder 10 is fixed to the top center of the horizontal pressure plate 6.

[0038] The central electric cylinder 10 is vertically installed in the middle of the constraint frame 3. The cylinder barrel is fixed to the top beam of the constraint frame 3 by bolts, and the telescopic end is rigidly connected to the top center of the horizontal pressure plate 6 through a flange.

[0039] When the central electric cylinder 10 is energized, the servo motor drives the ball screw pair to convert the rotational motion into linear motion, causing the horizontal pressure plate 6 to press down vertically. By adjusting the current or pulse count of the electric cylinder through the controller, the output force and pressing stroke can be precisely controlled, achieving control over the crimping force and pressing depth. During crimping, the electric cylinder initially moves downwards at a relatively fast idle speed, automatically switching to slow pressure when approaching the IDC connector 4. After reaching the preset pressure value, it holds the pressure for 2-3 seconds to complete the tight contact between the needle and the conductor.

[0040] Based on any of the above technical solutions, a further optimization is made as follows: the auxiliary pressure component includes a vertically arranged side electric cylinder 11, the middle part of the cylinder of the side electric cylinder 11 is fixed on the constraint frame 3, and the bottom of the telescopic end of the side electric cylinder 11 movably abuts against the top of one side of the horizontal pressure plate 6.

[0041] The side-mounted electric cylinder 11 is vertically installed on both sides of the constraint frame 3. The middle part of the cylinder is fixed to the column 2 of the constraint frame 3 by bolts. The bottom of the telescopic end contacts the side of the horizontal pressure plate 6 through a movable abutment structure (such as a spherical bearing or a spring buffer assembly). When the main pressure-applying component presses down, the side-mounted electric cylinder 11 can independently output pressure, achieving two functions by abutting the side of the pressure plate:

[0042] Lateral pressure compensation: For scenarios where the density of the needles on both sides of the IDC connector 4 is different (such as 3 rows of needles on the left and 2 rows on the right), the side electric cylinder 11 can adjust the pressure on both sides separately to ensure that the crimping force of each needle is uniform.

[0043] Example 2: Compared with Example 1, this example also includes the following technical features:

[0044] Based on any of the above technical solutions, a further optimization is made as follows: two guide columns 12 are respectively arranged at intervals on both sides of the inner cavity of the constraint frame 3. The top and bottom of each guide column 12 are fixedly arranged. The horizontal pressure plate 6 is movably sleeved on the outer wall of the guide column 12 through the corresponding through holes at its four corners. Vertical springs 13 are respectively sleeved on the outer wall of the guide column 12 below the horizontal pressure plate 6. The bottom of the vertical springs 13 is fixedly connected to the constraint frame 3.

[0045] Two guide posts 12 are installed on each side of the inner cavity of the constraint frame 3. The top and bottom of the guide posts 12 are fixed to the constraint frame 3 by bolts to form a vertical guide structure. The horizontal pressure plate 6 has through holes at its four corners and is sleeved on the outer wall of the guide posts 12, allowing it to slide up and down along the guide posts 12. The vertical spring 13 is sleeved on the guide posts 12 and located below the horizontal pressure plate 6. The bottom of the vertical spring 13 is fixed to the constraint frame 3, and the top abuts against the bottom surface of the horizontal pressure plate 6. When the main pressure component drives the horizontal pressure plate 6 to press down, the guide posts 12 restrict the horizontal displacement of the horizontal pressure plate 6 to ensure vertical movement; the horizontal pressure plate 6 presses down to compress the vertical spring 13; after pressing is completed, the vertical spring 13 releases its elastic potential energy to assist the pressure plate in returning to its original position, while also buffering the impact load during the pressing process.

[0046] Based on any of the above technical solutions, a further optimization is made by spraying a protective coating on the inner end face of the positioning disk 8.

[0047] The protective coating is applied to the contact surfaces of the positioning plate 8 and the IDC connector 4 using a spraying process, forming a thick protective coating. When the positioning plate 8 abuts against the IDC connector 4, the protective coating uses its own physical properties to isolate the metal contact surfaces.

[0048] Based on any of the above technical solutions, a further optimization is made as follows: a pressure alarm 14 is fixedly installed on the top of the horizontal pressure plate 6, and the top of the pressure alarm 14 abuts against the bottom of the horizontal pressure plate 6.

[0049] The pressure alarm 14 is bolted to the top of the horizontal pressure plate 6, with its built-in pressure sensor (such as a strain gauge sensor) directly contacting the bottom of the horizontal pressure plate 6. When the main pressure-applying component drives the horizontal pressure plate 6 downward, the sensor collects the crimping force data in real time and transmits it to the signal processing module. When the pressure exceeds the preset threshold or the crimping force fluctuates by more than ±5%, the alarm sounds an alarm via an audible and visual device (flashing LED light + buzzer alarm), and simultaneously, it can link with the control system to cut off the power to the electric cylinder to prevent overpressure damage to the wire 5 or the IDC connector 4. The alarm supports manual setting of the alarm threshold via a knob or human-machine interface, with a threshold range covering 5-500N to adapt to different crimping requirements.

[0050] Specific crimping process:

[0051] The IDC connector 4 is placed at the crimping station at the bottom of the inner cavity of the constraint frame 3. The position of the positioning plate 8 is adjusted by the adjustment and clamping mechanism on the left and right sides: the rotating toggle lever 9 drives the adjusting screw 7 to move horizontally, so that the inner end face of the positioning plate 8 abuts against both sides of the IDC connector 4, ensuring that its center is aligned with the crimping station, and the positioning accuracy reaches ±0.1mm.

[0052] If the surface of IDC connector 4 has a precision plating, ensure that the protective coating (such as PTFE) on the inner end face of the positioning disk 8 is intact to avoid scratching the outer shell.

[0053] The positioning discs 8 of the two-sided adjusting clamping mechanisms abut against the IDC connector 4 through threaded transmission, forming a rigid positioning to prevent displacement during the crimping process. At this time, the horizontal pressure plate 6 is sleeved on the guide column 12 through the four corner through holes and is in the state of waiting to be pressed down.

[0054] After the main pressure component (central electric cylinder 10) is powered on, the telescopic end drives the horizontal pressure plate 6 to press down vertically along the guide column 12. In the initial stage, it moves down quickly without stopping, and automatically switches to slow pressure (e.g., 5mm / s) when it approaches the IDC connector 4.

[0055] If the auxiliary pressure device (side electric cylinder 11) is activated, the two side electric cylinders 11 will output pressure synchronously or asynchronously, and press against the side of the horizontal pressure plate 6 through the movable abutment structure:

[0056] For the symmetrical IDC connector 4, the main and auxiliary pressure components are pressed down synchronously according to the preset pressure (e.g., main pressure 50N + 30N on each side).

[0057] For asymmetrical structures, the pressure of a single side pressure component can be adjusted (e.g., 40N on the left and 30N on the right) to compensate for differences in needle density.

[0058] The guide post 12 limits the horizontal offset of the horizontal pressure plate 6 (accuracy ±0.05mm) to ensure that the crimping force is applied vertically to the IDC connector 4; the vertical spring 13 compresses and stores energy when the pressure plate is pressed down, absorbing 30%-50% of the impact load and preventing the needle from excessively piercing the conductor of the wire 5.

[0059] The pressure alarm 14 has a built-in sensor that collects the pressure data of the horizontal pressure plate 6 in real time. When the pressure reaches the preset value (50N), it starts to hold the pressure. If the pressure exceeds the threshold (55N), the alarm will immediately issue an audible and visual alarm and cut off the power supply to the electric cylinder to avoid overpressure damage.

[0060] After holding the pressure for 2-3 seconds to ensure close contact between the needle and the conductor, the main and auxiliary pressure cylinders are de-energized, the vertical spring 13 releases its elastic potential energy, and the auxiliary horizontal pressure plate 6 quickly returns to its original position, shortening the return time by 0.5 seconds per cycle.

[0061] The positioning clamping mechanism releases the positioning plate 8, and the operator takes out the crimped IDC connector 4. At this time, the piercing needle has pierced the insulation layer of the wire 5 and formed a permanent electrical connection with the conductor.

[0062] The above embodiments are only used to illustrate the technical solutions of this utility model, and are not intended to limit it. Although this utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this utility model. For those skilled in the art, any alternative improvements or transformations made to the implementation of this utility model fall within the protection scope of this utility model.

[0063] Any aspects of this utility model not described in detail are known to those skilled in the art.

Claims

1. An IDC puncture and crimping tool, characterized in that: The device includes a support box, on the top of which are several columns. Each column has a constraint frame fixed to its top. A crimping station is located at the bottom of the inner cavity of the constraint frame, where an IDC connector is placed. Corresponding wires are inserted into the IDC connector. Adjustment clamping mechanisms are installed on the left and right sides of the IDC connector, and the two adjustment clamping mechanisms cooperate to position the IDC connector. A main pressure-applying component is installed on the constraint frame above the IDC connector, and the lower end of the main pressure-applying component is fixedly connected to the top center of the horizontal pressure plate.

2. The IDC puncture and crimping tool according to claim 1, characterized in that: Auxiliary pressure-applying components are symmetrically spaced on both sides of the main pressure-applying component, and the two auxiliary pressure-applying components and the main pressure-applying component are independent of each other in the working state.

3. The IDC puncture and crimping tool according to claim 2, characterized in that: The adjusting clamping mechanism includes a horizontally arranged adjusting screw. The inner end of the adjusting screw moves through a threaded hole on the lower outer side wall of the constraint frame and extends to the crimping station. A vertically arranged positioning plate is fixedly installed at the end of the adjusting screw. The inner end of the positioning plate is used to abut against the corresponding end of the IDC connector. Several actuating rods are fixedly installed at even intervals along the circumference of the outer side wall of the adjusting screw.

4. The IDC puncture and crimping tool according to claim 3, characterized in that: The main pressure-applying component includes a vertically arranged central electric cylinder, the middle part of which is fixed to the constraint frame, and the bottom of the telescopic end of which is fixed to the top center of the horizontal pressure plate.

5. The IDC puncture and crimping tool according to claim 4, characterized in that: The auxiliary pressure-applying component includes a vertically arranged side electric cylinder, the middle part of which is fixed to the constraint frame, and the bottom of the telescopic end of which movably abuts against the top of one side of the horizontal pressure plate.

6. The IDC puncture and crimping tool according to claim 5, characterized in that: Two guide columns are respectively arranged at intervals on both sides of the inner cavity of the constraint frame. The top and bottom of each guide column are fixedly arranged. The horizontal pressure plate is movably sleeved on the outer wall of the guide column through the corresponding through holes at its four corners. Vertical springs are respectively sleeved on the outer wall of the guide column below the horizontal pressure plate. The bottom of the vertical spring is fixedly connected to the constraint frame.

7. The IDC puncture and crimping tool according to claim 6, characterized in that: A protective coating is sprayed onto the inner end face of the positioning disk.

8. The IDC puncture and crimping tool according to claim 7, characterized in that: A pressure alarm is fixedly installed on the top of the horizontal pressure plate, with the top of the pressure alarm abutting against the bottom of the horizontal pressure plate.

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