Adapter Plate Alignment Gauge for Crimping Tool Precision
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Solution Overview
Problem
The existing crimping tool alignment process is not reproducible, leading to frequent realignment of cable tips during tool changes in crimping presses, resulting in increased operational interruptions and costs due to the lack of precise alignment in the longitudinal direction with a tolerance of 0.1 mm or less.
Innovation Solution
An adapter plate alignment gauge system that includes an adapter plate and an alignment gauge, allowing the crimping tool to be fixed in a predetermined position, eliminating the need for realignment by enabling precise and reproducible placement of the crimping tool relative to the crimping press and cable, with features like height-adjustable and lockable alignment gauges and detachable fastening mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the crimping tool is inserted by hand without a fixed positioning system, then the tool can be quickly changed, but the position of the cable tip is not identical after each tool change, requiring realignment
Solution Approach 1:
An adapter plate is introduced as an intermediary component between the crimping press and the crimping tool. The adapter plate includes a receiving plate with a receiving groove that detachably receives the crimping tool, and an adapter plate frame that is immovably arranged in the crimping press. This intermediary structure enables both quick tool changes and precise, reproducible positioning of the cable tip at 0.1 mm or less tolerance.
2Manufacturing precision
If the crimping tool is realigned after every tool change to maintain precision, then the cable tip position precision is maintained, but the operational interruptions increase and costs are elevated
Solution Approach 1:
The adapter plate is pre-configured with a receiving groove in a predetermined position on the adapter plate frame. The crimping tool is detachably received in this pre-positioned groove, which is designed to automatically position the cable tip at the correct location relative to the crimping press. This preliminary positioning structure eliminates the need for realignment after tool changes, maintaining precision while reducing operational interruptions.
3Productivity
If a fixed positioning system is implemented to eliminate realignment needs, then the operational continuity is improved, but the device complexity increases due to the adapter plate and alignment gauge components
Solution Approach 1:
The positioning system is segmented into modular components: an adapter plate frame that is immovably arranged in the crimping press, a receiving plate that can be detached and repositioned, and a crimping tool that is detachably received in the receiving groove. This segmentation allows each component to perform its specific function independently, simplifying the overall system while maintaining operational continuity and reducing the need for complex alignment mechanisms.
Data Source
AI summary
An adapter plate alignment gauge system includes an adapter plate for holding a crimping tool in different positions and an alignment gauge for aligning the crimping tool in a predetermined set crimping tool position relative to the alignment gauge. The adapter plate is immovably arrangeable in a predetermined set adapter plate position in a crimping press which, in order to create a crimp connection, connects one conductor end of a cable to a crimp contact. The alignment gauge can be fastened to the adapter plate whereby the alignment gauge is arranged in a predetermined set alignment gauge position relative to the adapter plate.