Adjustable Crimping Clamp with Elastic Clip for Variable Wire Sizes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing crimping clamps are limited to crimping specific sizes of bushings and wires, as they have a fixed crimping opening, which restricts their ability to accommodate various sizes, and the use of expensive disc springs for movable clamps is costly.
Innovation Solution
A crimping clamp design featuring a first and second clamp, a connecting rod, and a pair of jaws with an elastic clip body made of spring steel, allowing for adjustable clamping through a toggle mechanism and an eccentric shaft for adjusting the jaw opening to accommodate different sizes, utilizing an elastic clip body that deforms to accommodate larger sizes and an adjusting mechanism to fine-tune the opening size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed crimping opening is used, then the clamp structure is simple, but it can only crimp bushings of a specific size
Solution Approach 1:
The patent applies the dynamics principle by making the crimping opening adjustable through a toggle mechanism. The movable clamp can be pushed by the wire and bushing to move outward, changing the opening size dynamically. This allows the same clamp to accommodate various sizes of bushings and wires, resolving the contradiction between adaptability and structural simplicity.
2Adaptability or versatility
If a disc spring is used to make the clamp movable, then the clamp can accommodate larger sizes, but the material cost is expensive
Solution Approach 1:
The patent applies parameter changes by replacing the disc spring with an elastic clip body made of spring steel. The elastic clip body can deform elastically to provide the necessary movement and restoring force. This substitution maintains the functional requirement of accommodating various sizes while significantly reducing material cost, as spring steel is more economical than special disc spring materials.
3Adaptability or versatility
If the elastic clip body deforms to accommodate larger sizes, then the crimping opening increases, but the clamping force may decrease
Solution Approach 1:
The patent applies segmentation by dividing the clamp into two parts: a fixed clamp that provides stable support and maintains clamping force, and a movable clamp with the elastic clip body that adjusts the opening size. This segmentation allows the fixed clamp to maintain strong clamping force while the movable clamp accommodates various sizes, resolving the contradiction between adaptability and clamping force.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables crimping of bushings and wires of various sizes with a strong clamping force, extending the lifespan of the clamp by preventing elastic fatigue and allowing for easy adjustment to fit different sizes, thus addressing the cost and size limitations of prior clamps.
Implementation Method 1
the first crimping end will be driven by the elastic force to deform and move away from the second crimping end
Implementation Method 2
the elastic clip body with an elastic force
Data Source
AI summary
A crimping clamp includes a first clamp, a second clamp, a connecting rod and a pair of jaws. The first clamp includes a first clamp body and an elastic clip body. A portion of the elastic clip body combines with the first clamp body. The second clamp includes a second clamp body and a clip body having a first end connected with the second clamp body. The connecting rod has one end connected with the first clamp body and the other end connected with the second clamp body. The jaws have one jaw combined with one end of the elastic clip body and the other jaw combined with a second end of the clip body. When the jaws crimp a bushing and a wire of larger size, the elastic clip body is deformed, such that the first clamp body rotates to a predetermined position.