Adjustable Prong Crimping Tool for Wire Length Adaptation
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Solution Overview
Problem
Existing devices for crimping wires lack efficiency and versatility in design, particularly in the coupling mechanism of jaws and prongs, which affects the precision and ease of use when closing handles to crimp wires of varying lengths.
Innovation Solution
A device comprising a pair of handles with a set of prongs coupled to jaws, where the prongs can be either welded or cast as a single unit with the jaws, and are releasably coupled via fasteners and a hinge, allowing for adjustable length and improved crimping functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the prongs are welded or cast as a single unit with the jaws, then the manufacturing precision and structural integrity are improved, but the device complexity and ease of repair worsen
Solution Approach 1:
The device is divided into separate functional components: the jaws assembly and the prongs assembly are connected via a hinge mechanism rather than being welded or cast as one piece. This segmentation allows each component to be optimized independently while maintaining overall precision through the hinge coupling.
Solution Approach 2:
The hinge mechanism introduces dynamic adjustability to the coupling between jaws and prongs, allowing the relative position and angle to be adjusted during operation to accommodate wires of varying lengths while maintaining crimping precision.
2Ease of repair
If the prongs are releasably coupled via fasteners and hinge, then the ease of repair and adaptability are improved, but the manufacturing precision and structural integrity worsen
Solution Approach 1:
The hinge and fastener mechanisms are pre-configured with adjustment features that allow precise positioning to be established before use. This preliminary setup ensures that even with separable components, the crimping precision can be maintained through pre-adjustment of the jaw-prong relationship.
Solution Approach 2:
The releasable coupling allows for parameter adjustments in the relative position, angle, and spacing between jaws and prongs. By changing these geometric parameters through the hinge mechanism, the system maintains precision while enabling easy replacement and adaptation of components.
3Adaptability or versatility
If the device accommodates wires of different lengths, then the adaptability is improved, but the device complexity increases
Solution Approach 1:
The hinge-coupled jaw and prong assemblies create a universal coupling mechanism that can accommodate multiple wire lengths and configurations. The same basic structure serves multiple functions by allowing positional and angular adjustments, eliminating the need for multiple specialized tools.
4Adaptability or versatility
If the prongs are made adjustable in length, then the adaptability for different wire lengths is improved, but the manufacturing complexity and precision maintenance worsen
Solution Approach 1:
The adjustability of prong length is achieved through the dynamic hinge mechanism rather than fixed adjustable components. This allows the effective length and position of the prongs to be dynamically changed during operation while maintaining structural integrity and crimping precision through the rigid hinge connection.
Data Source
AI summary
Certain exemplary embodiments can provide a device comprising a pair of handles, and a set of prongs. The pair of jaws is coupled to the pair of handles. The set of prongs is coupled to the pair of jaws. The set of prongs comprises a pair of prongs coupled to a first jaw of the pair of jaws. The set of prongs comprises a single prong coupled to a second jaw of the pair of jaws. The device, via the set of prongs is constructed to crimp a wire as the pair of handles is closed.