C-Frame Press Tool Deflection Compensation
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Solution Overview
Problem
C-frame crimping tools are limited by deflection constraints that lead to misalignment of dies during crimping operations, resulting in distorted crimp profiles and increased stress on mating parts, which can cause mechanical failures and make the tools heavier and less user-friendly.
Innovation Solution
A C-frame tool head design that deflects to align crimping inserts and faces upon load application, using a hook member and crimping inserts with a gap that closes under load, and a ram die holder with an arcuate face to maintain alignment and reduce stress, allowing for proper die closure and weight optimization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the C-frame head is optimized for weight by using lighter materials and smaller cross-section, then the tool weight is reduced and ease of use is improved, but the C-frame head deflects under load causing die misalignment and distorted crimp profiles
Solution Approach 1:
The C-frame head is pre-bent during manufacturing to compensate for the expected deflection under load. This preliminary anti-action ensures that when the tool is used, the pre-bent frame deflects into a straight position, maintaining die alignment throughout the crimping operation while allowing the use of lighter materials.
Solution Approach 2:
The patent changes the geometric parameters of the C-frame head, specifically introducing a pre-bent configuration with specific angle ranges (10-30 degrees) and dimensional relationships. This parameter change allows the frame to dynamically adjust its shape under load, compensating for deflection while reducing overall material usage and weight.
2Manufacturing precision
If the C-frame head is made heavier with larger cross-section and higher tensile strength material, then die alignment and structural integrity are maintained, but the tool weight increases reducing ease of use
Solution Approach 1:
Instead of over-engineering the C-frame head with excessive material, the patent applies a preliminary anti-action by pre-bending the frame to counteract expected deflection. This allows use of optimized, lighter materials while maintaining alignment precision through the pre-configured geometry rather than mass.
Solution Approach 2:
The patent introduces asymmetry in the C-frame head design through the pre-bent configuration, where different portions of the frame have different initial angles and geometries. This asymmetric design allows strategic placement of material where needed for strength while removing material where not needed, reducing overall weight while maintaining alignment.
3Manufacturing precision
If the C-frame head is designed to be rigid and resistant to deflection, then die alignment is maintained, but the stress on mating parts increases leading to mechanical failures
Solution Approach 1:
The patent transitions from a static, rigid C-frame design to a dynamic one where the frame is intentionally designed to deflect in a controlled manner. The pre-bent configuration allows the frame to dynamically adjust its rigidity - appearing rigid in the pre-bent state for alignment, then becoming more compliant under load to reduce stress on mating parts.
Solution Approach 2:
The patent changes the mechanical parameters of the C-frame head by introducing a pre-bent geometry with specific angle ranges. This parameter change allows the frame to transition from a rigid alignment-maintaining structure to a more compliant stress-distributing structure during operation, reducing the risk of mechanical failures.
4Weight of moving object
If the C-frame head allows deflection to reduce weight, then tool weight is reduced, but the crimp profile becomes distorted and quality decreases
Solution Approach 1:
The C-frame head is pre-bent to counteract the deflection that would otherwise occur during use. This preliminary anti-action ensures that when the tool is operated, the frame deflects into the correct position, maintaining crimp profile quality while allowing the use of lighter, more compliant materials.
Solution Approach 2:
The patent applies preliminary action by pre-configuring the C-frame head geometry before use. The pre-bent shape is established during manufacturing to anticipate and compensate for the deflection that will occur during crimping, ensuring quality results are achieved from the start of each operation.
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
The design compensates for deflection, ensuring proper alignment and reducing the risk of mechanical failures, while also achieving a lighter and more user-friendly tool with improved crimp quality and reduced weight.
Implementation Method 1
Upon the tool head being in an unloaded state, the center axis is spaced from the extension axis, and upon being in a loaded state, the center axis is displaced towards the extension axis
Data Source
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AI summary
Press tools and particularly crimp tools having a C-frame tool head (100, 200, 300, 500) are described which are configured such that upon a typical use load, the C-frame head (26) deflects to a position in which mating components or surfaces are aligned. Also described are C-frame heads (26) that utilize a particular deflection compensating engagement connection between a piston (50) and a ram die holder (60). In addition, various methods of compensating for deflection are described. The use of such configurations, engagement connections, and methods enables such tools to be formed from lighter weight materials and/or to incorporate weight optimization designs.