Portable C-Head Crimp Tool With Linear Force Control
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Solution Overview
Problem
Existing battery-powered crimp tools with scissor-type jaws face limitations in efficiently crimping conductors to terminations, as they rely on rotational motion which may not provide consistent and controlled linear force required for effective crimping across various wire gauges.
Innovation Solution
A portable, hand-held crimp tool utilizing linear motion driven by an electric motor, gear reduction assembly, ram drive assembly, and linkage system, which translates rotational motion into linear motion to securely crimp conductors to terminations, featuring a C-shaped head and adjustable force control through a sensor module and controller.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If scissor-type jaws with rotational motion are used, then the tool can crimp conductors, but the linear force control is inconsistent across various wire gauges
Solution Approach 1:
The patent replaces the traditional scissor-type rotational mechanical system with a linear motion system. The linear actuator directly provides linear force to move the C-shaped head's jaws, eliminating the rotational-to-linear conversion mechanism. This substitution ensures consistent linear force application across different wire gauges, resolving the force control inconsistency issue.
Solution Approach 2:
The patent changes the motion parameter from rotational to linear. By using a linear actuator that moves the C-shaped head in a straight line, the system provides controlled linear force rather than rotational force. This parameter change enables precise force control across various conductor sizes, improving crimping consistency.
2Manufacturing precision
If rotational motion is used to crimp conductors, then the crimping action can be achieved, but the force control precision is insufficient
Solution Approach 1:
The patent substitutes the rotational mechanical transmission system with a direct linear actuation system. The linear actuator provides precise linear force control without the losses and inconsistencies associated with rotational-to-linear conversion, thereby improving force control precision for different wire gauges.
Solution Approach 2:
The patent makes the force application dynamic and adjustable through the linear actuator system. The linear motion mechanism allows for controlled force application that can be optimized for different conductor sizes, enhancing manufacturing precision in the crimping process.
3Ease of operation
If a battery-powered portable design is used, then mobility is improved, but the available power and force may be limited
Solution Approach 1:
The patent uses a linear actuator that is optimized for battery-powered operation. By eliminating complex rotational transmission mechanisms, the system reduces power consumption and mechanical losses, allowing sufficient crimping force to be achieved with battery power while maintaining portability.
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 efficient crimping of conductors ranging from #22 AWG to #2 AWG with precise force control, ensuring reliable connections across different wire gauges and terminations, enhancing operational efficiency and consistency.
Implementation Method 1
The drive system includes an electric motor, a gear reduction assembly, a ram drive assembly and a linkage assembly
Implementation Method 2
The gear reduction assembly is used to reduce the output speed of a shaft of the electric motor by a factor in the range of about 30 percent and about 50 percent
Implementation Method 3
The wedge has a drive surface, e.g., a camming surface. The linkage assembly includes a first link pair, a second link pair and a roller... the roller is positioned between the first and second link pairs so that the roller is aligned with and in contact with the drive surface, e.g., the camming surface, of the wedge
Data Source
AI summary
The present disclosure provides a mini or micro hand-held, portable, battery-powered 2-3 ton crimp tool capable of crimping conductors ranging between #22 AWG and #2 AWG to a termination. The crimp tool has a C-shaped head portion that uses linear motion to perform the crimp operation.