Integrated Cable Assembling Apparatus for Terminal Formation and Crimping
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Solution Overview
Problem
Conventional coaxial cable connection structures face challenges in achieving high accuracy for round-shape crimping of core wires, require separate facilities and molds for terminal molding and crimping, and involve increased work and costs for isolating resin molding.
Innovation Solution
A cable assembling apparatus with a press having multiple parallel dies, an electric wire support jig, and a feeder that sequentially processes a metal plate to form terminals and crimp electric wires, using the same apparatus for both terminal formation and crimping, and integrates a resin-molding machine for efficient isolating resin application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate facilities are used for terminal molding and crimping operations, then each process can be performed with dedicated equipment, but facility costs increase and device complexity increases
Solution Approach 1:
The patent combines the terminal molding die and crimping die into a single integrated die structure. The die includes both a molding portion for forming the terminal from metal plate and a crimping portion for crimping the electric wire to the terminal. This integration eliminates the need for separate facilities while maintaining process reliability through sequential operations within the same equipment.
Solution Approach 2:
The press equipment is designed to perform multiple functions using a single die that can both mold terminals and crimp electric wires. The die structure incorporates both molding and crimping capabilities, allowing one piece of equipment to replace multiple dedicated facilities, thereby reducing device complexity while maintaining operational reliability.
2Manufacturing precision
If separate molds are used for terminal molding and crimping, then each operation can be optimized independently, but manufacturing costs increase
Solution Approach 1:
The patent integrates the molding die and crimping die into a single composite die structure. This die includes a molding portion for forming the terminal and a crimping portion for crimping the electric wire. By combining these functions in one die, the patent reduces the number of molds required, lowering manufacturing costs while maintaining precision through the integrated design that ensures proper positioning and sequencing of operations.
3Productivity
If conventional separate process facilities are used, then each process can be performed independently, but productivity decreases due to multiple handling steps
Solution Approach 1:
The patent combines terminal molding and electric wire crimping operations into a single integrated die and process step. The die structure allows both operations to be performed sequentially without removing the workpiece from the press, eliminating multiple handling steps and improving productivity. The integrated approach reduces process complexity by consolidating operations that were previously performed in separate facilities.
Data Source
AI summary
A cable assembling apparatus for allowing a terminal and a electric wire to be accurately crimped and to resolve increase of facility cost incurred by separation of a press and a crimping machine, includes a press having a downside press mold having a plurality of types of dies arranged in parallel, an electric wire support jig arranged in parallel, having a metal plate guide at an end thereof entering into between the plurality of types of dies, and a feeder adapted to lift the electric wire support jig together with the metal plate above the dies of the downside press mold, and advance and descend the electric wire support jig to an adjacent die of next process. Furthermore, an electric wire chuck disposed in a midstream die of the plurality of types of dies and supplying the electric wire support jig with the electric wire is disposed.