Cable Crimping Structure for Reproducible Force Separation
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Solution Overview
Problem
The crimping process for securing crimp barrels on cable conductors is hindered by unpredictable and difficult-to-repeat forces and stresses between the cutter and cutter actuator, and the crimper and anvil, particularly in automated manufacturing with short cycle times.
Innovation Solution
A crimping device with a cutter having a receiving surface for the cable dielectric and a holding sheet with a molded portion that fully encompasses the dielectric at the reversal point, separating the forces and stresses between the crimper and cutter actuator, and the anvil, ensuring secure, adjustable, and reproducible crimping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the cutter and cutter actuator are actuated jointly with the crimper in automated manufacturing with short cycle times, then productivity is improved, but the forces and stresses between these components become unpredictable and difficult to repeat
Solution Approach 1:
The patent segments the forces and stresses by introducing a holding sheet that separates the interaction between the cutter-actuator-cutter system and the crimper-anvil system. This segmentation isolates the two previously interacting force systems, allowing independent optimization of each subsystem while maintaining overall system productivity.
Solution Approach 2:
The holding sheet acts as an intermediary element between the cutter actuator and the crimper. It mediates the force transmission and prevents direct interaction between the cutter and crimper forces, thereby eliminating the unpredictable force combinations that occurred when both components were actuated jointly without separation.
2Device complexity
If an intermediate shim is introduced between the crimper and cutter actuator to maintain distance, then spatial separation is achieved, but the shim does not prevent force interaction and the crimping quality remains inconsistent
Solution Approach 1:
The holding sheet serves as a functional intermediary that not only maintains spatial separation but also actively manages force transmission. Unlike the previous shim that merely maintained distance, the holding sheet with its molded portion and receiving surface creates a controlled interface that prevents harmful force interactions while ensuring consistent crimping quality.
Solution Approach 2:
The patent changes the parameters of the intermediate element from a simple spacing shim to a structured holding sheet with specific geometric features (molded portion, receiving surface). This parameter change transforms the intermediate element from a passive spacer to an active force-management component that ensures reproducible crimping.
3Manufacturing precision
If the molded portion and receiving surface fully encompass the cable dielectric, then force flow prediction is improved and reproducibility is enhanced, but the device complexity increases
Solution Approach 1:
The holding sheet and cutter combination serves multiple functions: it maintains spatial separation, manages force transmission, and provides precise positioning through the encompassing molded portion and receiving surface. This multi-functionality justifies the increased structural complexity by delivering comprehensive control over the crimping process.
Solution Approach 2:
The patent introduces specific geometric parameters through the molded portion and receiving surface that fully encompass the dielectric. These parameter changes create a controlled environment for force application, improving predictability and reproducibility despite the increased structural complexity.
Data Source
AI summary
A crimping device for securing a crimp barrel on a conductor of a cable includes a crimper, an anvil that interacts with the crimper, a cutter, a cutter actuator and a holding sheet. The cutter has a receiving surface configured to receive a cable dielectric enclosing the conductor. The cutter actuator is configured to press the cutter down at a reversal point and to be actuated jointly with the crimper. The holding sheet has a molded portion on a side facing toward the receiving surface of the cutter. The molded portion of the holding sheet and the receiving surface of the cutter substantially fully encompass the cable dielectric when the cutter actuator is at the reversal point.