Cable Crimping with Movable Faces for Residue-Free Connections
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Solution Overview
Problem
The production of high-quality cables for applications in motor vehicles and aircraft requires a cost-effective and simple method for constructing and preparing cables with multiple individual wires and insulation, where existing methods are inefficient and result in residue-filled crimp connections.
Innovation Solution
A method involving heating the conductor with an induction process and using crimping tools with specific temperature-controlled crimping faces to compress and spread the conductor, allowing the insulation to be displaced and creating a residue-free crimp connection, while also using a device with movable tools to facilitate the crimping process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional crimping methods are used on heated conductors, then the crimping process can be performed, but the conductor compression is localized and results in residue-filled crimp connections
Solution Approach 1:
The crimping device employs movable crimping faces that dynamically change position during the crimping process. The first crimping face moves from a first position to a second position, enabling the compression to spread along the conductor axis. This dynamic movement transforms a static localized compression into a progressive distributed compression, eliminating material accumulation while maintaining crimp connection quality.
Solution Approach 2:
The invention introduces axial movement of the crimping faces in addition to the radial compression force. By moving the first crimping face axially from a first position to a second position during compression, the process transitions from simple radial compression to a combination of radial and axial compression, spreading the effect along the conductor and preventing residue accumulation.
2Reliability
If high compression force is applied during crimping, then electrical contact is achieved, but material accumulates in the crimp connection region
Solution Approach 1:
The movable first crimping face enables the compression force to be applied progressively along the conductor axis. As the face moves from the first position to the second position, the high compression force is distributed over a longer axial distance, maintaining electrical contact quality while preventing material accumulation in any single location.
Solution Approach 2:
The crimping process is segmented into multiple stages through the axial movement of the crimping faces. The compression is divided into incremental applications along the conductor axis, with each segment contributing to the overall electrical contact while distributing the material displacement, preventing accumulation.
3Ease of manufacture
If the conductor is compressed locally during crimping, then the process is simple, but the crimp connection contains residues and has poor quality
Solution Approach 1:
The invention maintains relative simplicity by using a movable crimping face mechanism that spreads compression along the conductor. The dynamic movement of the first crimping face from one axial position to another transforms a simple localized compression into an effective distributed compression, achieving clean crimp connections without significantly complicating the manufacturing process.
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
This method enables the production of high-quality cables with a low production outlay, achieving a largely residue-free crimp connection suitable for cables with high twist pitches and numerous individual wires, improving tool longevity and reducing material accumulation.
Implementation Method 1
The conductor is heated and a crimping process is carried out
Data Source
AI summary
A method is for producing a cable which comprises a conductor and a barrel. The conductor has individual wires and is enclosed, at least in portions, by a piece of insulation. The conductor is heated and a crimping process is carried out for electrically contacting the barrel with the conductor. The barrel is pressed together with the heated conductor during the crimping process in such a way that the conductor is initially compressed on a first axial sub-portion of the conductor and subsequently the compression of the conductor is spread to a larger second axial sub-portion.