Variable-Force Cam Crimp Tool for Consistent Barrel Compression
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Solution Overview
Problem
Conventional crimp tools provide a linear mechanical advantage, which is inadequate for efficiently crimping contact wire barrels of varying diameters, leading to inconsistent crimping force and potential ergonomic issues during the crimping process.
Innovation Solution
A crimp tool featuring a circular cam with an inner camming surface and curvilinear ramps, where the ramps have different rates of change in radius, allowing the indentor elements to exert varying forces on contact wire barrels as the cam rotates, providing a continuously variable mechanical advantage optimized for both large and small diameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a linear mechanical advantage is provided by the crimp tool, then the structure is simple and easy to manufacture, but the crimping force is inconsistent for contact wire barrels of varying diameters
Solution Approach 1:
The patent applies the dynamics principle by implementing a cam mechanism that transforms the static linear mechanical advantage into a dynamic variable mechanical advantage. The cam profile is specifically designed with varying curvature radii that change during rotation, causing the indenter elements to exert different forces on contact wire barrels of varying diameters. This dynamic adjustment allows the crimping force to adapt to different contact wire barrel sizes, improving crimping force consistency without requiring multiple tools or complex adjustments.
2Reliability
If a uniform crimping force is applied to all contact wire barrels, then the crimping process is simple, but the connection quality varies for different diameters
Solution Approach 1:
The patent applies the local quality principle by designing the cam profile with different curvature radii at different locations. Specifically, the cam has a first curvature radius in a first rotation range and a second curvature radius in a second rotation range, allowing different portions of the cam to provide different mechanical advantages for different contact wire barrel diameters. This ensures that each contact wire barrel receives the appropriate localized force required for high-quality connection, while the operator simply needs to perform a single crimping action without complex adjustments.
3Strength
If the crimping force is increased for large diameter contact wire barrels, then the connection strength is improved, but the force may be excessive for small diameter barrels
Solution Approach 1:
The patent applies the parameter changes principle by varying the curvature radius parameter of the cam profile during rotation. The cam is designed with a first curvature radius for a first rotation range and a second curvature radius for a second rotation range, enabling the mechanical advantage parameter to change dynamically. This allows the crimping force parameter to be automatically adjusted according to the contact wire barrel diameter, ensuring optimal connection strength for large diameter barrels while preventing excessive force on small diameter barrels, all through a single continuous crimping motion.
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 crimp tool ensures a secure connection between the contact wire barrel and wire with improved ergonomics, as the force exerted adapts to the size of the contact wire barrel, enhancing crimping efficiency and consistency across different diameters.
Implementation Method 1
A crimp tool is disclosed having a circular cam with an inner camming surface and curvilinear ramps
Implementation Method 2
The plurality of indentor elements may have a plurality of spring elements forcing distal ends of the plurality of the indentor elements to maintain continuous contact with the inner camming surface
Data Source
AI summary
A crimp tool for crimping a prepared wire into a corresponding contact wire barrel includes a circular cam having an aperture therein, where the aperture forms an inner camming surface. The crimp tool also includes a cam handle extending from the circular cam, a lower handle pivotably connected to the cam handle at the circular cam, and an indentor holder mounted within the aperture of the circular cam, where the indentor holder has a plurality of radially extending channels or holes. In addition, the crimp tool includes a plurality of indentor elements slidingly engaged with the plurality of radially extending channels, where the inner camming surface has a plurality of curvilinear ramps for the plurality of indenter elements to slide along as the circular cam rotates from an open position to a closed position. The plurality of curvilinear ramps have at least one change in ramp geometry.