Cam-Driven Variable Gap Crimp Head With Tool Usage Feedback
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Solution Overview
Problem
Current crimp tools, whether pneumatic or battery-driven, lack the ability to reliably open and close the roller gap, leading to damage during the crimping process, as pneumatic systems fail to provide feedback on tool usage time and electric tools are not powerful enough to achieve this functionality without increasing size or weight.
Innovation Solution
A mechanical cam-based tool head assembly that allows for programmable operation on various power sources, incorporating a drive shaft, one-way locking bearing, and movable slide, enabling the rollers to open and close dynamically, mimicking pneumatic tools while providing feedback on usage time and parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If pneumatic systems are used to open and close rollers, then the ability to dynamically adjust roller gap is achieved, but feedback capability on tool usage time is lost
Solution Approach 1:
The patent replaces the pneumatic system with an electric motor-driven mechanical cam system. The cam mechanism converts rotational motion into linear motion to open and close the rollers, while the electric motor provides feedback capability through programmable control, thus eliminating the information loss inherent in pneumatic systems.
Solution Approach 2:
The electric motor system incorporates feedback mechanisms that track and report tool usage time and operational parameters to the control system. This allows the controller to verify correct usage duration and provide real-time information, resolving the feedback capability loss present in pneumatic systems.
2Loss of information
If electric drive is used to replace pneumatic system, then feedback capability is achieved, but the ability to open and close rollers is lost due to insufficient power
Solution Approach 1:
The patent introduces a cam mechanism as an intermediary between the electric motor and the rollers. The cam converts the motor's rotational motion into the linear motion required to open and close the rollers, amplifying the motor's capability to perform the required mechanical work despite the motor's limited direct power output.
Solution Approach 2:
The cam mechanism operates through periodic rotation, creating cyclic opening and closing actions of the rollers. This periodic motion allows the electric motor to repeatedly perform the work of opening and closing rollers throughout the crimping process, accumulating the necessary mechanical effect over time.
3Loss of information
If battery drive with fixed gap is used, then feedback capability is achieved, but seal damage occurs due to inability to open rollers
Solution Approach 1:
The patent transforms the fixed gap design into a dynamic system where the roller gap can change during operation. The cam mechanism enables the gap to open during positioning and closing during crimping, allowing the tool to adapt its geometry to different operational phases and prevent seal damage that occurs with fixed gap designs.
Solution Approach 2:
The cam mechanism performs preliminary action by opening the roller gap before the crimping operation begins. This preliminary opening allows proper positioning of the seal and flange without compression, preventing damage that would occur if the rollers remained closed during the entire operation.
4Volume of moving object
If pneumatic cylinder is eliminated, then tool size and weight are reduced, but roller opening/closing functionality must be maintained
Solution Approach 1:
The patent extracts the pneumatic cylinder and associated hoses from the tool head, removing the bulky components that contributed to the tool's size and weight. The functionality is retained through a more compact electric motor and cam mechanism assembly that achieves the same roller opening and closing capability in a smaller package.
Solution Approach 2:
The patent substitutes the pneumatic mechanical system with an electric-mechanical system. The electric motor drives the cam mechanism, which replaces the pneumatic cylinder's function of opening and closing rollers. This substitution enables a more compact design while maintaining the required functionality.
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 reliable crimping without pneumatic components, ensuring proper seal application and providing feedback on tool usage, thus preventing damage and enhancing operational efficiency.
Implementation Method 1
The head was designed to have an internal cam that would spin freely on the drive shaft in one direction and lock onto the shaft in the other direction. That cam would rotate against the moving slide forcing it to move away from the drive shaft opening the gap between rollers.
Implementation Method 2
The head includes at least one of each of the following: drive shaft, cam, oneway locking bearing, and a movable slide.
Data Source
AI summary
A tool head assembly for crimping, the assembly including an internal cam that spins freely on a stationary shaft in one direction and locks onto the shaft in the other direction. That cam rotates against the moving slide forcing to move away from the stationary shaft opening a gap between rollers. A controller is programmed to have the drive rotate in one direction for a set time period, then reverse the rotation to begin the crimp process. The start rotation of the drive rotates the cam and opens the roller gap. The forward rotation allows the cam to swing, closing the gap and rotating the rollers around a seal. The tool eliminates the air cylinder and related pneumatic hoses and valve making the head smaller and allows a controller to communicate with any OEM production system to verify the tool has been used and was used correctly.