Cam-Actuated Wire Termination Contact Without Crimp Tools
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Solution Overview
Problem
Existing wire termination methods using crimp tools and die sets are expensive and require periodic calibration, leading to unreliable electrical connections, especially in environments where precise tolerances are critical for safety and operational reasons.
Innovation Solution
A wire termination system featuring a contact with a barrel, clip, and cam portion, where the clip is biased by the wire's passage and engages the conductor to form a mechanical and electrical connection upon pulling, eliminating the need for external tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If crimp tools and die sets are used to terminate wires, then mechanical and electrical connections can be formed, but the equipment is expensive and requires periodic calibration
Solution Approach 1:
The contact assembly performs the crimping operation itself through its internal cam mechanism and spring-loaded components, eliminating the need for external crimping tools. The contact body acts as both the terminal and the crimping device, with the cam portion providing the mechanical advantage needed to deform the barrel and secure the wire conductor.
Solution Approach 2:
The patent extracts the crimping function from separate external equipment (crimp tools and die sets) and integrates it directly into the contact assembly itself. This eliminates the need for expensive, calibrated external equipment while maintaining reliable electrical connections.
2Manufacturing precision
If crimp tools are used with small specified tolerances, then safety and operational requirements are met, but wire bundles are frequently rejected due to out-of-tolerance terminations
Solution Approach 1:
The patent employs a cam mechanism with specifically engineered geometry that controls the crimping force and deformation parameters. The cam profile ensures consistent compression of the barrel onto the conductor, maintaining precision within specified tolerances without requiring expensive calibrated equipment or risking out-of-tolerance terminations.
3Ease of manufacture
If traditional crimping methods are used, then wire termination can be achieved, but the process requires expensive equipment and periodic calibration
Solution Approach 1:
The patent merges the contact terminal function with the crimping tool function into a single integrated assembly. The contact body, barrel, cam mechanism, and spring components work together to both establish electrical connection and perform the crimping operation, eliminating the need for separate expensive equipment.
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 solution provides a simple, safe, and reliable method for wire termination, ensuring consistent electrical connections without the need for crimping tools, thereby reducing costs and improving reliability.
Implementation Method 1
The plurality of inwardly directed tines are biased outwards in response to passage of a conductor of the wire through the clip
Data Source
AI summary
An electrical contact system includes a contact having a barrel with a wire entry portion having a first diameter, a clip portion having a second diameter, and a cam portion having a second diameter at a first end that tapers to a third diameter at a second end near the wire entry portion. The system also includes a clip positioned in the clip portion of the barrel, wherein ends of inwardly directed tines of the clip are configured to engage the conductor to enable the clip to be drawn onto the cam portion in response to a user pulling the wire after insertion of the conductor through the clip.