Compression Tool Work Head With Necked Abutment Seat Geometry
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Solution Overview
Problem
Compression tools with dieless jaws face challenges in accommodating objects of varying sizes due to incompatible abutment seat shapes, leading to incorrect positioning and increased energy consumption, as they require a thick abutment jaw for larger objects, which hinders small object visibility and positioning, and applies maximum compression force throughout the stroke, increasing energy usage.
Innovation Solution
A work head with an abutment seat having an arched surface that narrows towards a neck-shaped apex, allowing better visibility and positioning of small objects and accommodating larger objects with increased width, combined with a punch surface featuring recesses and ridges that concentrate pressure for efficient compression, reducing energy consumption by delaying maximum force application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the abutment jaw is made with large thickness to accommodate larger objects, then larger objects can be compressed, but small objects are hidden and difficult to position correctly
Solution Approach 1:
The abutment seat is divided into multiple levels or zones with different thicknesses. The first level has greater thickness for accommodating larger objects, while the second level has reduced thickness for small objects, allowing both to be properly positioned and visible during compression operations.
Solution Approach 2:
Different regions of the abutment seat have different geometric properties tailored to specific object sizes. The abutment seat includes a first region with greater thickness for large objects and a second region with reduced thickness for small objects, optimizing both visibility and accommodation for each object size category.
2Reliability
If maximum compression force is applied throughout the entire stroke, then compression is achieved, but energy consumption increases
Solution Approach 1:
The compression force is applied in a staged manner rather than continuously at maximum level. The method includes a first compression phase with initial force, followed by a second compression phase with increased force, and optionally a third phase with maximum force only in the final stages, reducing overall energy consumption while achieving reliable compression.
Solution Approach 2:
A preliminary compression phase is performed before the main compression phase. This initial phase prepares the object by applying a lower force to position it correctly and begin deformation, allowing the subsequent maximum force application to be more efficient and require less total energy.
3Ease of manufacture
If the abutment seat has uniform thickness, then manufacturing is simple, but it cannot properly accommodate objects of varying sizes
Solution Approach 1:
The abutment seat is segmented into distinct zones with different thicknesses corresponding to different object size categories. This segmentation allows the single abutment seat to accommodate both small and large objects properly, maintaining versatility while remaining part of a unified structure.
Solution Approach 2:
The abutment seat is designed with multi-functional regions that can handle different object sizes within a single component. By incorporating varying thickness zones, the abutment seat serves multiple functions - accommodating small objects in thinner regions and large objects in thicker regions - eliminating the need for multiple specialized jaws.
4Productivity
If the compression jaw applies force early in the stroke, then compression begins immediately, but energy is wasted during the entire stroke duration
Solution Approach 1:
The compression operation is divided into distinct phases with different force levels. Lower force is applied during the initial and intermediate phases when full compression is not yet needed, and maximum force is applied only during the final phase when actual compression completion is required, minimizing energy waste throughout the stroke.
Solution Approach 2:
The method skips applying maximum compression force during the early and middle portions of the stroke where it is not yet needed. By delaying the application of maximum force until the final compression phase, the system rushes through the non-critical phases with minimal force and concentrates energy expenditure only when necessary for actual compression.
Data Source
AI summary
A work head for or of a compression tool includes a compression jaw and an abutment jaw forming an arched abutment surface having a longitudinal extension arched in a hypothetical arc plane orthogonal to an insertion direction of the object into the abutment seat. The longitudinal extension has a first side segment, a second side segment opposite to the first side segment, and an apex segment in the shape of a neck extending between the first side segment and the second side segment, and an abutment width measurable in the insertion direction and orthogonal to the arc plane. The abutment width decreases from a first base width of the first side segment to an apex width of the apex segment. The abutment width decreases from a second base width of the second side segment to the apex width of the apex segment.