Conductive Sleeve Positioning Aid for Precise Crimp Alignment
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Solution Overview
Problem
Existing crimping methods for connecting conductors, particularly aluminum conductors, face issues with mechanical and electrical insecurity due to manufacturing tolerances, thermal overheating, and asymmetrical deformation, which can lead to connection failures and require additional space, while existing pressing methods lack precise central alignment and result in banana-shaped deformations.
Innovation Solution
A conductive sleeve with a positioning aid, such as a recess, is integrated into the receiving section to guide the press mandrel, ensuring precise alignment and preventing lateral displacement, allowing for symmetrical deformation and reduced installation space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional crimping methods are used to connect conductors, then the connection can be established, but manufacturing tolerances and material variations result in insufficient mechanical and electrical security, leading to connection failures and thermal overheating
Solution Approach 1:
The patent introduces a positioning aid as an intermediary element between the crimping tool and the sleeve. This positioning aid, integrated into the receiving section, mediates the interaction by providing a positive engagement feature that ensures accurate alignment of the crimping tool with the sleeve axis, thereby eliminating alignment errors caused by manufacturing tolerances and ensuring reliable connections
Solution Approach 2:
The positioning aid is pre-integrated into the receiving section of the sleeve before the crimping operation. This preliminary action of incorporating the alignment feature into the sleeve structure itself ensures that when the crimping tool is applied, the alignment is automatically established without requiring additional setup or adjustment steps
2Adaptability or versatility
If pressing methods with conical mandrels are used to eliminate tool changes, then a single tool can handle various conductor cross-sections, but asymmetrical deformation occurs resulting in banana-shaped deformations and imprecise central alignment
Solution Approach 1:
The positioning aid serves as an intermediary that guides the pressing mandrel during the deformation process. By providing a positive engagement feature, it ensures the mandrel remains centrally aligned throughout the pressing operation, preventing the asymmetrical deformation and banana-shaped distortions that occur when mandrels are not precisely centered
Solution Approach 2:
The positioning aid is pre-formed as an integral part of the receiving section before the pressing operation begins. This preliminary structuring of the receiving section with built-in alignment features ensures that subsequent pressing operations, regardless of conductor size variations, will maintain symmetrical deformation and central alignment
3Ease of operation
If crimping marks are used to indicate crimping positions, then crimping points can be marked, but the marks cannot guarantee correct alignment and positioning, allowing the crimping tool to be applied to the edge or end of the receiving section
Solution Approach 1:
The positioning aid acts as an intermediary mechanical guide that replaces inadequate visual marks. Instead of relying on painted or printed marks that cannot ensure precision, the positioning aid provides a physical, positive engagement feature that mechanically guarantees correct alignment and positioning of the crimping tool relative to the receiving section
Solution Approach 2:
The patent replaces the insufficient mechanical indication system (crimping marks) with a superior mechanical guidance system (positioning aid with positive engagement). This substitution transforms the alignment method from visual indication to mechanical constraint, ensuring precise positioning and preventing edge or end application of the crimping tool
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 solution provides a precise, mechanically stable, and electrically conductive connection with reduced deformation, eliminating the need for multiple crimping points and ensuring consistent alignment, suitable for a range of conductor cross-sections.
Implementation Method 1
In these methods, a conical mandrel is hydraulically extended under force control and pressed into the receiving section of the end sleeve along with the conductor section it contains
Data Source
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AI summary
In order to create an electrically conductive sleeve (10), in particular a sleeve (10) designed as a crimp sleeve, having at least one connecting section (11) and at least one receiving section (12) for receiving at least one stripped conductor section (21) of an electrically conductive conductor (20), which enables a precisely positioned formation of a connection (40) between the receiving section (12) and the conductor section (21) of a conductor (20), it is proposed to provide at least one positioning aid (30) for positioning a crimping mandrel (110) of a crimping tool (100) on the outside of the receiving section (12).