Coreless Motor Crimping Mechanism for Precise Crimp Height
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Solution Overview
Problem
Existing crimp devices are bulky, heavy, and have a high space requirement, making them unsuitable for mobile hand tools and requiring a complex adjustment mechanism for achieving the correct crimphic height.
Innovation Solution
A compact crimping device with a coreless motor and cycloid gear mechanism, allowing for precise control of the crimphic height and enabling efficient operation in both industrial and mobile applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a conventional pneumatic pressure device with lever and mechanical stop is used, then crimping force is achieved, but the device has high space requirement and high weight
Solution Approach 1:
The patent replaces the conventional pneumatic pressure device with an electric motor (specifically a coreless motor) that directly drives the pressing elements through a gear mechanism. This substitution eliminates the need for pneumatic cylinders, levers, and mechanical stops, significantly reducing device weight while maintaining sufficient crimping force for the application.
Solution Approach 2:
The patent integrates the motor, gear mechanism, and pressing elements into a compact unified structure where the pressing elements are arranged within the motor housing. This merging of components eliminates the need for separate pneumatic devices and adjustment mechanisms, reducing both weight and space requirements while maintaining crimping functionality.
2Manufacturing precision
If an adjustable mechanical stop with complex adjustment mechanism is used, then correct crimp height is achieved, but device complexity increases
Solution Approach 1:
The patent replaces the mechanical stop and adjustment mechanism with an electrically controlled system. The motor's position control capabilities, combined with electronic sensors and control circuitry, enable precise crimp height adjustment without mechanical stops. This substitution simplifies the mechanical structure while improving precision and ease of adjustment.
Solution Approach 2:
The patent implements a dynamically adjustable crimp height system where the pressing element position can be changed electrically rather than through fixed mechanical stops. This allows the crimp height to be adapted to different contact sleeve and cable combinations through electronic control, reducing mechanical complexity while maintaining manufacturing precision.
3Area of stationary object
If a compact design is implemented, then space requirement is reduced, but achieving sufficient crimping force becomes difficult
Solution Approach 1:
The patent uses a coreless motor which provides high torque in a compact form factor. The direct-drive configuration with integrated gear mechanism eliminates the need for large pneumatic cylinders, achieving sufficient crimping force in a much smaller footprint compared to conventional pneumatic devices.
Solution Approach 2:
The patent concentrates the force generation capability in the motor and gear mechanism located at the crimping zone. The pressing elements are positioned within the motor housing, creating a localized high-force generation area that maintains compact overall device dimensions while delivering adequate crimping force at the critical interface.
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 compact design and high torque of the coreless motor, combined with the cycloid gear mechanism, provide a reliable and efficient crimping solution with precise control over the crimphic height, suitable for various applications including mobile hand tools.
Implementation Method 1
The drive is particularly advantageously designed as an electrically driven, substantially flat-cylindrical coreless motor
Implementation Method 2
A mechanism particularly suitable for operating a coreless motor and the crimping device can be designed as a gear that interacts with the motor and the pressing elements and can be designed particularly advantageously as a cycloidal gear
Implementation Method 3
During crimping, two components are joined together by plastic deformation using a forming tool and a pressing force. This creates a crimp, i.e., a mechanical connection that is difficult to break between a conductor and a connecting element
Data Source
Figure 1A~1C
Figure 2A~2B
Figure 3A~3B
AI summary
The invention relates to a crimping device (1) for crimping a conductor of a predetermined cable (7) with a predetermined contact sleeve (8) having the following features: the crimping device (1) has at least two suitable crimping elements (5) for providing a crimp with a predetermined crimp height (H), which are reversibly movably mounted to a central crimping zone (40) of the crimping device (1); the crimping device (1) has a drive (2) suitable for the intended operation of the crimping elements (5), wherein the drive (2) is operatively connected to the crimping elements (5) via a suitable mechanism (3); the drive (2) is an electrically driven, essentially flat cylindrical coreless motor (2), and the crimping elements (5) and the mechanism (3) are arranged inside the cylindrical motor (2).The invention also relates to a control (10) for controlling the operation of the crimping device (1), as well as a method (VK) for calibrating the crimping device (1) and a method (V) for controlling the operation of the crimping device (1).