Coreless Motor Crimping Mechanism for Precise Height Control
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Solution Overview
Problem
Conventional crimping devices are bulky, complex, and unsuitable for mobile applications due to their large size and weight, and they have a cumbersome mechanism for setting the crimp height.
Innovation Solution
A compact crimping device with a low-profile coreless motor and a cycloidal gearing mechanism, allowing for precise control of crimp height and enabling the device to be used in both stationary and mobile applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If conventional crimping devices use pneumatic pressure devices with levers and mechanical stops, then crimping force can be applied, but the device becomes large, heavy, and complex
Solution Approach 1:
The patent replaces the conventional pneumatic pressure device with an electric motor (specifically a coreless motor) that directly drives the crimping action through a cam mechanism. This substitution eliminates the need for complex pneumatic systems, levers, and mechanical stops, thereby reducing device complexity while maintaining the ability to apply sufficient crimping force
Solution Approach 2:
The patent employs a cam mechanism that converts rotational motion from the motor into linear pressing motion of the spikes. This dimensional transformation allows the crimping force to be generated through a compact rotational actuator rather than requiring a large linear pneumatic cylinder, thus reducing overall device size and complexity
2Manufacturing precision
If conventional crimping devices use adjusting spikes and setting mechanisms, then crimp height can be set, but the mechanism becomes cumbersome and space-consuming
Solution Approach 1:
The patent makes the crimp height setting dynamic and adjustable during operation. The cam mechanism includes an adjustable cam follower that can be positioned at different locations along the cam profile, allowing the operator to change crimp height on-the-fly without complex mechanical stops or adjusting spikes. This dynamic adjustment simplifies the setting mechanism while maintaining precision
Solution Approach 2:
The patent extracts the height adjustment function from a separate mechanical stop system and integrates it into the cam mechanism itself. By incorporating the adjustment capability directly into the driving cam, the patent eliminates the need for separate adjusting spikes and stop mechanisms, thereby reducing overall mechanism complexity
3Power
If conventional crimping devices use large drive arrangements, then sufficient power can be delivered, but the device becomes unsuitable for mobile hand-held applications
Solution Approach 1:
The patent replaces large pneumatic drive systems with a compact electric coreless motor that delivers sufficient crimping power in a much smaller package. The direct electric drive eliminates the need for large pneumatic cylinders, hoses, and associated components, making the device compact enough for mobile hand-held applications while maintaining adequate crimping force
Solution Approach 2:
The patent changes the driving force generation method from pneumatic pressure to electromagnetic motor torque. This parameter change allows power delivery in a more compact form factor, as electric motors can generate high torque in small sizes compared to pneumatic actuators, enabling portable application of sufficient crimping power
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 advanced gearing mechanism allow for efficient and precise crimping operations, reducing the complexity of setting crimp height and enabling the device to be used in a variety of applications, including mobile hand-held tools.
Implementation Method 1
The drive is advantageously realized as an electrically driven, substantially low-profile cylindrical coreless motor
Implementation Method 2
A mechanism that is suitable for operating a coreless motor and the crimping device may be realized as a gearing acting in combination with the motor and the pressing elements, and advantageously realized as a cycloidal gearing
Data Source
AI summary
A crimping device is provided for a conductor of a predefined cable to a predefined contact sleeve, having a crimp of a predefined crimp height, the crimping device has at least two suitable pressing elements that are mounted so as to be reversibly movable relative to a central crimping zone of the crimping device; for the proper operation of the pressing elements, the crimping device has a drive, the drive being operatively connected to the pressing elements via a mechanism; the drive being an electrically driven, substantially low-profile cylindrical coreless motor, and the pressing elements and the mechanism being arranged within the cylindrical motor. A controller for controlling the operation of the crimping device, a method for calibrating the crimping device, and a method for controlling the operation of the crimping device is also provided.