Crimp Connection Gripper Axial Compensation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional crimping devices cause undesired length extension and deformation of aluminum cables during crimping, leading to kinking and permanent damage.
Innovation Solution
A crimping device with a gripper that moves along the cable axis to compensate for length extension during crimping, using actuators like electric motors or pneumatic cylinders to execute a return movement, ensuring the cable remains stable and preventing buckling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the gripper remains in unchanged axial position during crimping, then the crimping process is simple to control, but the cable undergoes undesired length extension and kinking
Solution Approach 1:
The gripper is transformed from a static component to a dynamic one that can move axially during crimping. The gripper executes a return movement in opposite direction to the feed movement, compensating for cable length extension and preventing kinking while maintaining reliable cable integrity.
2Manufacturing precision
If the gripper is moved passively or actively during crimping to compensate for length extension, then cable deformation is reduced, but the actuator system becomes more complex
Solution Approach 1:
The actuator's holding moment is temporarily reduced during crimping to permit the gripper's return movement. This parameter change enables passive compensation for cable length extension without requiring a completely new actuator system, maintaining manufacturing precision while limiting complexity increases.
Solution Approach 2:
The system utilizes the cable's own deformation forces to drive the gripper's compensating movement. The longitudinal forces arising in the cable during crimping automatically produce the passive return movement of the gripper, eliminating the need for additional active control mechanisms.
3Ease of operation
If the holding moment is reduced to permit passive return movement, then the system becomes simpler to operate, but control precision during crimping may be affected
Solution Approach 1:
The actuator operates in distinct phases: normal holding mode during feeding and positioning, then reduced holding moment mode during crimping compensation. This periodic switching maintains control precision when needed while enabling easy passive operation when cable deformation compensation is required.
Data Source
AI summary
A method for producing a crimp connection includes initially guiding a cable end of a cable with a gripper to a crimping press. For this feed movement the gripper is moved by an actuator in an axial direction along the cable axis. The cable end is thereafter connected with a crimp contact. During the crimping process the gripper is, for compensation for length extension of the cable during crimping, moved along the cable axis in a return movement in an opposite direction to the feed movement.