Crimp Height Measurement Using Intermediary Tip and Piezo Force
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Solution Overview
Problem
Existing devices for measuring crimp height of conductor crimps using two cutting edges are unreliable due to the formation of 'bones' caused by play between the crimper and anvil, leading to incorrect measurement results.
Innovation Solution
A measuring device with a first cutting edge and a tip that scans the top and underside of the conductor crimp, respectively, using a single drive, allowing for mechanical measurement of crimp height independently of the crimp contact geometry, utilizing a force measuring device with piezo elements to determine crimp height from force and position data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If two cutting edges are used to measure crimp height, then the measurement can be performed automatically, but the measurement precision deteriorates due to bone formation caused by play between crimper and anvil
Solution Approach 1:
A tip is introduced as an intermediary measuring element that contacts the underside of the conductor crimp at a single point. This tip works in conjunction with the first cutting edge to define the measurement points, eliminating the influence of bone formation on measurement accuracy while maintaining automatic operation.
Solution Approach 2:
The measurement system is segmented into distinct functional elements: the first cutting edge for contacting the top side at two points, and a separate tip for contacting the underside at one point. This segmentation allows each element to perform its specific function optimally without interference from play between tools.
2Extent of automation
If two cutting edges are used for measurement, then automation is achieved, but the device complexity increases
Solution Approach 1:
The first cutting edge serves dual purposes: it acts as a cutting tool during crimping and simultaneously serves as a measuring element by contacting the top side of the conductor crimp at two points. This multi-functionality reduces the need for separate dedicated measuring components.
3Measurement precision
If manual measurement outside the crimping machine is performed, then measurement precision can be maintained, but the processing time increases
Solution Approach 1:
The measuring device is merged with the crimping machine, integrating the measurement function directly into the crimping process. The first cutting edge and tip work together within the crimping machine to perform automatic measurement, eliminating the need for separate manual measurement steps outside the machine.
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
Enables reliable, automatic measurement of crimp height for various geometries without manual intervention, reducing processing time and allowing for quality assurance through recorded data, independent of the outer contour of the crimp contact.
Implementation Method 1
a force measuring device with piezo elements is required to measure the crimp height, with the crimp height being able to be determined from the increase in force on the piezo elements and the position of the cutting edge and tip
Data Source
Figure 1
Figure 2~4
Figure 5
AI summary
The head (1) has upper and lower parts (3, 4), and a drive that is provided for actuating the parts. The parts are linearly moved in an opposite directions for determining a crimp height of a conductor crimp (18). A blade (11) is arranged at the upper part, and a cone end (22) is arranged at the lower part. An upper side of the crimp is scanned at two points, and the cone end of a lower side of the crimp is scanned at third point, during the determination of the crimp height. Another blade (38) is provided at the parts (3, 4), where the blade (38) is movable in relation to the cone end. An independent claim is also included for a method for determining a crimp height of a conductor crimp.