Crimp Tool Pressure Curve Analysis for Accurate Crimp Evaluation
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Solution Overview
Problem
Existing power tools used for crimping electrical connections rely on mechanical compression and tonnage assurance for quality control, but these methods can lead to inaccurate grading, resulting in bad crimps despite passing tool indications.
Innovation Solution
The integration of an embedded machine learning model within a power tool's control system, utilizing pressure sensors and electronic processors to monitor pressure curves, process features, and evaluate crimping applications, thereby enhancing accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tonnage assurance methods are used for quality control, then the reliability of infrastructure is improved, but the measurement precision of crimp quality is worsened
Solution Approach 1:
The patent replaces mechanical tonnage assurance methods with an electronic sensor-based measurement system. Pressure sensors electronically monitor the crimping process and provide digital signals to a microprocessor, which analyzes the pressure curve to determine crimp quality. This substitution of mechanical indication with electronic measurement and analysis significantly improves measurement precision while maintaining reliability.
Solution Approach 2:
The patent implements a feedback system where pressure sensors continuously monitor the crimping process, and the microprocessor analyzes the pressure curve in real-time to provide feedback on crimp quality. The system compares the measured pressure curve against stored reference curves to determine whether the crimp meets acceptance criteria, providing accurate quality feedback that was not achievable with traditional tonnage assurance methods.
2Ease of operation
If traditional pressure monitoring is used, then the ease of operation is improved, but the manufacturing precision of crimp connections is worsened
Solution Approach 1:
The patent implements a self-service quality control system where the tool automatically performs quality assessment without requiring user interpretation. The microprocessor automatically analyzes the pressure curve, compares it against reference curves, and determines crimp acceptability. This self-service approach maintains ease of operation while significantly improving manufacturing precision through automated electronic analysis.
Solution Approach 2:
The patent introduces an intermediary microprocessor system between the pressure sensor and the user. The microprocessor acts as a mediator that receives raw pressure signals, processes them through curve analysis algorithms, and provides simplified quality determination. This intermediary layer translates complex pressure data into clear quality decisions, maintaining ease of operation while enabling precise manufacturing quality control.
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
This approach significantly improves the accuracy of crimping evaluations, reducing rework and lowering the risk profile for electrical grid inspections by providing a more reliable assessment of crimp quality.
Implementation Method 1
a pressure sensor configured to provide pressure signals associated with a crimping application
Data Source
AI summary
Systems and methods for evaluating a crimping application. A power tool includes a pair of jaws configured to crimp a workpiece, a piston cylinder configured to actuate at least one of the pair of jaws, and a pressure sensor configured to provide pressure signals associated with a crimping application. The power tool also includes an electronic processor connected to the pressure sensor. The electronic processor is configured to monitor, while performing the crimping application, a pressure applied by the piston cylinder, construct a pressure curve indicative of a change in the pressure applied during the crimping application, process the pressure curve into a vector indicative of one or more features, evaluate the crimping application based on the vector, and provide an output indicative of the evaluation.