Crimp Sleeve Tooling With Built-In Measuring Locations
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Solution Overview
Problem
Existing crimping tools struggle to ensure consistently high-quality crimp connections, particularly in measuring crimp diameters quickly and easily, and in relating these measurements across a batch of crimp sleeves.
Innovation Solution
A crimping tool with sub-tools that include a mechanically effective sub-crimp surface for partial crimping of the crimp sleeve, and a local measuring location insertion device to form measuring locations within the crimp sleeve, allowing for precise measurement of crimp dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional crimping tools are used without integrated measuring capabilities, then device complexity is reduced, but measurement precision and quality assurance capability deteriorate
Solution Approach 1:
The patent combines the crimping function and measurement function into a single integrated crimping tool. The measuring location insertion device is integrated into the crimping punch or anvil, allowing both crimping and measurement to be performed by the same tool without requiring separate measuring equipment.
Solution Approach 2:
The measuring location is formed during the crimping process itself, before the actual measurement takes place. The insertion device creates the measuring location (such as a groove or indentation) as part of the crimping action, so that when measurement occurs, the location is already prepared and marked on the crimp sleeve.
2Reliability
If multiple measuring locations are formed in the crimp sleeve, then measurement reliability across batch production is improved, but manufacturing precision requirements worsen
Solution Approach 1:
The insertion device creates specific localized features (measuring locations) at particular positions on the crimp sleeve, such as grooves, indentations, or flattened areas. These local modifications provide distinct reference points for measurement, ensuring that measurements are taken at consistent locations across all crimp sleeves in a batch.
Solution Approach 2:
The crimp sleeve is divided into multiple measuring locations around its circumference, allowing for multiple measurement points. This segmentation enables comprehensive quality checking at different positions, ensuring consistency across the entire batch while distributing the precision requirements across multiple standardized locations.
3Productivity
If crimp diameter measurement is performed quickly and easily, then productivity is improved, but measurement precision may worsen
Solution Approach 1:
The crimping tool automatically creates the measuring location during the crimping process itself, without requiring separate preparation steps. The measuring location is self-formed by the insertion device as part of the normal crimping operation, enabling immediate measurement without additional time investment while maintaining precision through consistent location formation.
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 solution enables efficient and accurate measurement of crimp diameters, improving the quality of installed crimp connections by ensuring consistent crimp dimensions across a batch, thus enhancing productivity and reliability.
Implementation Method 1
Crimping is a joining process in which, for example, a crimp terminal and a cable are firmly connected to each other by plastic deformation of a crimp sleeve (crimp portion) of the crimp terminal
Data Source
AI summary
A crimping tool, in particular for a crimp applicator or a crimping machine, for crimping a crimp sleeve, in particular a crimp sleeve of an electrical crimping terminal, includes a plurality of sub-tools movable against each other, wherein an individual sub-tool has a mechanically effective sub-crimp surface global to it for partial crimping of the crimp sleeve, and at least one sub-tool, in particular exactly or at least two sub-tools, has a local measuring location insertion device within the relevant global sub-crimp surface, by means of which a measuring location can be incorporated into the crimp sleeve.