Crimp Tool Calibration System Using Programmable Memory Positioner
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Solution Overview
Problem
Current mechanical crimp tools require high levels of manual supervision and are prone to errors due to incorrect positioner usage, out-of-date calibration, and operator-dependent settings, leading to inconsistent crimp quality.
Innovation Solution
A programmable memory positioner and calibration system for crimp tools, equipped with a memory chip and electronic communication, automatically adjusts crimp depth and monitors tool condition, ensuring precise crimping through digital communication with a controlling computer and automated adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual adjustment and supervision are used for crimp depth setting, then operator flexibility and adaptability are maintained, but manufacturing precision and consistency deteriorate due to operator-dependent errors
Solution Approach 1:
The patent replaces manual mechanical adjustment and supervision with an automated electronic calibration system that includes a memory positioner, electronic communication interface, and controlling computer. The system automatically determines crimp depth settings, communicates them to the crimp tool, and monitors compliance, eliminating operator-dependent manual adjustments while maintaining precision.
Solution Approach 2:
The calibration system enables the crimp tool to automatically determine and adjust its own crimp depth settings without requiring manual intervention. The tool self-calibrates by receiving crimp depth information from the memory positioner and automatically positioning the indenter, thereby serving itself rather than requiring continuous operator supervision.
2Reliability
If automated memory positioner and electronic calibration system are implemented, then manufacturing precision and consistency are improved, but device complexity and initial setup requirements increase
Solution Approach 1:
The memory positioner serves multiple functions: it stores crimp depth information, communicates with the crimp tool electronically, and provides calibration data for various wire and contact combinations. This multi-functionality consolidates what would otherwise require separate devices into a single universal component, reducing overall system complexity despite the advanced capabilities.
Solution Approach 2:
The electronic communication interface acts as an intermediary between the memory positioner and the crimp tool, translating and transmitting calibration data automatically. This intermediary layer simplifies the interaction between components by handling data exchange protocols and ensuring proper communication, thereby managing system complexity through specialized intermediate components.
3Productivity
If real-time monitoring and automated calibration are implemented, then productivity and error reduction are improved, but device complexity and cost increase
Solution Approach 1:
The system implements real-time feedback by continuously monitoring whether the crimp tool is positioned at the correct crimp depth setting through electronic communication. The controlling computer receives status information from the tool and can alert operators or automatically adjust settings, providing continuous feedback that ensures compliance without requiring constant manual inspection, thereby improving productivity through automated quality assurance.
Data Source
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AI summary
A crimp tool calibration system for crimping a prepared wire into a corresponding contact wire barrel includes a computer, a positioner having a memory chip storing positioner data, and a tool frame. The tool frame includes a head having a receiving port therethrough, and configured for the positioner to be removably engaged with the receiving port during a crimping operation. The tool frame also includes a plurality of crimping dies positioned around a periphery of the receiving port, an adjustment device to adjust a crimp depth, and a positioner interface coupled to the tool frame. The positioner interface includes a tool memory for storing tool data, a reader, and a transmitter, where the reader is configured to read the positioner data stored on the memory chip of the positioner, and the transmitter is configured to transmit the positioner data and the tool data to the computer.