Mechanical Crimp Tool Head With Cam-Controlled Roller Gap
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Solution Overview
Problem
Current crimp tools, whether pneumatic or battery-driven, lack the ability to reliably open and close the roller gap, leading to damage during the crimping process, as pneumatic systems fail to provide feedback on tool usage time and electric tools are not powerful enough to achieve this functionality without increasing size or weight.
Innovation Solution
A mechanical cam-based tool head assembly that can be mounted on various power sources, incorporating a drive shaft, one-way locking bearing, and movable slide, allowing for programmable operation to open and close the roller gap, and communicate feedback on tool usage, eliminating the need for pneumatic cylinders and hoses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If pneumatic cylinders are used to open and close rollers, then the tool can function similarly to traditional crimp tools, but the tool size and weight increase due to pneumatic hoses and valves
Solution Approach 1:
The patent removes the pneumatic cylinder, hoses, and valves from the tool head assembly, extracting the problematic components that caused weight and size increases while retaining the essential roller gap control function through an electric drive mechanism with cam-based positioning
Solution Approach 2:
The electric drive mechanism serves multiple functions: it provides power for roller operation, enables programmable control, integrates feedback systems, and eliminates the need for separate pneumatic components, making the tool adaptable to different crimping applications without requiring additional pneumatic infrastructure
2Weight of moving object
If electric drive is used to eliminate pneumatic components, then tool size and weight are reduced, but the ability to open and close rollers reliably is lost
Solution Approach 1:
The patent incorporates feedback systems that monitor tool usage time and operational parameters, providing real-time data to verify correct operation and enabling reliable control of roller gap positioning through programmable electric drive mechanisms that can detect and respond to operational conditions
Solution Approach 2:
The electric drive mechanism dynamically adjusts roller gap positioning through programmable control, allowing the system to adapt roller opening and closing actions based on real-time feedback and operational requirements, ensuring reliable operation without the bulk of pneumatic systems
3Loss of information
If battery drive is used to power the tool, then feedback capability is improved, but the ability to open and close rollers is eliminated
Solution Approach 1:
The battery-powered electric drive mechanism performs multiple functions simultaneously: it provides mechanical power for roller operation, enables programmable control sequences, and integrates feedback systems to monitor tool usage, eliminating the need to choose between feedback capability and roller control
4Ease of operation
If pneumatic system is used for roller control, then roller opening and closing is achieved, but feedback on tool usage time cannot be verified
Solution Approach 1:
The patent integrates feedback systems with the electric drive mechanism that monitor and record tool usage time and operational parameters, providing verifiable data on tool operation that pneumatic systems cannot provide, while maintaining roller gap control through programmable electric actuators
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 crimping with feedback verification, maintaining tool functionality similar to pneumatic systems while reducing size and weight, ensuring proper seal application without damage, and providing real-time communication with OEM systems for process validation.
Implementation Method 1
The head includes at least one of each of the following: drive shaft, cam, oneway locking bearing, and a movable slide. The developed head utilized the ability to program the drive to a specific process. The head was designed to have an internal cam that would spin freely on the drive shaft in one direction and lock onto the shaft in the other direction.
Implementation Method 2
That cam would rotate against the moving slide forcing it to move away from the drive shaft opening the gap between rollers.
Data Source
AI summary
A tool head assembly for crimping, the assembly including an internal cam that spins freely on a stationary shaft in one direction and locks onto the shaft in the other direction. That cam rotates against the moving slide forcing to move away from the stationary shaft opening a gap between rollers. A controller is programmed to have the drive rotate in one direction for a set time period, then reverse the rotation to begin the crimp process. The start rotation of the drive rotates the cam and opens the roller gap. The forward rotation allows the cam to swing, closing the gap and rotating the rollers around a seal. The tool eliminates the air cylinder and related pneumatic hoses and valve making the head smaller and allows a controller to communicate with any OEM production system to verify the tool has been used and was used correctly.