Hydraulic Crimp Tool Force Tracking With Crimp Localization
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Solution Overview
Problem
Existing hydraulic crimping tools lack the ability to monitor and record the maximum force applied during crimp formation and determine the geographic location of the crimp, which can lead to unstable connections and excessive electrical resistance.
Innovation Solution
A hydraulic power tool equipped with a force sensor, location sensor, and control system to monitor and record the force and location of crimp formation, allowing for data storage and review of crimp quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional power tool is designed to perform multiple functions (drilling, driving, crushing, tightening, etc.), then the versatility of the tool is improved, but the device complexity increases due to multiple switchable modules and function selection mechanisms
Solution Approach 1:
The power tool is designed with a universal motor unit that can perform multiple functions (drilling, driving, crushing, tightening) through a single integrated structure. The motor unit includes a rotor with eccentric weights that can be selectively activated to produce different motion patterns, eliminating the need for separate modules for each function and thereby reducing structural complexity while maintaining versatility
2Adaptability or versatility
If a power tool includes multiple switchable modules for different functions, then the adaptability is improved, but the ease of operation deteriorates due to the need for function selection and module switching
Solution Approach 1:
The power tool employs a self-service mechanism where the user simply selects the desired attachment tool (drill bit, driver bit, crusher, etc.), and the system automatically configures the motor unit to the appropriate function through a cam selection mechanism. This eliminates the need for manual function switching and module reconfiguration, thereby improving ease of operation while maintaining multi-functionality
3Ease of repair
If the motor unit is designed to be separable from the battery pack, then the ease of repair and maintenance is improved, but the device complexity increases due to additional connection and disconnection mechanisms
Solution Approach 1:
The power tool is segmented into distinct modular components: a motor unit and a battery pack, connected through a standardized interface. The motor unit can be easily separated from the battery pack for independent maintenance, repair, or replacement. The segmentation is achieved through a simple bayonet-style connection mechanism that requires minimal steps to assemble or disassemble, thereby improving maintainability without significantly increasing structural complexity
Data Source
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AI summary
Portable, hand-held, battery operated, hydraulic tools are provided with a tool frame, a force sensor, and a location detector. A piston actuated by a hydraulic system within the tool frame applies force to the working head to perform a task, such as to apply a crimp to an electrical connector. The tool determines the maximum force applied to the crimp and records that maximum force along with the geographic location of the tool when the crimp was formed. The maximum force provides an indication of the quality of the crimp and the recorded location allows a potentially defective crimp to be located.