Integrated Crimp and Trim Tool for Electrical Cables
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Solution Overview
Problem
Existing crimp tools require multiple steps and are inefficient in sizing and trimming electrical cable conductors, often leading to damage or improper length, which increases time and costs.
Innovation Solution
A multi-functional crimp tool with pivotally coupled jaw members and integrated cutting members that allow for simultaneous crimping and trimming of electrical cables, using complementary recessed surfaces and adjustable spacers to achieve precise conductor lengths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a traditional crimp tool is used to crimp connectors to electrical cables, then the crimping operation can be completed, but additional separate steps are required to trim the exposed inner conductor to the precise length needed
Solution Approach 1:
The patent combines the crimping function and trimming function into a single integrated tool. The crimp tool includes both crimping dies for compressing the connector and cutting members positioned to trim the inner conductor to a precise length during the same crimping operation, eliminating the need for separate trimming steps and improving overall productivity.
Solution Approach 2:
The crimp tool is designed with multi-functionality, performing both crimping and trimming operations with a single device. The tool includes crimping dies for various connector types and integrated cutting members that can trim conductors to different lengths, making it a universal tool that replaces multiple specialized tools.
2Ease of operation
If the inner conductor protrusion length is not precisely controlled, then the crimping operation is simpler, but the protrusion may be too long and damage solder joints or the connector itself when mated with the female receiving element
Solution Approach 1:
The cutting members are positioned in advance at a predetermined distance from the crimping dies. This preliminary positioning ensures that when the crimping operation is performed, the inner conductor is automatically trimmed to the exact length needed before the connector is mated, preventing damage to solder joints or the connector while maintaining ease of operation.
Solution Approach 2:
The cutting members act as an intermediary element between the crimping operation and the final connector assembly. By positioning the cutting members at a specific distance from the crimping dies, the tool automatically controls the conductor protrusion length, serving as a mediator that ensures proper length without requiring manual measurement or adjustment.
3Manufacturing precision
If manual measurement and cutting of the inner conductor is performed to maintain proper protrusion length, then precise length control is achieved, but the process becomes more complex and time-consuming
Solution Approach 1:
The crimp tool is designed to automatically trim the inner conductor to the precise length needed during the crimping operation itself. The cutting members are positioned at a predetermined distance from the crimping dies, allowing the tool to self-regulate the conductor length without requiring manual measurement or separate cutting operations, thus maintaining precision while reducing process complexity.
Data Source
AI summary
A crimp tool for concurrently crimping and trimming includes a first jaw member and a second jaw member pivotally coupled to the first and second jaw members moveable between a crimp position and a release position. The crimp tool also includes a first crimp die coupled to the first jaw member and having a first recessed surface and a second crimp die coupled to the second jaw member and having a second recessed surface, the first and second recessed surfaces being complementary to each other and forming a crimping opening in the crimp position to receive a connector having a conductor received therein. The crimp tool includes cutting members that are spaced apart relative to the respective jaw members to trim an exposed inner conductor of the conductor when substantially abutting one another in the crimp position, and may be adjustable depending on the desired protrusion of the inner conductor. Related methods to use the same are also provided.