Crimper Anvil Alignment via Force Sensing Gap Measurement

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Solution Overview

Problem

Existing crimping press devices face challenges in aligning the crimper and anvil efficiently, reliably, and quickly, especially when tools are changed, which affects the quality of crimp connections.

Innovation Solution

A method involving moving the crimper relative to the anvil in a first direction, detecting contact through transverse movement, measuring the gap, and adjusting the anvil position by half the gap distance to center it within the crimper's cavity, utilizing force sensors or servo motors for precise alignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If traditional alignment methods are used, then alignment precision can be maintained, but alignment time increases and productivity decreases

Engineering Contradiction:

Improvealignment precisionVSAvoidalignment speed

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The patent replaces traditional optical measurement systems with a mechanical sensing approach. Force sensors detect contact between the crimper and anvil to determine alignment, eliminating the need for complex optical equipment and manual measurement procedures. This mechanical substitution enables faster alignment while maintaining precision through automated feedback control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The alignment system performs self-alignment through automated feedback control. The force sensors continuously monitor contact forces between the crimper and anvil, and the control unit automatically adjusts positions to achieve optimal alignment without requiring manual intervention or external measurement equipment. This self-service capability significantly reduces alignment time while maintaining high precision.

Inventive Principle:

Principle #25Self-service

2Measurement precision

If optical measurement/alignment is used, then alignment precision can be achieved, but the system fails in bad lighting or dirty environments

Engineering Contradiction:

Improvealignment precisionVSAvoidenvironmental sensitivity

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The patent replaces optical measurement systems that are sensitive to lighting and environmental conditions with a mechanical sensing system using force sensors. These sensors detect contact forces between the crimper and anvil, providing reliable alignment data independent of lighting conditions, dust, or contamination. This mechanical approach eliminates the harmful effects of environmental factors on measurement accuracy.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Device complexity

If manual alignment procedures are used, then equipment complexity remains low, but alignment reliability and precision decrease

Engineering Contradiction:

Improvesystem complexityVSAvoidalignment reliability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent implements feedback control using force sensors that continuously monitor contact forces between the crimper and anvil. The control unit processes this feedback information and automatically adjusts positions to achieve optimal alignment. This feedback mechanism significantly improves alignment reliability and precision while adding only minimal system complexity through the integration of simple force sensors and control logic.

Inventive Principle:

Principle #23Feedback

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

This method allows for rapid, reliable, and precise alignment of the crimper relative to the anvil, ensuring high-quality crimp connections without the need for direct optical measurement, even in adverse conditions, and can be applied to existing crimping presses with minimal modifications.

Implementation Method 1

detecting a contact between the crimper and the anvil via force sensors

Methodology Applied

Scientific EffectForce sensing: Force

Data Source

PatentUS11128095B2Method for aligning a crimper of a first tool of a crimping press relative to an anvil of a second tool of the crimping press and a crimping press device

Publication Date: 2021.09.21 KOMAX HOLDING

AI summary

A method for aligning a crimper of a first tool relative to an anvil of a second tool in a crimping press, wherein a crimp connection is made by jointly by moving the crimper relative to the anvil in a first direction, includes: moving the crimper relative to the anvil in the first direction until the anvil is partially inside a cavity of the crimper; moving the anvil relative to the crimper in a second direction transverse to the first direction until detecting contact between the anvil and the crimper; moving the anvil relative to the crimper opposite to the second direction until detecting contact between the anvil and the crimper for determining a gap width between the anvil and the crimper; and moving the anvil relative to the crimper in the second direction by a distance which is equal to half of the determined gap width.