Crimping Apparatus Core Crimp Force Segmentation

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Solution Overview

Problem

Existing crimping technologies fail to consistently and reliably assess the quality of core crimp portions, especially for wire conductors of 20 gauge or smaller, due to the difficulty in detecting defects such as missing wire strands and insulation within the crimped area, which can lead to downstream quality issues in wiring harness manufacturing.

Innovation Solution

A crimping apparatus that applies a separate core crimp force using an independently moving core plate and load pin, allowing for the measurement of the core crimp force apart from the total press force, enabling accurate detection of defects in the core crimp portion by sensing the core crimp force with a load cell.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a press force is applied during the crimping cycle to assess the quality of a core crimp portion, then the quality assessment can be performed, but the measurement does not allow a consistent, reliable quality decision especially for wire conductors of 20 gauge or smaller

Engineering Contradiction:

Improvequality assessment accuracyVSAvoidconsistent quality decision

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The total press force measurement is segmented into its component forces, specifically isolating the core crimp force from other forces in the crimping cycle. This is achieved by applying the core crimp force separately through a dedicated core plate and measuring it independently, allowing for precise and reliable quality assessment of the core crimp portion without interference from other force components.

Inventive Principle:

Principle #1Segmentation

2Loss of information

If the press force is measured during the crimping cycle, then some quality information can be obtained, but the measurement cannot reliably detect defects such as missing wire strands and insulation in smaller gauge wires

Engineering Contradiction:

Improvequality informationVSAvoiddefect detection capability

Core Design Contradiction:

Loss of informationVSDifficulty of detecting and measuring

Solution Approach 1:

The core crimp force measurement is extracted from the total press force measurement. By isolating and measuring only the core crimp force component separately, the system can reliably detect quality defects such as missing wire strands and insulation in the core crimp portion, particularly for smaller gauge wires where such defects are difficult to detect with total press force measurement alone.

Inventive Principle:

Principle #2Taking out (Extraction)

3Measurement precision

If a core crimp force is applied separately from the press force, then accurate quality assessment of the core crimp portion can be achieved, but the device complexity increases

Engineering Contradiction:

Improvecore crimp force measurement accuracyVSAvoidcrimping apparatus structure

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

A dedicated core plate serves as an intermediary component between the ram and the terminal-wire assembly. This core plate is specifically designed to apply and transmit only the core crimp force, allowing for separate and accurate measurement of this force component. The intermediary core plate simplifies the measurement system by providing a dedicated force transmission path while maintaining the overall crimping process integration.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 approach provides a reliable quality assessment of the core crimp portion by measuring the core crimp force, increasing confidence in detecting defects and ensuring the mechanical and electrical integrity of the crimp connection, particularly for smaller gauge wires, with a higher force delta between acceptable and defective crimp portions.

Implementation Method 1

A part of the press force will be separately applied as a core crimp force to produce a core crimp portion that connects the terminal to the wire conductor

Methodology Applied

Scientific EffectMechanical Force: Force

Implementation Method 2

produce a core crimp portion that connects the terminal to the wire conductor

Methodology Applied

Scientific EffectDeformation: Deformation

Implementation Method 3

sensing the core crimp force with a load cell

Methodology Applied

Scientific EffectForce sensing: Force

Data Source

PatentUS8336351B2Apparatus and methods that apply a press force including a separately applied core crimp force

Publication Date: 2012.12.25 APTIV MANUFACTURING MANAGEMENT SERVICES GMBH

AI summary

A crimping apparatus and methods are provided that apply a press force and a part of the press force is separately applied as a core crimp force for crimping a terminal to a wire conductor. A die assembly includes a die defining a cavity that includes an independently moveable core plate and a ram assembly includes a ram in force connection with a load pin and a core plate. When the ram applies the press force, the core crimp force will be separately applied from the ram through the load pin and core plate to produce a core crimp portion that connects the wire conductor to the terminal. The applied core crimp force is subsequently transferred from the core crimp portion to the core plate to the load pin and into the ram.