Crimping System Deflection Control for Precision Diameter
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Solution Overview
Problem
Conventional crimping machines lack precision in achieving consistent crimp diameters due to manual operator intervention and variability in workpieces, leading to inconsistencies and defects.
Innovation Solution
A crimping system with a controller that determines the deflection of actuated plates to control the crimping process, ensuring precise crimp dimensions by validating component combinations through identification information and automatically adjusting the crimping operation based on measured deflection and pressure data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual operator intervention is used to monitor and measure crimp diameter, then the system is simpler and easier to operate, but manufacturing precision and consistency deteriorate due to operator error and variability
Solution Approach 1:
The crimping system performs self-measurement and self-control through integrated sensors that automatically monitor crimp diameter and control actuators to maintain precision without requiring manual measurement or adjustment by operators
Solution Approach 2:
Manual mechanical measurement with calipers is replaced by electronic sensors and automated control systems that continuously monitor and adjust crimp parameters, eliminating operator error while maintaining ease of operation through automated interfaces
2Productivity
If full stroke of driving means is used to complete crimp, then the crimping operation is simpler and faster, but manufacturing precision deteriorates as crimp diameter becomes smaller or larger than desired
Solution Approach 1:
Sensors continuously measure crimp diameter during the crimping process and provide feedback to the controller, which adjusts actuator movement to achieve the exact desired crimp diameter regardless of the driving means stroke position
Solution Approach 2:
The crimping system transitions from a static full-stroke operation to a dynamic controlled process where actuator movement is continuously adjusted based on real-time sensor feedback to maintain precise crimp diameter throughout the operation
3Measurement precision
If visual monitoring with external measuring devices is implemented, then measurement capability is improved, but device complexity and operator workload increase
Solution Approach 1:
The measurement function is merged with the crimping system itself through integrated sensors that are part of the die assembly, eliminating the need for separate external measuring devices and reducing overall system complexity
Solution Approach 2:
Electronic sensors serve as intermediaries between the mechanical crimping process and the control system, providing automatic measurement and control signals that eliminate the need for manual measurement operations
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
The system achieves more precise and uniform crimping, reducing operator error and variability, resulting in higher quality crimps with improved reliability and safety, especially in high-pressure applications.
Implementation Method 1
The controller is configured to determine a value associated with an amount of deflection of the first portion while crimping
Implementation Method 2
at least one actuator configured to move the first portion relative to the second portion to compress a die disposed between the first portion and the second portion
Data Source
AI summary
A system for crimping a first component onto a second component includes a first portion and a second portion facing the first portion. The system also includes at least one actuator configured to move the first portion relative to the second portion to compress a die disposed between the first portion and the second portion. The compression of the die causes the first and second components located in the die to be crimped together. The system also includes a controller connected to the at least one actuator. The controller is configured to determine a value associated with an amount of deflection of the first portion while crimping and determine whether to stop the movement of the first portion based on the determined value.