Crimping Device Separate Anvils Force Sensor
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Solution Overview
Problem
Existing crimping devices measure the total crimping force, including both conductor and insulation forces, and often have sensors installed in wearing parts, which can lead to inaccurate measurements and reduced durability.
Innovation Solution
A crimping device with separate anvils for conductor and insulation crimpers, each equipped with a force sensor to measure the specific crimping force, allowing for precise recording and evaluation of the force curve for quality assurance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single force sensor measures the total crimping force in a common anvil, then the device complexity is reduced, but the measurement precision deteriorates because conductor and insulation forces cannot be separately measured
Solution Approach 1:
The common anvil is divided into separate conductor anvil and insulation anvil, with each having its own force sensor. This segmentation allows independent measurement of conductor crimping force and insulation crimping force, resolving the measurement precision issue while maintaining reasonable device complexity through modular design
2Device complexity
If the force sensor is installed in a wearing part, then the device complexity is reduced, but the reliability deteriorates due to sensor exposure to wear and mechanical stress
Solution Approach 1:
A force transmission element (intermediary component) is introduced between the anvil and the force sensor. This intermediary transfers the crimping force to the sensor while protecting it from direct exposure to wear and mechanical stress, thereby improving sensor reliability without significantly increasing device complexity
3Measurement precision
If separate anvils with individual force sensors are provided for conductor and insulation crimpers, then the measurement precision is improved, but the device complexity increases
Solution Approach 1:
The separate conductor anvil and insulation anvil are designed with unified mounting interfaces and standardized force sensor configurations. This universality allows the system to achieve separate force measurement precision while controlling device complexity through consistent design patterns across multiple components
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
Enables precise measurement of the force required for conductor crimping, ensuring high-quality connections by transmitting the force to a single sensor and evaluating the force curve for quality assessment.
Implementation Method 1
the force sensor (20) arranged on the sensor part (16), on which the force occurring in the conductor anvil (19) acts
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
Crimp device has an anvil (19,21) provided for each crimper (8,9). The crimp force occurring on a conductor anvil can be measured by means of a force sensor (20). The cable conductor (25) and cable insulation can be connected with the crimp contact by means of crimper and anvil.