Exchangeable Crimping Die Insert with Wear Indicators

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Solution Overview

Problem

Crimping die inserts wear rapidly in mass production, leading to inconsistent crimp profiles and reduced product reliability, as it is difficult to determine the wear level of multiple identical profiles, necessitating frequent replacements and quality control measures.

Innovation Solution

An exchangeable crimping die insert with multiple identical crimp profiles and a built-in indicator means to differentiate them, allowing for easy identification of used and unused profiles, thereby extending the tool's lifespan and preventing defective crimping.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Duration of action of stationary object

If multiple identical crimp profiles are integrated in one crimping die insert, then the lifetime of the crimping die is extended, but it becomes difficult to determine the wear level of individual profiles

Engineering Contradiction:

Improvelifetime of crimping die insertVSAvoidwear level of crimp profiles

Core Design Contradiction:

Duration of action of stationary objectVSDifficulty of detecting and measuring

Solution Approach 1:

The patent introduces asymmetric indicator means (such as notches, recesses, or markings) on specific crimp profiles that are visually distinguishable from identical non-indicated profiles. This asymmetry allows operators to easily identify which profiles have been used and their wear status without complex measurement tools, resolving the detection difficulty while maintaining multiple profiles for extended lifetime

Inventive Principle:

Principle #4Asymmetry

2Productivity

If crimping die inserts are used for mass production, then productivity is increased, but the inserts wear rapidly leading to inconsistent crimp profiles

Engineering Contradiction:

Improvemass production capabilityVSAvoidconsistency of crimp profiles

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent implements a visual feedback system through indicator means that provide immediate information about the wear status of each crimp profile. This allows operators to monitor the condition of profiles during mass production and replace them before wear affects crimp quality, maintaining reliability while enabling continuous high-volume production

Inventive Principle:

Principle #23Feedback

3Adaptability or versatility

If crimp profiles are made identical to maximize versatility, then adaptability is improved, but the ability to track usage and prevent defective crimping is reduced

Engineering Contradiction:

Improvecrimp profile interchangeabilityVSAvoididentification of used profiles

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The patent applies local differentiation through indicator means placed on specific crimp profiles while keeping the functional crimping surfaces identical. This allows the profiles to remain versatile and interchangeable for their intended function while having localized asymmetric features for easy identification of usage status, resolving both adaptability and ease of operation requirements

Inventive Principle:

Principle #3Local quality

Data Source

PatentEP3148015B1Exchangeable crimping die insert for a crimping die

Publication Date: 2019.01.09 APTIV TECHNOLOGIES LTD

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AI summary

The present invention refers to an exchangeable crimping die insert for a crimping die for crimping electrical contact terminals to electrical cables. The exchangeable crimping die insert comprises at least two essentially identical crimp profiles integrated in one part. Furthermore, the exchangeable crimping die insert comprises at least one indicator means to differentiate the at least two essentially identical crimp profiles.