Hydraulic Crimping Tool Force and GPS Traceability
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Solution Overview
Problem
Existing hydraulic crimping tools lack the ability to monitor and record the maximum force applied during crimp formation and determine the geographic location of the tool, which can lead to unstable connections and potential electrical resistance issues.
Innovation Solution
A hydraulic power tool equipped with a force sensor, location sensor, and data recording system to monitor and log the force applied during crimping, along with GPS capabilities to record the geographic location, allowing for quality control of crimp connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If hydraulic crimping tools are used to form crimp connections, then the connection strength is improved, but the ability to monitor and record crimp quality and location is insufficient
Solution Approach 1:
The patent implements feedback by integrating sensors that monitor crimping force and generate acoustic emissions during the crimping process. This real-time data is transmitted to a remote server, allowing operators to verify crimp quality immediately and take corrective action if deficiencies are detected, thus preventing information loss about crimp quality.
Solution Approach 2:
The patent introduces an intermediary data transmission system that acts as a mediator between the crimping tool and the remote server. Acoustic emission sensors capture crimping process data, which is then transmitted through a communication interface to the server, enabling remote monitoring and analysis of crimp quality and location without interfering with the actual crimping operation.
2Measurement precision
If force monitoring is added to crimping tools, then crimp quality control is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical measurement systems with acoustic emission sensing technology. Instead of using multiple mechanical sensors and complex transmission mechanisms, the system uses acoustic emission sensors that detect sound waves generated during crimping, providing force measurement capabilities with simpler hardware and reduced system complexity.
Solution Approach 2:
The patent implements a multi-functional integrated system where a single data transmission interface handles multiple functions: transmitting crimp force data, location information, and tool identification data. This universal communication protocol reduces the need for separate dedicated systems for each measurement parameter, thereby reducing overall device complexity.
3Reliability
If geographic location tracking is integrated, then quality assurance capability is improved, but energy consumption increases
Solution Approach 1:
The patent implements preliminary action by pre-configuring the tool with identification data and establishing communication protocols before field use. Location tracking and data transmission are activated only when needed for quality assurance verification, rather than continuously, thereby reducing energy consumption while maintaining reliability when required.
Solution Approach 2:
The patent enables the system to self-manage data transmission by automatically determining when crimping operations occur and transmitting relevant data without requiring continuous external prompting. The tool autonomously manages its own quality assurance data collection and transmission, reducing the energy burden on the operator and optimizing power usage.
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 monitoring and recording of crimping forces and locations, ensuring stable connections and providing tools for quality assurance through data analysis and geographic mapping.
Implementation Method 1
Some portable tools incorporate a hydraulic pump to drive a piston to apply a relatively large amount of force or pressure for a particular task
Implementation Method 2
the controller determines the maximum force that was applied to the workpiece during the crimp cycle
Implementation Method 3
the controller determines a location of the tool when the crimp connection is formed
Data Source
AI summary
Portable, hand-held, battery operated, hydraulic tools are provided with a tool frame, a force sensor, and a location detector. A piston actuated by a hydraulic system within the tool frame applies force to the working head to perform a task, such as to apply a crimp to an electrical connector. The tool determines the maximum force applied to the crimp and records that maximum force along with the geographic location of the tool when the crimp was formed. The maximum force provides an indication of the quality of the crimp and the recorded location allows a potentially defective crimp to be located.