Hydraulic Crimping Head Alignment With Extended Dies
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Solution Overview
Problem
Hydraulic crimping tools with biased open single pivot crimping heads face challenges in achieving precise alignment of crimping jaws with the desired crimp location, leading to inefficiencies and increased operating time, especially for large connectors.
Innovation Solution
A hand-held hydraulic power tool with a die set comprising extended moveable and stationary crimp dies of different geometrical shapes, along with alignment features on the dies and tool components, allowing for precise alignment and reduced ram stroke, thereby enhancing the duty cycle and reducing cycle time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a biased open single pivot crimping head is used, then the jaws remain open prior to crimping initiation, but proper alignment of the crimping jaws with the desired crimp location becomes difficult
Solution Approach 1:
The patent introduces alignment features (alignment pins, alignment grooves, or alignment marks) that pre-establish the correct positional relationship between the crimping head and connector before the crimping action begins. This preliminary alignment mechanism ensures that when the jaws close, they are already positioned at the desired crimp location, eliminating the need for manual alignment adjustments during operation.
2Manufacturing precision
If the user jogs the device to approach closed jaw position, then alignment may be achieved, but additional time and touch labor are required
Solution Approach 1:
The alignment features are designed to automatically guide the crimping head into the correct position relative to the connector without requiring manual intervention. The alignment pins fit into corresponding grooves or the alignment marks visually guide the user, allowing the system to self-align during the normal closing motion of the jaws, thereby eliminating the need for time-consuming jogging operations.
3Productivity
If extended dies are used, then the ram stroke is shortened and duty cycle is improved, but the geometrical shapes of moveable and stationary dies must be different
Solution Approach 1:
The patent applies extended dies with different geometrical shapes to the moveable and stationary die components. These extended dies feature localized geometric variations (such as extended crimping surfaces or specialized profiling sections) that enable the crimping action to be completed over a shorter ram stroke distance. The different geometries are strategically designed to work together, with one die providing the extended crimping surface while the other provides the corresponding shaping features, thereby achieving both shortened stroke and proper crimp formation.
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 solution enables faster crimping cycles and improved alignment, reducing the time required for crimping operations, especially for large connectors, by minimizing the distance the ram assembly needs to travel.
Implementation Method 1
a hydraulic tool comprising a hydraulic pump is utilized for pressurizing hydraulic fluid and transferring it to a cylinder in the tool. This cylinder causes an extendable piston or ram assembly to be displaced towards a working head
Data Source
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AI summary
A working head (22) for a hydraulic power tool (10). The working head (22) includes a head frame and a first moveable die head configured to move along the working head frame (25). The first moveable die head is configured to receive a first moveable die (200) comprising a first body length and a second die head is adapted to receive a second die (250) comprising a second body length. At least one of the moveable die (200) or stationary die (250) comprises an elongated die.