Crimping Insert for Strip-Fed Wire End Ferrule Processing
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Solution Overview
Problem
Existing hand-operated crimping tools require a high time investment for processing multiple wire ends due to the manual threading and crimping of wire end ferrules, which is inefficient for large quantities.
Innovation Solution
A crimping insert for hand-operated pressing tools with parallel, moveable jaws that include a stamp part and a die part, featuring a holding element for secure ferrule alignment and a cutting edge for easy separation, allowing for efficient processing of interconnected wire end sleeves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If wire end ferrules are individually threaded onto conductor cable ends and crimped one by one using conventional pressing tools, then each crimping operation can be performed with simple tooling, but the time required for processing multiple wire ends becomes excessively high
Solution Approach 1:
Wire end ferrules are pre-assembled into interconnected strips before crimping operations. The strips are prepared in advance with multiple ferrules connected together, allowing the pressing tool to crimp multiple wire ends in sequence without repeated threading operations, thereby reducing total processing time
Solution Approach 2:
The crimping process is segmented into distinct functional zones within the die part: a feed area for receiving strips, a cutting and pressing area for separation and crimping. This segmentation allows continuous processing of multiple wire ends through different stages in a single operational cycle
2Manufacturing precision
If wire end ferrules are processed as individual components, then alignment and positioning can be straightforward, but the overall processing time for multiple ferrules increases significantly
Solution Approach 1:
Interconnecting material (such as tape or adhesive) serves as an intermediary element that bonds multiple wire end ferrules together to form strips. This intermediary maintains precise alignment and relative positioning of ferrules within the strip while allowing the entire assembly to be fed through the crimping tool efficiently
3Productivity
If a receiving bearing is integrated into the pressing tool handle to accommodate wire end ferrule strips, then batch processing becomes possible, but the tool's versatility is limited to crimping operations only
Solution Approach 1:
The pressing tool is designed with interchangeable pressing jaws that can be attached to different die parts. By changing the die part, the tool can accommodate different strip types and perform various crimping operations, maintaining versatility while enabling batch processing through strip feeding
4Device complexity
If manual threading of wire end ferrules is required for each conductor cable end, then simple tooling can be used, but the time investment for processing multiple wire ends becomes unacceptably high
Solution Approach 1:
Wire end ferrules are pre-assembled into interconnected strips before crimping operations. The strips are prepared in advance with multiple ferrules connected together, allowing the pressing tool to crimp multiple wire ends in sequence without repeated threading operations, thereby reducing total processing time
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 rapid and precise crimping of interconnected wire end sleeves, reducing the time required for each work step and improving the overall efficiency of the crimping process.
Implementation Method 1
A holding element is arranged in the feed area, with which the strip can be frictionally secured in the feed area
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The invention relates to a crimping insert (1) for a manually operated pressing tool (2) having pressing jaws (23, 24), which are oriented parallel to each other and movable perpendicularly toward each other, for processing strips (6) of interconnected wire end ferrules (61), said crimping insert having a punch part (3), which is fixable to a first of the pressing jaws (23, 24), a die part (4), which is fixable to a second of the pressing jaws (23, 24), wherein the die part (4) has a feed region (43) having a receiving opening (48) for feeding the strip (6) into a separating and pressing region (49) of the die part (4), wherein a retaining element (5) is arranged in the feed region (44), to which retaining element the strip (6) is frictionally fixable in the feed region (44). The invention furthermore relates to a manually operated pressing tool (2).