Crimping Machine with Gravity-Assisted Contact Element Transport
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Solution Overview
Problem
Existing crimping machines require significant setup times and investment costs for processing different cable cross-sections and contact elements, or they become overly complex and costly with multiple machines, lacking flexibility and efficient stripping capabilities.
Innovation Solution
A crimping machine with a storage arrangement of plural drum magazines, a transport unit, a centering device, and a guiding device that uses gravity and compressed air to convey contact elements directly to the crimping head, eliminating the need for complex shuttles and reducing apparatus effort, while integrating a stripper for flexible manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple crimping machines are provided for processing different cable cross-sections/contact elements, then processing capability for different cable types is improved, but investment costs and space requirements increase considerably
Solution Approach 1:
The patent implements a single crimping machine that can process multiple cable cross-sections and contact element types by providing a storage arrangement with multiple drum magazines holding different wire ferrule types. The transport unit can convey different contact elements to the joint crimping head, enabling one machine to perform the functions previously requiring multiple dedicated machines
Solution Approach 2:
The patent combines multiple drum magazines, transport units, and crimping functions into a single integrated machine system. The joint crimping head and joint transport unit serve all drum magazines, merging previously separate machine functions into one unified apparatus that reduces overall system complexity and space requirements
2Adaptability or versatility
If a crimping machine is retooled for crimping different cable cross-sections and/or contact elements, then versatility is improved, but setup times and personnel costs increase
Solution Approach 1:
The patent prepares different wire ferrule types in advance by storing them on separate drum magazines in the storage arrangement. Each drum magazine is pre-loaded with contact elements for a specific cable cross-section, so when processing is needed, the appropriate magazine is already ready and can be quickly selected without retooling or setup time
Solution Approach 2:
The patent enables dynamic selection and switching between different drum magazines and their corresponding transport units based on the required cable cross-section. The system can adapt its configuration during operation by selecting different magazines without requiring physical retooling, making the machine dynamically reconfigurable rather than statically fixed
3Ease of operation
If a shuttle is used to guide the contact element to the crimping head, then the contact element can be transported, but the design becomes complex and requires considerable space
Solution Approach 1:
The patent removes the complex shuttle mechanism from the system and replaces it with a simpler guiding device consisting of channels and gravity-assisted transport. The contact element is separated from the webbing and guided directly through channels to the crimping head without requiring a mechanical shuttle, extracting the unnecessary complexity while maintaining the essential transport function
Solution Approach 2:
The patent replaces the mechanical shuttle system with a gravity-based guiding device that uses channels and controlled falling motion to transport contact elements. This substitution eliminates complex mechanical components in favor of a simpler system that uses gravity and basic guiding structures, reducing both complexity and space requirements
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 machine achieves flexible and efficient crimping and stripping with a simple design, reducing setup times and costs, and improving productivity by directly guiding contact elements to the crimping head with minimal apparatus effort, supported by gravity and compressed air, and enabling easy selection of cable cross-sections and contact elements through a control panel.
Implementation Method 1
The guiding device has a plurality of inputs each of which is assigned to a transport unit and, respectively, a contact element cross-section. The inputs open into an output on the crimping head side via channels along which the contact element to be crimped is guided.
Implementation Method 2
supported by gravity and compressed air
Data Source
AI summary
Disclosed is a crimping machine for crimping contact elements comprising a conveying device via which a separated wire ferrule is guided from a transport unit towards a crimping head.