Multi-wire Cable Crimping Device with Offset Guide Recesses
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Solution Overview
Problem
Existing devices for crimping or stripping multi-wire cables face difficulties in processing cables for subsequent automatic processing, as the cables produced are often misaligned and require manual bending, leading to unpredictable deformation and complexity in further processing.
Innovation Solution
A device with a first tool and a second tool, where one tool is movable relative to the other in the z-direction for crimping or stripping, incorporating free spaces and guide elements to precisely position wires without permanent bending, allowing for simultaneous processing of multiple cores and reducing deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional crimping devices process multi-wire cables, then crimping can be performed, but the cables require manual bending and alignment for subsequent processing
Solution Approach 1:
The device performs preliminary positioning of all wires in the multi-core cable during the crimping process itself. The wires are guided through guide elements and positioned in a predetermined arrangement before crimping, so that no additional bending or alignment is needed for subsequent automated processing steps.
Solution Approach 2:
The device processes different wires in separate processing positions along the z-direction, allowing each wire to be crimped independently while maintaining their spatial relationships. This segmentation enables precise control over the final wire arrangement without requiring post-processing manipulation.
2Manufacturing precision
If wires are permanently bent for alignment, then they can be processed, but unpredictable deformation occurs
Solution Approach 1:
Wires are positioned in their final predetermined arrangement before the crimping action occurs. Guide elements and positioning structures ensure that wires are correctly aligned in advance, eliminating the need for post-positioning bending operations that cause unpredictable deformation.
Solution Approach 2:
The wire positioning is achieved through the wire's own properties and the guiding structures, without requiring external manipulation or bending. The wires naturally follow the guide paths and settle into their predetermined positions through the crimping process itself.
3Productivity
If multiple wires are processed simultaneously, then productivity increases, but device complexity increases
Solution Approach 1:
The device is divided into multiple independent processing positions along the z-direction, each capable of crimping one or more wires. This segmentation allows simultaneous processing of multiple wires while maintaining a modular structure that manages complexity through repetition of standardized components.
Solution Approach 2:
The device structure is designed with universal components that can handle multiple wires through different processing positions. The same basic crimping mechanism is replicated and positioned to accommodate different wires, allowing simultaneous processing without requiring entirely separate systems for each wire.
4Extent of automation
If cables are processed for automatic production, then productivity increases, but the cables must be bent and realigned
Solution Approach 1:
The device performs preliminary positioning and arrangement of wires in the predetermined configuration required for automated subsequent processing. By establishing the correct wire arrangement during crimping, the device eliminates the need for additional bending or realignment operations in automated production lines.
Solution Approach 2:
The device incorporates positioning feedback through guide elements and predetermined geometric arrangements that ensure wires are correctly positioned before and during crimping. This feedback mechanism guarantees that the output cables are already in the correct configuration for automated handling without requiring post-processing adjustment.
Data Source
Figure 1a
Figure 1b
Figure 2a~2f
AI summary
The device has a crimper (1) movable in a z-direction relative to an anvil (2) into a processing position for crimping or stripping a set of leads (5.1, 5.2) of a multi-core cable (5). Clearances are formed as recesses in the respective crimper and anvil, and another set of leads (5.3, 5.4) is accommodatable in the clearances in the processing position. The clearances are arranged offset to the former set of leads in the z-direction, and are arranged offset to each other in an x-direction. A guiding element is provided for guiding the respective leads into a preset position.