Crimping Station Variable Gearbox Positioning
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Solution Overview
Problem
Existing crimping stations face challenges with precise vertical positioning of cable ends during crimping, leading to vibrations and mechanical stresses, and are inflexible when switching between different cables or crimping tools, requiring costly re-fitting processes.
Innovation Solution
A crimping station with a crimping press and gripper system that uses a variable gearbox connected to the positioning unit, allowing adjustable reduction ratios and flexible operation, enabling precise cable placement and easy adaptation to varying cable diameters and crimping tools through a lever mechanism and adjustable gearbox.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the positioning unit is rigidly connected to the crimping press, then the positioning is stable, but abrupt impinging on the cable gripper causes vibrations and mechanical stresses
Solution Approach 1:
A cushioning element is introduced as an intermediary between the positioning unit and the cable gripper. This cushioning element absorbs the impact during positioning, eliminating abrupt impinging while maintaining stable positioning. The mediator allows force transmission during normal operation but absorbs shock during positioning events.
Solution Approach 2:
The cushioning element is pre-installed in the positioning unit to anticipate and prevent harmful impacts before they occur. By having the cushioning element in place beforehand, the system prepares for the inevitable positioning contact, transforming a potentially harmful rigid impact into a controlled, cushioned interaction.
2Device complexity
If the crimping station uses fixed components, then the structure is simple, but switching between different cables and crimping tools requires expensive re-fitting processes
Solution Approach 1:
The crimping station incorporates adjustable and interchangeable components that allow dynamic reconfiguration for different cable types and crimping tools. The positioning unit's adjustable parameters and replaceable fixtures enable the system to adapt to varying operational requirements without requiring complete re-fitting, maintaining structural simplicity while enhancing versatility.
Solution Approach 2:
The positioning unit is designed with universal features that allow it to accommodate multiple cable types, diameters, and crimping tool configurations. By incorporating adjustable parameters and standardized interfaces, a single positioning unit structure can serve multiple functions across different crimping applications, eliminating the need for expensive re-fitting processes.
3Manufacturing precision
If the crimping station is designed for high precision, then crimp quality is improved, but the system becomes less flexible for varying operational parameters
Solution Approach 1:
The positioning unit incorporates adjustable parameters such as position, speed, and force that can be modified to maintain high crimp quality across different cable types and applications. By allowing parameter changes rather than requiring physical reconfiguration, the system preserves manufacturing precision while gaining flexibility for varying operational parameters.
Data Source
AI summary
A crimping station with a crimping press for producing a crimp connection, the crimping press including a drivable press part movable in vertical direction, with which a cable end of a cable can be connected with a crimp contact, a gripper for supplying the cable end to the crimping press, and a positioning unit for vertically positioning the cable end at the crimping press. During the process of moving the press part the gripper is moved by the positioning unit between a starting position and an end position. The positioning unit is connected via a variable gearbox with the press part whereby during the moving of the press part, the positioning unit is moved in relation to the press part at a speed reduced by a reduction ratio of the gearbox, and the reduction ratio can be adjusted by an adjusting device.