Terminal Crimping Apparatus Third Die Wire Insertion
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Solution Overview
Problem
Existing terminal crimping apparatuses face issues with securely crimping shielded wires due to interference between the braid wire and curved crimping pieces, leading to incomplete connections and potential disconnection during the crimping process.
Innovation Solution
A terminal crimping apparatus with a third die that slides to insert the electric wire between curved crimping pieces, a servomotor-driven mechanism for precise movement, and a detecting system to ensure proper insertion and crimping, along with a pressure-contact member for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the crimping piece has a curved end to improve crimping contact, then the crimping contact with the braid wire is improved, but the braid wire is interfered with by the curved end during insertion
Solution Approach 1:
The patent introduces a third die that performs preliminary action by pushing the electric wire toward the bottom plate and inserting it between the crimping pieces before the second die crimps the crimping pieces. This preliminary insertion action resolves the contradiction by ensuring the wire is properly positioned before the crimping action occurs, preventing interference from the curved ends while maintaining strong crimping contact.
2Device complexity
If the braid wire is inserted between curved crimping pieces without preliminary positioning, then the crimping process is simplified, but the wire may not be thoroughly inserted leading to insufficient connection
Solution Approach 1:
The third die performs the preliminary action of positioning and inserting the electric wire between the crimping pieces before the actual crimping operation. This ensures thorough insertion and reliable connection while maintaining a relatively simple overall device structure, as the third die integrates multiple functions into a single component.
Solution Approach 2:
The third die acts as an intermediary component between the wire feeding mechanism and the crimping pieces. It mediates the insertion process by pushing the wire toward the bottom plate and ensuring proper positioning, thereby guaranteeing connection reliability without significantly complicating the device.
3Productivity
If the crimping piece is crimped while the braid is not thoroughly inserted, then the crimping speed is maintained, but the braid and crimping pieces are not sufficiently connected
Solution Approach 1:
The third die performs preliminary insertion of the electric wire between the crimping pieces before the second die executes the crimping action. This sequence ensures the wire is thoroughly inserted while maintaining efficient productivity, as the preliminary positioning is done in a single preparatory motion that enables subsequent rapid crimping.
Solution Approach 2:
The patent incorporates a detecting device that monitors whether the electric wire has been properly inserted between the crimping pieces before the crimping operation proceeds. This feedback mechanism ensures connection reliability by preventing crimping until proper insertion is confirmed, while the automated detection and control system maintains high productivity through rapid feedback loops.
Data Source
AI summary
To provide a reliable terminal crimping apparatus and a terminal crimping method, which crimps an electric wire to a terminal having crimping pieces, ends of which curve in a direction of approaching each other, the terminal crimping apparatus includes a first die for placing the terminal on a surface thereof, a second die arranged correspondingly to the first die and freely approaching and parting the first die to crimp the crimp pieces by approaching the first die, and a third die arranged correspondingly to the first die and freely approaching and leaving from the first die to approach the first die before the second die crimps the crimping piece so as to push the electric wire toward the bottom plate and insert the electric wire between the pair of crimp pieces.