Crimping Tool Curved Surface for Wire Terminal Uniformity
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Solution Overview
Problem
Conventional crimping tools cause partial thinning of wire terminals due to excessive force application, leading to uneven deformation and quality issues in wire with terminal production.
Innovation Solution
A crimping tool with a curved surface featuring inclined surfaces that control the inclination angles of wire barrels during crimping, preventing excessive lifting and stress concentration, thereby maintaining even deformation and avoiding partial thinning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional crimping tool is used to crimp wire barrels to a core, then the wire barrels are deformed to embrace the core, but strong force is applied to end edge parts of the wire barrels causing them to lift excessively and the bottom plate to extend locally, producing partial thinning
Solution Approach 1:
The curved surface is divided into distinct functional zones: first and second inclined surfaces that contact and press end parts of wire barrels to prevent excessive lifting, and a contact surface that allows controlled deformation. This local differentiation of surface properties ensures uniform deformation without partial thinning.
Solution Approach 2:
The use of a curved surface with inclined surfaces replaces a conventional flat crimping surface. The curvature and inclination angles are specifically designed to guide the deformation of wire barrels, distributing stress evenly and preventing concentration at end edge parts, thereby avoiding partial thinning.
2Strength
If the crimping tool applies strong force to deform wire barrels, then the wire barrels embrace the core effectively, but end parts of wire barrels are lifted and stress is concentrated, causing quality issues
Solution Approach 1:
The curved surface parameters (inclination angles, surface geometry) are optimized to distribute crimping force more uniformly across the wire barrels. This parameter optimization maintains effective crimping strength while preventing stress concentration and excessive lifting, thereby improving overall product reliability.
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 solution effectively suppresses excessive lifting and stress concentration, resulting in high-quality wire with terminals by controlling the formation of inclined portions and maintaining even deformation, thus preventing partial thinning.
Implementation Method 1
the first and second inclined surfaces contact and press end parts (end parts in the extending direction of the wire) of the wire barrels that would otherwise be lifted in a direction away from the core, thereby suppressing excessive lifting in the process of crimping the wire barrels to the core
Data Source
AI summary
A wire/terminal production method includes placing a core on a bottom plate and crimping wire barrels to the core by a crimping tool. The crimping tool includes a first tool having a placing surface on which the bottom plate and the core are placed, and a second tool having a curved surface for curving the wire barrels toward the placing surface. The curved surface has a first inclined surface inclined out on a first end in an extending direction of the wire, a second inclined surface inclined out on a second end in the extending direction and a contact surface located between the inclined surfaces. A dimension of the curved surface in the extending direction exceeds a dimension of the wire barrels in the extending direction. A dimension of the contact surface in the extending direction is no greater than the dimension of the wire barrels in the extending direction.