Hydraulic Crimping Tool Piston Tracking for Precise Pressure Control
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Solution Overview
Problem
Hydraulic crimping tools often result in crimps at undesired locations and with improper pressure, lacking precision in crimping processes due to the absence of accurate tracking and control of ram assembly movement.
Innovation Solution
A power tool equipped with a linear sensor to track and identify the movement of a moveable piston, allowing for precise control of crimp pressure and movement through a controller that operates based on sensor information, enabling accurate crimping without the need for crimp dies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If hydraulic crimping tools are used without accurate tracking of ram assembly movement, then the crimping process can be performed, but the crimping precision and control over crimp location and pressure deteriorate
Solution Approach 1:
The patent implements a feedback control system where a sensor continuously monitors the position of the ram assembly during crimping operations. The controller receives this position data and uses it to adjust hydraulic pressure in real-time, ensuring the crimp is applied at the correct location with the correct force. This closed-loop feedback mechanism resolves the contradiction by providing precise control without requiring overly complex manual intervention systems.
Solution Approach 2:
The patent replaces traditional mechanical position-sensing methods with electronic sensors and digital control systems. The sensor electronically tracks ram assembly position, and the controller processes this data to manage hydraulic pressure, substituting complex mechanical linkages and manual measurement systems with more precise and controllable electronic mechanisms.
2Measurement precision
If traditional hydraulic crimping tools are used without sensor tracking, then the device structure remains simple, but the control accuracy over piston movement and crimp pressure deteriorates
Solution Approach 1:
The sensor continuously measures piston position and feeds this information back to the controller, which adjusts hydraulic pressure accordingly. This real-time feedback loop enables precise measurement of piston movement (improving measurement precision) while using a relatively simple sensor-controller configuration rather than complex measurement equipment.
Solution Approach 2:
The sensor and controller system is integrated directly into the hydraulic crimping tool, allowing the device to self-monitor and self-adjust its operation. The sensor automatically tracks piston position without external intervention, and the controller autonomously adjusts pressure based on position data, reducing the need for external measurement equipment or manual monitoring.
3Reliability
If accurate sensor tracking of piston movement is implemented, then crimping consistency and pressure control improve, but the device complexity and cost increase
Solution Approach 1:
The feedback control system continuously monitors piston position and adjusts hydraulic pressure in real-time, ensuring consistent crimping results regardless of variations in material properties or operating conditions. This automated feedback mechanism improves reliability by eliminating human error and ensuring repeatable crimp quality, while the integrated sensor-controller design keeps the added complexity manageable.
Solution Approach 2:
The patent replaces manual monitoring and adjustment mechanisms with electronic sensors and automated control systems. This substitution improves crimping consistency by providing precise, real-time measurement and control, while the electronic systems are more compact and easier to integrate than equivalent mechanical control systems would be.
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
This solution ensures consistent and precise crimping by accurately tracking piston movement and adjusting pressure, thereby improving the efficiency and robustness of the crimping process.
Implementation Method 1
the linear sensor comprises a hall effect sensor
Data Source
AI summary
A power tool including a moveable piston, a motor capable of driving the moveable piston to perform work on a work piece, and a distance sensor configured to sense a movement of the moveable piston. The distance sensor operable to provide sensor information indicative of the movement of the piston. A controller receives the sensor information from the distance sensor. The controller operates the motor to perform work on the work piece based in part on the sensor information that the controller receives from the distance sensor.