Decagon Compression Die for Damage-Free Composite Core Crimping
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Solution Overview
Problem
The challenge lies in effectively connecting the sensitive outer surface of a composite core cable in high voltage transmission conductors to an electrical connector assembly without causing deformation or damage, as conventional crimping methods often lead to scratches and cracks that compromise the integrity and efficiency of the composite core.
Innovation Solution
A decagon-shaped crimp die with a crimping area formed by ten planar surfaces, each angled between 0° and 180°, minimizes deformation by distributing the radial compression force evenly, and incorporates flash cutting pockets to manage excess material, ensuring a secure connection without damaging the composite core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional crimping methods are used to connect composite core cable to electrical connector, then mechanical connection is achieved, but the outer surface of composite core suffers scratches and cracks leading to fracture
Solution Approach 1:
The crimping die is segmented into multiple planar surfaces (ten surfaces) that distribute the crimping force across different contact points. This segmentation prevents concentration of force at single points that would cause surface damage, while still achieving adequate mechanical connection through distributed compression.
Solution Approach 2:
Each planar surface of the crimping die is designed with specific angular orientation (0° to 180°) to optimize the local distribution of compressive forces. The varying angles create different local compression zones that collectively distribute force evenly across the composite core surface, preventing localized damage while maintaining connection integrity.
2Strength
If radial compression force is applied to crimp composite core, then mechanical connection is secured, but deformation and ovalization of composite core occurs
Solution Approach 1:
The compression force is segmented into multiple application points corresponding to the ten planar surfaces of the die. This segmentation transforms a single-point radial compression into distributed multi-point compression, securing mechanical connection while preventing excessive deformation at any single location that would cause ovalization.
Solution Approach 2:
The crimping die is designed with curved planar surfaces arranged in a circular pattern, and the composite core maintains its circular cross-section throughout the crimping process. The curved geometry of the die surfaces conforms to the circular shape of the core, applying compression forces that secure connection without inducing ovalization or excessive deformation.
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 decagon crimp die reduces deformation and ovalization of the composite core, maintaining its structural integrity and transmission efficiency by evenly distributing the crimping force and managing excess material, thus enhancing the mechanical connection with the electrical connector.
Implementation Method 1
A decagon-shaped crimp die with a crimping area formed by ten planar surfaces, each angled between 0° and 180°, minimizes deformation by distributing the radial compression force evenly
Implementation Method 2
incorporates flash cutting pockets to manage excess material, ensuring a secure connection without damaging the composite core
Data Source
Figure 1~2
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AI summary
A compression die configured to crimp a composite core is disclosed. The compression die includes an outer body having a tool engaging surface, and an inner body coupled to the outer body. The inner body has a crimping area, wherein the crimping area of the inner body includes ten planar surfaces. The ten planar surfaces are positioned at an angle with respect to an adjacent planar surface such that the combination of the ten planar surfaces form a decagon shaped channel. Crimping is performed by the compression die by inserting the composite core into an encasing connector, which is then inserted into the decagon shaped channel of the compression die. A radial force towards the center of the decagon shaped channel is applied until an outer circumference of the encasing connector containing the composite core fully engages a surface area of each of the ten planar surfaces.