Die Set Guide Member for Connector Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing die sets for crimping large power connectors onto conductors or busses require additional force, which is challenging for battery-powered hydraulic power tools to achieve consistent and precise alignment and crimping.
Innovation Solution
A die set with a guide member and an indentor system that aligns with the electrical connector's crimping channel, ensuring proper positioning and engagement during crimping, and a connector design with grooves and detents for enhanced gripping force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If additional force is applied to crimp large power connectors onto large conductors or busses, then the crimping connection strength is improved, but the alignment precision deteriorates due to the challenge of achieving consistent and precise alignment
Solution Approach 1:
The guide member is attached to the die set before the crimping operation begins. This guide member pre-aligns the electrical connector with the die set, ensuring that when the crimping force is applied, the alignment is already established. This preliminary alignment action prevents misalignment that would otherwise occur during high-force crimping operations.
Solution Approach 2:
The guide member acts as an intermediary element between the die set and the electrical connector. It mediates the interaction by providing a alignment interface that guides the connector into the correct position before the crimping force is applied, thus resolving the conflict between applying sufficient force and maintaining alignment precision.
2Force
If battery-powered hydraulic power tools are used to provide added force for crimping, then the crimping force capability is improved, but the alignment consistency deteriorates
Solution Approach 1:
The guide member performs the alignment function before the hydraulic crimping force is applied. By establishing the correct position in advance, the system ensures that even when high forces are applied by the battery-powered hydraulic tool, the alignment remains consistent and reliable throughout the crimping process.
Solution Approach 2:
The guide member serves as an intermediary that decouples the alignment function from the force application function. This allows the battery-powered hydraulic tool to provide consistent high force while the guide member independently ensures alignment consistency, resolving the trade-off between force capability and alignment reliability.
3Manufacturing precision
If a guide member and indentor system are added to the die set, then the alignment precision is improved, but the device complexity increases
Solution Approach 1:
The alignment function is segmented into separate components: the guide member attached to one die and the corresponding guide feature on the electrical connector. This segmentation allows the alignment system to be added as a relatively simple attachment rather than redesigning the entire die set, thus improving alignment precision while minimizing the increase in overall device complexity.
Solution Approach 2:
The guide member is a simple intermediary component that provides alignment without requiring complex mechanisms. By using a straightforward guide geometry that interfaces with a corresponding feature on the connector, the system achieves improved alignment precision with minimal added complexity, avoiding the need for complex adjustment or control systems.
Data Source
AI summary
Die sets for crimping busses to electrical connectors are provided. The die set includes a pair of dies where one die has a guide member for aligning the dies with the electrical connector, and the other die has a one or more indentors for impacting the electrical connector. The electrical connectors include a guide hole that receives the guide member.