Die Set Shearing Electrical Connector Lugs
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for modifying electrical connectors with thick lugs or large volumes of lugs are inefficient and exhausting when using manually operated hand tools, particularly when trying to cut or break off the end of the lug, and can void UL approval if not done carefully.
Innovation Solution
A die set and tool system using a first and second die with spring-loaded members to contact opposite sides of the lug, allowing for controlled shearing of the lug end, which can be adapted for use in hydraulic or pneumatic tools to efficiently modify electrical connectors without manual exhaustion and maintain UL approval.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manually operated hand tools are used to cut or break off the end of a thick lug, then the modification can be performed, but the process becomes difficult and manually exhausting for large volumes of connectors
Solution Approach 1:
The patent replaces manual mechanical hand tools with a machine tool system that uses a hydraulic or pneumatic actuator to drive the dies. This substitution eliminates operator fatigue while maintaining the shearing function, allowing for efficient modification of large volumes of connectors without manual exhaustion.
Solution Approach 2:
The invention introduces a movable die system where one die is stationary and the other is movable, driven by a hydraulic or pneumatic actuator. This dynamic mechanism allows controlled application of force to shear the lug end, providing both automation and precision that manual tools cannot achieve.
2Productivity
If manually operated hand tools are used to cut or break off the end of a thick lug, then the modification can be performed, but it would be difficult to quickly break off or cut off the end of the lug
Solution Approach 1:
The patent replaces complex manual cutting operations with a simpler machine-driven shearing mechanism. The hydraulic or pneumatic actuator provides the necessary force automatically, eliminating the need for manual sawing or breaking operations while increasing speed and consistency.
Solution Approach 2:
The invention extracts the cutting function from manual operations and isolates it into a dedicated shearing mechanism with offset contact surfaces. This specialized mechanism is designed specifically for shearing lug ends, making the overall system simpler and more efficient than general-purpose manual tools.
3Reliability
If manual tools are used to cut or break off the end of a lug, then modification is possible, but UL approval may be voided if not done carefully
Solution Approach 1:
The patent incorporates a positioning mechanism that pre-aligns the movable die with the lug end before applying force. This preliminary positioning ensures that the cut occurs at the correct location and angle, maintaining UL approval requirements without requiring complex manual skill or careful manual positioning.
Solution Approach 2:
The invention uses spring-loaded members that provide tactile feedback and controlled force application during the shearing process. This feedback mechanism ensures consistent, controlled cutting that meets UL specifications while simplifying the manufacturing process by eliminating the need for operator judgment and careful manual control.
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 system enables efficient and controlled cutting of electrical connector lugs, ensuring a clean and uniform cut, reducing manual effort, and allowing for reproducible modifications without voiding UL approval, even for large volumes of connectors.
Implementation Method 1
The first die includes a first frame and a spring loaded member connected to the first frame
Implementation Method 2
The first and second contact surfaces are adapted to shear off the end of the lug from the electrical connector
Data Source
AI summary
A die set adapted to remove an end of a substantially flat lug of an electrical connector. The die set includes a first die and a second die. The first die includes a first frame and a spring loaded member connected to the first frame. The first frame includes a first contact surface adapted to directly contact a first side of the lug. The second die includes a second frame having a second contact surface adapted to contact a second side of the lug at a position offset from the first contact surface. The spring loaded member is adapted to contact the first side of the lug directly opposite the second contact surface. The first and second contact surfaces are adapted to shear off the end of the lug from the electrical connector.