Dieless Crimp Head Positioning for Multi-Size Connector Accuracy

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Solution Overview

Problem

Dieless crimp heads often fail to properly position connectors of varying sizes, leading to improper crimping and potential damage to the tool or connection.

Innovation Solution

A dieless crimp head with a frame and positioning devices, including a connector slot and crimp center alignment, which are removably secured to ensure accurate positioning of connectors relative to the indentors, allowing for use with multiple connector sizes without damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a dieless crimp head is configured for multiple connector sizes, then the adaptability of the tool is improved, but the positioning accuracy of connectors deteriorates leading to improper crimping

Engineering Contradiction:

Improvecompatibility with multiple connector sizesVSAvoidpositioning accuracy of connector

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The crimp head is divided into modular components: a frame, multiple positioning devices, and an indentor. Each positioning device can be independently installed or removed from the frame, allowing the system to be segmented and reconfigured for different connector sizes while maintaining precise positioning for each specific size.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The positioning devices are designed to be dynamically interchangeable on the frame. The frame includes multiple mounting locations that allow different positioning devices to be installed based on the specific connector size being crimped, enabling the system to adapt its positioning characteristics dynamically rather than being fixed for a single size.

Inventive Principle:

Principle #15Dynamics

2Manufacturing precision

If positioning devices are added to the crimp head, then the positioning accuracy is improved, but the device complexity increases

Engineering Contradiction:

Improvepositioning accuracy of connectorVSAvoidnumber of components in crimp head

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The frame serves multiple functions: it provides structural support, houses the indentor, and acts as a mounting platform for multiple positioning devices. This multi-functionality reduces the need for separate dedicated structures, thereby limiting the increase in overall device complexity while still enabling precise positioning.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The positioning devices are designed as simple, interchangeable components that can be easily manufactured and replaced. Rather than creating a complex, permanently integrated positioning system, the invention uses simpler, replaceable positioning devices that achieve the required precision without excessive complexity.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Data Source

PatentUS11894648B2Dieless crimp head with positioning devices for crimp connectors

Publication Date: 2024.02.06 HUBBELL INC

AI summary

A dieless crimp head is provided that includes a frame, an indentor, and a first positioning device. The frame has a first frame shell and a second frame shell, which define a frame opening. The indentor converges on a crimp center within the frame opening. The first positioning device has a connector slot defining a connector receipt area. The first positioning device is removably secured in the frame opening of the first frame shell at a use position in which the connector receipt area and the crimp center are aligned with, but offset along, a longitudinal axis of the crimp head.