Dieless Hydraulic Crimping Head for High-Force Open Access
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Solution Overview
Problem
Existing portable dieless crimping tools lack suitable locking mechanisms for environments requiring high force applications, such as overhead high tension power lines.
Innovation Solution
The development of a dieless crimping tool with a working head featuring a movable indentor and an indentor guide assembly, coupled with a tool frame that includes a piston to move the indentor between a home and impacting position, providing open access to the working area for easy crimping operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a locking nest structure is used to withstand crimping forces, then the tool can handle high force applications, but the working area becomes difficult to access
Solution Approach 1:
The nest structure is divided into multiple segments that can move independently. The nest body remains fixed to withstand crimping forces, while the nest insert can be removed or adjusted to provide access to the working area, resolving the contradiction between structural strength and operational accessibility
Solution Approach 2:
The nest structure transitions from a static locking design to a dynamic system where the nest insert can be positioned, removed, or adjusted during operation. This allows the structure to adapt between providing maximum strength during crimping and providing access during setup or maintenance phases
2Ease of operation
If a dieless crimping operation with movable nest is used, then accessibility to working area is improved, but the ability to withstand high crimping forces is reduced
Solution Approach 1:
The nest is segmented into a fixed body and a movable insert. The fixed body maintains the structural integrity and force-withstanding capability, while the movable insert provides accessibility. This segmentation allows each component to optimize its function without compromising the other
Solution Approach 2:
The nest insert acts as an intermediary between the fixed nest body and the crimping operation. It can be positioned to provide access when needed and removed or secured during high-force crimping, mediating between the conflicting requirements of accessibility and structural strength
3Manufacturing precision
If an indentor guide assembly is added to control indentor movement, then crimping precision is improved, but device complexity increases
Solution Approach 1:
The guiding function is extracted from the main nest structure and implemented as a separate, simple guide assembly. This allows the guide to be optimized for its specific function of controlling indentor movement without adding unnecessary complexity to the overall nest structure
Solution Approach 2:
The guide assembly provides precision control only in the specific local area where the indentor moves, rather than requiring the entire nest structure to be complex. The rest of the nest structure remains simple and easy to manufacture, with complexity localized only where precision is needed
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 enables efficient crimping operations in various environments by providing the necessary force and accessibility, while avoiding the limitations of traditional locking nest structures.
Implementation Method 1
a piston coupled to the indentor that moves the indentor along the indentor guide assembly between a home position adjacent the tool frame and an impacting position adjacent the nest
Data Source
AI summary
Portable, hand held, battery operated, dieless, hydraulic crimping tools are provided with a working head and a tool frame. The working head has a head frame with an open access to a working area of the working head. The open access may be in the form of a C-shape. The working head has a nest to receive a crimping member. An indentor is attached to a piston within the tool frame. The piston moves the indentor between a home position adjacent the tool frame and an indenting position where the indentor impacts the crimping member.