Direct-Mount Crimp Tooling for Space-Efficient Terminal Crimping
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Solution Overview
Problem
Conventional terminal crimping machines are bulky and expensive due to the need for a separate applicator and tight tolerances, which limits space around the crimping zone and makes it difficult to integrate components like cameras or sensors for monitoring.
Innovation Solution
A crimp tooling system that eliminates the need for a separate applicator by directly coupling the upper and lower tooling to the terminator ram, allowing for improved adaptability and reduced bulk, with the upper tooling supported by the lower tooling assembly during storage and operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a separate applicator with housing is used to hold crimp tooling, then the tooling is supported and positioned, but the housing occupies much space around the crimping zone making it difficult to place monitoring components
Solution Approach 1:
The patent extracts the applicator housing from the crimping system, eliminating the bulky housing that occupied space around the crimping zone. The crimp tooling (anvil and wire crimper) is now directly supported by the terminator frame and ram, with no intervening applicator housing, thereby freeing up space for monitoring components like cameras and sensors.
Solution Approach 2:
The terminator frame and ram are made to directly support the crimp tooling functions previously handled by the separate applicator. The terminator ram directly positions and moves the wire crimper relative to the anvil, combining the functions of the terminator and applicator into a single integrated system.
2Manufacturing precision
If tight tolerances are used for locating the wire crimper relative to the anvil, then positioning precision is improved, but manufacturing cost increases
Solution Approach 1:
The patent segments the positioning function into two parts: coarse positioning is achieved through the terminator frame's built-in features, while fine positioning is achieved through adjustable mounting mechanisms for the wire crimper and anvil. This allows tight tolerances to be achieved only where necessary, reducing overall manufacturing complexity and cost.
Solution Approach 2:
The patent introduces intermediary positioning features such as adjustable mounts and alignment mechanisms between the terminator ram and the crimp tooling. These intermediaries provide precise positioning without requiring the entire system to be manufactured to tight tolerances, thereby reducing manufacturing cost while maintaining positioning precision.
3Ease of operation
If an intervening applicator is used between the terminator ram and crimp tooling, then the tooling is supported, but the system bulk increases and adaptability decreases
Solution Approach 1:
The patent removes the intervening applicator from between the terminator ram and the crimp tooling. The wire crimper and anvil are now directly mounted to the terminator frame and ram, eliminating the applicator's housing and components. This reduction in system bulk enhances adaptability by allowing easier integration of monitoring components and greater flexibility for different crimping applications.
4Ease of operation
If a bulky applicator housing is used, then crimp tooling is supported, but it becomes expensive to manufacture due to tight tolerances requirements
Solution Approach 1:
The patent extracts and eliminates the bulky applicator housing, supporting the crimp tooling directly through the terminator frame and ram. This eliminates the need for the housing's tight tolerance features, significantly reducing manufacturing cost while maintaining adequate tooling support through the terminator's own structural features.
Data Source
Figure 1
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AI summary
Crimp tooling (100) includes upper tooling (126) for forming a terminal (120) around a wire (122) during crimping. The upper tooling includes a wire crimper (140) and a wire crimper holder (142) for holding the wire crimper. The wire crimper holder is removably coupled directly to a terminator ram (136) of a terminal crimping machine (102) and being driven by the terminator ram. The crimp tooling includes lower tooling assembly (128) for supporting the terminal during crimping. The lower tooling assembly includes a base (152) having a plate (300) and an anvil (150) supported by the plate. The base is removably coupled directly to the terminal crimping machine.