Double Crimping Tool Sequential Cam Actuation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing crimping tools require excessive force for establishing double crimp connections in electrical conductors and insulation, are limited in adapting to various cross-sections and contact element sizes, and fail to meet stringent safety requirements, especially when used manually.
Innovation Solution
A double crimping tool with separate front and rear crimping units, each driven by a cam plate, reduces force requirements through sequential actuation and toggle-lever force-path conversion, allowing for adjustable crimping stamps to accommodate different cross-sections and sizes, and meets MIL-standard specifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If concurrent pressing in conductor region and insulation region is performed, then double crimp connection is established, but excessive force is required that cannot be exerted by manual operation
Solution Approach 1:
The crimping process is divided into two separate sequential operations: first crimping the conductor region, then crimping the insulation region. This segmentation allows the total pressing force to be applied in two separate steps rather than simultaneously, reducing the peak force requirement for manual operation while still achieving both crimp connections.
Solution Approach 2:
The conductor region is crimped first as a preliminary action before crimping the insulation region. This preliminary crimping stabilizes the conductor in the contact sleeve, preventing unfavorable position displacement during the subsequent insulation crimping operation.
2Ease of manufacture
If fixed crimping stamps are used, then crimping process is simple, but adaptation to various cross-sections and contact element sizes is limited
Solution Approach 1:
The crimping stamps are made adjustable rather than fixed, allowing their position and configuration to be dynamically changed. This enables the same tool to accommodate various cross-sections and contact element sizes while maintaining a relatively simple overall tool structure.
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
Enables efficient, single-handed operation with reduced force exertion, adaptable to various cross-sections and contact elements, while ensuring crimp connections meet stringent safety standards.
Implementation Method 1
The crimping stamps are displaced by rotation of the drive cam plates to carry out the pressing procedure by narrowing the receiving cross section
Implementation Method 2
toggle-lever force-path conversion, allowing for adjustable crimping stamps
Data Source
AI summary
A double crimping tool for fastening an electrical conductor with insulation to a contact element, which includes a front crimping unit with a front drive cam plate and front crimping stamps for forming a front press section in the region of the stripped end of the conductor; and a rear crimping unit with a rear drive cam plate and rear crimping stamps for forming a rear press section in the region of the insulation of the conductor. The crimping stamps are displaced by rotation of the drive cam plates. By levers the two drive cam plates are connected to a shared force introduction element such that during the pressing procedure at first optionally the front or the rear drive cam plate is rotated by a predefined initial pressing angle while the other drive cam plate is made to rotate only after the first drive cam plate has attained the initial pressing angle.