Dual-Tier Crimping Tool with Cam Mechanism for Aircraft Wiring
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Solution Overview
Problem
Existing tools for crimping contacts onto aluminum wires in aircraft wiring are inadequate as they either fail to provide a suitable air-tight seal, lead to oxidation of the conductor core, or require excessive force, causing wear and compatibility issues with aeronautical connectors.
Innovation Solution
A crimping tool with two tiers that simultaneously crimp the contact onto both the conductor core and insulating jacket, featuring a cam mechanism with a rotating element that reduces friction and force required for crimping, allowing for elliptical or circular crimping sections compatible with aeronautical connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a contact is crimped solely onto the conductor core, then the crimping operation is simple, but the conductor core is exposed to ambient air causing oxidation and loss of electrical continuity
Solution Approach 1:
The crimping tool is divided into two independent tiers: a first tier for crimping the contact onto the conductor core, and a second tier for crimping the contact onto the insulating jacket. This segmentation allows each tier to perform its specific function independently while working in coordination to solve both the simplicity and reliability requirements.
Solution Approach 2:
The first tier is positioned inside the second tier, with the first tier handling the conductor core and the second tier handling the insulating jacket. This nested arrangement allows both crimping operations to occur simultaneously within a single tool structure, maintaining operational simplicity while ensuring electrical continuity through dual crimping.
2Reliability
If a contact is crimped onto both the conductor core and insulating jacket simultaneously, then air-tightness and oxidation protection are improved, but the tool requires strong compression forces causing rapid wear
Solution Approach 1:
The tool incorporates a cam mechanism that converts rotational motion into the linear compression force needed for crimping. The cam profile is designed to dynamically control the force application, providing the necessary strong forces during crimping while reducing forces during the return stroke, thereby preventing rapid wear of tool parts.
Solution Approach 2:
The cam mechanism operates in periodic cycles: during the forward stroke, it applies strong compression forces for crimping; during the return stroke, it reduces forces to minimize wear. This periodic variation in force application allows the tool to achieve air-tight crimping while managing wear through controlled force reduction during non-crimping phases.
3Reliability
If a crimping tool with two tiers is used to crimp both conductor core and insulating jacket, then oxidation protection is improved, but the tool requires strong forces on compression handles that are a hindrance when returning to rest position
Solution Approach 1:
The cam mechanism dynamically adjusts the force requirements throughout the operation cycle. During crimping, it provides the necessary strong forces to ensure proper contact deformation and air-tightness. During the return to rest position, the cam geometry reduces the required forces, making the tool easier to operate and reducing operator fatigue.
Solution Approach 2:
The cam acts as an intermediary mechanism between the operator's input force and the crimping action. It mediates the force transmission by amplifying operator input during crimping and reducing the reverse force during return, thereby protecting the tool and operator while ensuring reliable oxidation protection through simultaneous dual-tier crimping.
4Device complexity
If contacts with a triangular section are crimped, then the crimping tool can be simpler, but the contacts are not compatible with aeronautical connectors requiring elliptical or circular sections
Solution Approach 1:
The second tier is designed with specific jaw geometries that locally apply force to deform the contact into an elliptical or circular section, which is required for compatibility with aeronautical connectors. This local quality control at the contact interface ensures connector compatibility while the overall tool structure remains relatively simple through the use of standard cam mechanisms.
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 tool achieves a secure air-tight seal, reduces oxidation risks, and minimizes tool wear by lowering the forces needed for crimping, ensuring compatibility with aeronautical connectors and maintaining mechanical and electrical integrity.
Implementation Method 1
at least one of said first and second tiers comprises a cam cooperating with the crimping components of the tier under consideration and moving the latter so that they crimp the contact
Implementation Method 2
at least one rotating element is arranged between at least one of said crimping components and said cam... so that when this rotating element is in contact both with this crimping component and with said cam the distance between said cam and one end of this crimping component... is different in said at least two positions
Implementation Method 3
a first tier to crimp a first part of said contact onto the conductor core of the wire; a second tier to crimp a second part of said contact onto the insulating jacket of the wire
Data Source
AI summary
A crimping tool to crimp a contact onto the end of a wire, the contact configured to receive both a stripped part and an insulated part of the wire end. The crimping tool includes a first and second tier to crimp the contact onto the conductor core and onto the insulating jacket of the wire respectively. A mechanism actuates the first and second tiers in substantially a simultaneous manner. At least one rotating element is arranged between at least one crimping component and a cam of at least one of the tiers, the rotating element possibly taking up at least two positions with respect to the crimping component. A crimping method crimps a contact both onto an insulating jacket of a wire and onto its conductor core.