Two-Step Electric Terminal Crimping Method
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Solution Overview
Problem
Crimping methods for electric terminals face reliability issues in low current and low voltage applications due to elastic spring back phenomena, leading to reduced terminal pressure and potential electrical contact losses.
Innovation Solution
A two-step crimping method using a crimping tool with a separable stamping element, where the first step provides minimal compression and the second step applies localized increased compression to reverse the elastic spring back effect, enhancing contact pressure between terminal wings and wire strands.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single-step crimping method is used, then the manufacturing process is simple and fast, but the contact pressure is insufficient due to elastic spring back leading to poor reliability
Solution Approach 1:
The crimping process is divided into two distinct steps: a first crimping step that applies initial compression, and a second crimping step that applies additional compression after elastic spring back occurs. This segmentation allows each step to serve a specific function - the first step establishes initial contact while the second step compensates for elastic recovery and ensures sufficient contact pressure for reliable electrical connection.
Solution Approach 2:
The first crimping step performs a preliminary compression action that positions the terminal and wire in proper contact before the final crimping operation. This preliminary action prepares the system for the second step, allowing the subsequent crimping to effectively counteract elastic spring back and achieve the required contact pressure.
2Reliability
If increased compression is applied to counteract elastic spring back, then contact pressure is maintained, but the risk of microcracks and terminal damage increases
Solution Approach 1:
The first crimping step performs a preliminary compression that establishes initial contact between the terminal wings and wire strands before the elastic spring back fully manifests. This preliminary action allows the second crimping step to apply additional compression more effectively, as the terminal and wire are already in contact position, thereby maintaining contact pressure while reducing the risk of damage compared to applying single high-force compression.
Solution Approach 2:
The crimping process uses periodic compression actions with two distinct phases: an initial compression phase followed by a second compression phase after elastic recovery. This periodic application of force allows the material to respond elastically between compression events, preventing excessive stress accumulation that would cause microcracks while ensuring sufficient contact pressure is achieved in the second phase.
3Reliability
If a two-step crimping method is used, then contact pressure and reliability are improved, but the manufacturing time and process complexity increase
Solution Approach 1:
The crimping operation is segmented into two sequential steps performed by a single crimping tool: a first crimping step with initial compression, and a second crimping step with additional compression. This segmentation allows the process to efficiently address elastic spring back without requiring multiple separate tools or complex equipment, thereby improving reliability while minimizing the increase in manufacturing time.
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 method improves mechanical and electrical contact reliability by reducing residual voids and maintaining contact pressure, even under mechanical or thermal stress, with residual voids minimized to less than 1% in critical zones.
Implementation Method 1
a first crimping step for crimping the crimping section (30) on the stripped part (12) of the wire by folding wings (4, 5) on the wire (2) by means of a crimping tool comprising a stamping element (6) and an anvil (7)
Implementation Method 2
crimping can lose its efficiency due to an elastic spring back phenomenon of the crimping wings which causes a reduction of the terminal pressure between the wings and the strands of crimped wire
Implementation Method 3
a second crimping step for crimping the crimping section (30) on the stripped part (12) of the wire by folding wings (4, 5) on the wire (2) by means of a crimping tool comprising a stamping element (6) and an anvil (7), the second crimping step being conducted in a localized zone of the wings (4, 5) in an initial part of the crimping section (30) at a second crimping height different from the first crimping height
Data Source
Figure 1~2
Figure 3a~4
Figure 5a~6
AI summary
A method of crimping an electrical terminal onto a wire, comprises: providing an assembly comprising a wire and an electrical terminal, applying an initial crimping step, by folding an initial part of the crimping section (30) over the stripped part (12) of the wire, applying a subséquent crimping step, by compressing a subséquent part of the crimping section over the stripped part of the wire.