Handheld Crimping Die Control for Cable Alignment Stability
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Solution Overview
Problem
Existing handheld devices for producing crimp connections suffer from relative movement of the cable section with respect to the crimp contact due to device movement, leading to defects such as lower tensile strength in the crimp connection.
Innovation Solution
A handheld pulling and pushing device with a threaded drive and electric motor, featuring a crimping die and punch, adjusts to predefined motor performance data to ensure precise alignment of the cable section relative to the crimp contact, using intermediate positions to correct any displacement and terminate the crimping process at optimal compressive force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a handheld crimping device is used for producing crimp connections, then portability and ease of operation are improved, but relative movement between the cable section and crimp contact occurs due to device movement, leading to defects and lower tensile strength
Solution Approach 1:
The patent replaces manual alignment operations with an automated optical alignment system. A camera captures images of the crimp contact and cable section, and a control unit automatically calculates and executes alignment corrections, eliminating the need for manual positioning while ensuring precise alignment despite device movement.
Solution Approach 2:
The patent implements a feedback mechanism where a camera continuously monitors the positions of the crimp contact and cable section, the control unit processes this visual information to detect misalignment, and the system automatically adjusts the crimping device to correct the alignment, creating a closed-loop control system that maintains precision throughout the crimping process.
2Device complexity
If manual alignment is used in traditional crimping devices, then device complexity is reduced, but alignment precision deteriorates due to relative movement during crimping
Solution Approach 1:
The patent replaces manual alignment operations with an automated optical alignment system. A camera captures images of the crimp contact and cable section, and a control unit automatically calculates and executes alignment corrections, eliminating the need for manual positioning while ensuring precise alignment despite device movement.
Solution Approach 2:
The patent introduces a camera as an intermediary device to observe and measure the positions of the crimp contact and cable section. This intermediary enables precise alignment detection without requiring complex mechanical alignment mechanisms, allowing the system to achieve high precision through optical measurement and automated control.
3Manufacturing precision
If automated alignment systems are implemented to improve alignment precision, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent introduces a camera as an intermediary device to observe and measure the positions of the crimp contact and cable section. This intermediary enables precise alignment detection without requiring complex mechanical alignment mechanisms, allowing the system to achieve high precision through optical measurement and automated control.
Solution Approach 2:
The system performs self-alignment by automatically capturing images, calculating misalignment, and executing correction operations without external intervention. The control unit autonomously processes visual data and controls the crimping device to maintain precise alignment throughout the process, eliminating the need for operator skill and reducing overall system complexity.
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
Ensures high-quality crimp connections with enhanced tensile strength by precisely aligning the cable section with the crimp contact, utilizing motor performance data monitoring and automated adjustments to maintain consistent crimping pressure.
Implementation Method 1
a threaded drive connected to the electric motor and arranged in a housing body for transmitting tensile and compressive forces resulting from the direction of rotation of the electric motor to a coupling unit
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a method for producing a crimp connection using a handheld pulling and pushing device (1) and a handheld pulling and pushing device (1) for carrying out the method.The handheld pulling and pushing device (1), which enables the reliable production of crimp connections, is provided to have a control unit (12) for controlling the electric motor (2) for adjusting the crimping die (3) between the crimping position and the opening position, and a sensor unit connected to the control unit (12) for monitoring the motor power data during the adjustment of the crimping die (3) towards the crimping position, wherein the control unit (12) interrupts the adjustment of the crimping die (3) in the intermediate position if predefined first motor power data is exceeded and/or fallen below, after reactivation further adjusts the crimping die (3) towards the crimping position and terminates the crimping process when predefined second motor power data is reached.