Hydraulic Crimp Pressure Feedback for Accurate Hose Fitting Crimps
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Solution Overview
Problem
The initial crimping of hydraulic hose fittings is often inaccurate due to factors like spring back, wear and tear, and manufacturing tolerances, leading to inefficiencies and potential quality issues.
Innovation Solution
The use of hydraulic crimp pressure data feedback to iteratively adjust crimping settings and improve the accuracy of the initial crimp, while also detecting potential crimp anomalies and providing real-time alerts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional crimping methods are used without feedback, then the manufacturing process is simple and fast, but the crimping accuracy is poor due to spring back, wear and tear, and manufacturing tolerances
Solution Approach 1:
The patent implements a feedback mechanism where actual crimping force data is measured during the crimping process and compared against target force values. Based on this comparison, the system automatically adjusts crimping parameters to compensate for variations caused by spring back, wear and tear, and manufacturing tolerances, thereby improving crimping accuracy without requiring complex manual intervention
Solution Approach 2:
The patent replaces traditional mechanical trial-and-error adjustment methods with an automated control system that uses sensors to measure crimping force and a controller to adjust parameters. This substitution of mechanical adjustment with automated sensing and control improves precision while managing system complexity through integration
2Manufacturing precision
If multiple trial crimps are performed to achieve accurate crimping, then the crimping accuracy improves, but the production time increases significantly
Solution Approach 1:
The patent performs preliminary measurement and adjustment actions by measuring the actual crimping force during the first crimping attempt and using this data to adjust parameters before subsequent crimps. This preliminary feedback allows the system to achieve accurate crimping in fewer trials, reducing production time while maintaining precision
Solution Approach 2:
The real-time feedback of crimping force data enables the system to detect deviations from target values during the crimping process and make immediate corrections. This feedback loop reduces the number of trial crimps needed by guiding the adjustment process efficiently, thereby improving both accuracy and production speed
3Reliability
If real-time crimping force monitoring is implemented, then quality issues can be detected early, but the system complexity and cost increase
Solution Approach 1:
The patent implements monitoring by measuring actual crimping force during the process and comparing it against predetermined target values or acceptable ranges. This feedback mechanism enables real-time detection of quality issues such as under-crimping or over-crimping without requiring complex inspection equipment, as the crimping force measurement serves dual purposes of process control and quality verification
Solution Approach 2:
The crimping system performs self-verification by using its own process data (crimping force measurements) to detect quality issues. The system monitors its own performance and can automatically identify deviations from quality standards, eliminating the need for separate complex inspection systems
Data Source
AI summary
A crimping system for crimping fittings on hoses is disclosed and includes an interface and a crimper machine. The crimper machine is configured to analyze collected information based on identified hose and fitting properties; perform a crimping operation based on the collected information and the identified hose and fitting properties; measure crimping characteristics for the crimping operation; generate an alert based on the measured crimping characteristics and the collected information; and provide the alert to the interface.