Hydraulic Crimp Quality Monitoring via Pressure and Flow Analysis
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Solution Overview
Problem
Current crimp quality monitoring systems are inadequate for accurately assessing the quality of crimps made with hydraulic crimping apparatuses, particularly for large gauge terminals, and often fail to identify defects such as insulation in the barrel or incorrect terminal/wire sizes, leading to unsatisfactory connections being mistaken as high-quality.
Innovation Solution
A method that involves determining the pressure and flow of hydraulic fluid supplied to the crimping head and analyzing these parameters to assess crimp quality, using pressure and flow sensors connected to a controller for real-time monitoring and comparison against established standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If crimp quality is monitored by measuring crimp height, then the monitoring system is simple to implement, but defective crimps with correct appearance are incorrectly identified as good
Solution Approach 1:
The patent replaces mechanical/optical measurement systems (crimp height measurement) with a hydraulic pressure-based monitoring system. By measuring the hydraulic pressure required to effect the crimp, the system obtains a direct indication of the crimping process quality without relying on post-crimp dimensional measurements that can be misleading.
Solution Approach 2:
The patent introduces hydraulic pressure as an intermediary parameter to indirectly measure crimp quality. Instead of directly measuring the crimped terminal dimensions, the system measures the hydraulic pressure during the crimping process, which serves as a reliable indicator of whether the crimp was properly formed.
2Measurement precision
If crimp quality is monitored by analyzing crimping forces during the crimp stroke, then defect detection capability is improved, but the system incorrectly identifies crimps with insulation in the barrel as good crimps
Solution Approach 1:
The patent changes the measurement parameter from direct crimping force analysis to hydraulic pressure measurement. By monitoring the hydraulic pressure required to drive the crimping operation, the system captures a more comprehensive indicator of the crimping process that reflects actual material deformation and contact conditions, reducing false positives.
3Strength
If hydraulic pressure is used to ensure sufficient crimping force, then the crimping capability is improved, but the system lacks accurate feedback on actual crimp quality
Solution Approach 1:
The patent implements a feedback mechanism by monitoring hydraulic pressure during the crimping operation. The system uses the measured pressure information to provide real-time feedback on crimp quality, enabling identification of defective crimps and triggering appropriate actions such as rejection or re-crimping.
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
This approach allows for accurate identification of defective crimps, reducing the likelihood of unsatisfactory connections being passed and enabling timely corrective action, thereby improving the reliability of crimping processes in hydraulic systems.
Implementation Method 1
measuring: a) a pressure of a hydraulic fluid in a hydraulic system supplied to a hydraulic crimping head
Implementation Method 2
b) a flow rate of the hydraulic fluid supplied in the hydraulic system to the hydraulic crimping head
Implementation Method 3
a hydraulic crimping apparatus... a hydraulic crimping head... a pressure of a hydraulic fluid supplied to a hydraulic crimping head
Data Source
Figure 1
Figure 2~5
Figure 3
AI summary
A method and system of monitoring crimp quality of a crimp terminal in a hydraulic crimping apparatus (10). The method includes: determining a pressure of a hydraulic fluid supplied to a hydraulic crimping head (22, 24) of the hydraulic crimping apparatus (10); determining a flow of the hydraulic fluid supplied to the hydraulic crimping head (22, 24) of the hydraulic crimping apparatus (10); and analyzing the pressure and the flow of the hydraulic fluid to determine if a crimp is defective or not defective. The hydraulic crimping apparatus (10) may include a hydraulic pump (34) connected to the crimping head (22, 24) through hoses (36a, 36b), a pressure transducer (40) and a flow meter (44) connected to a flow sensor (46). The pressure transducer (40) and the flow sensor (46) transmit signals to a microprocessor (52) which may act as a controller.