Hydrodynamic Compression Tool Adaptive Jaw Control
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Solution Overview
Problem
Hydrodynamic compression tools face limitations in adjusting compression force and energy efficiency due to fixed maximum calibration forces, leading to unnecessary mechanical stress and reduced fatigue life, especially when dealing with connectors of varying sizes.
Innovation Solution
A method and tool that utilize an electronic control system with sensors to monitor the closed position of jaws, automatically stopping the electric motor and hydraulic pressurization upon completion of compression, allowing for adjustable compression force and reduced mechanical stress, thereby enhancing energy efficiency and extending tool lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the compression tool uses a fixed maximum calibration force to ensure sufficient compression for all connectors, then the compression reliability is improved, but the mechanical stress on components increases and fatigue life decreases
Solution Approach 1:
The patent applies dynamics by making the compression force adaptive rather than fixed. The control system dynamically adjusts the maximum calibration force based on real-time feedback from sensors that detect connector characteristics, allowing the tool to apply only the necessary force for each specific connector type, thereby reducing unnecessary mechanical stress while maintaining compression reliability
Solution Approach 2:
The patent implements feedback through sensors that monitor compression progress and connector characteristics. This feedback loop enables the control system to detect when compression is complete or when maximum force should be applied, preventing excessive stress on mechanical components while ensuring sufficient compression force is applied when needed
2Reliability
If the compression tool applies maximum calibration force to all connectors, then the compression completeness is improved, but the electric energy consumption increases
Solution Approach 1:
The patent applies partial action by allowing the compression tool to use less than maximum calibration force when it is sufficient for the specific connector being compressed. The control system determines the appropriate force level based on sensor feedback, applying only the necessary amount of compression rather than always using maximum force, thus reducing energy consumption while maintaining compression completeness
Solution Approach 2:
The patent implements parameter changes by dynamically adjusting the compression force parameter based on connector characteristics detected by sensors. The control system modifies operational parameters in real-time, changing the maximum calibration force from a fixed value to a variable parameter that adapts to each compression task, thereby optimizing energy consumption
3Reliability
If the compression tool continues pressing until maximum calibration force is reached even for small connectors, then the compression consistency is improved, but the operation time increases
Solution Approach 1:
The patent uses feedback to monitor compression progress and detect when the compression objective has been achieved. Sensors provide real-time information about connector deformation and compression status, allowing the control system to terminate the compression cycle early when sufficient compression is reached, eliminating unnecessary time consumption while maintaining compression consistency
Solution Approach 2:
The patent applies preliminary action by using sensors to detect connector characteristics before full compression begins. This advance detection allows the control system to pre-determine the appropriate compression parameters and terminate the operation early when the compression goal is achieved, reducing operation time while ensuring consistent compression quality
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 reduces electric energy consumption, increases the number of compression cycles per battery charge, decreases operation time, and allows for potential size reduction of mechanical components while maintaining fatigue life, ensuring sufficient force application for connectors of all sizes without excessive stress.
Implementation Method 1
a hydraulic pump (11) operable by the electric motor (6) and suitable to cause an increase in pressure of a hydraulic fluid acting on an actuation piston (12) to move the actuation piston (12) against the force of a pressure spring (15)
Implementation Method 2
an electric motor (6) powered by a battery (5) and a transformation mechanism (8) connected to the electric motor (6) and suitable, in response to a rotation of the electric motor (6), to transform a rotational movement into a cyclical or reciprocating movement
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A hydrodynamic compression tool (1) comprises a motor (6) which actuates a hydrodynamic group (11) suitable to increase the pressure of a hydraulic fluid acting on an actuation piston (12) connected to jaws (13, 14), an electronic control system (9) connected to the electric motor (6) and to a user operating member (7) for the actuation of the electric motor (6) wherein the control system (9) monitors the reaching of a closed position of the jaws (13, 14) and switches off the motor (6) automatically upon reaching the closed position.