Linear-Sensor Crimping Tool for Accurate Ram Position Control
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Solution Overview
Problem
Hydraulic crimping tools often result in crimps at undesired locations and with improper pressure, leading to inefficiencies and suboptimal results.
Innovation Solution
A die-less power crimping tool equipped with a linear sensor to track and identify the movement of the ram assembly, allowing for precise control of crimp pressure and movement through a controller that operates based on sensor feedback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a hydraulic crimping tool is used without position sensing, then the device complexity is reduced, but the manufacturing precision of the crimp location deteriorates
Solution Approach 1:
The patent implements feedback control by using a position sensing device to detect the actual position of the ram assembly during the crimping operation. The controller receives this position information and compares it with the target position, then adjusts the hydraulic pump operation to ensure the crimping head reaches the precise desired location, thereby resolving the contradiction between precision and complexity.
Solution Approach 2:
The patent replaces traditional mechanical position indication methods with electronic sensing and control systems. The position sensing device (optical, magnetic, or electronic sensor) and controller work together to provide precise digital control of the crimping position, substituting mechanical feedback mechanisms with electronic feedback to achieve higher precision without excessive mechanical complexity.
2Manufacturing precision
If a hydraulic crimping tool is used without pressure control, then the device complexity is reduced, but the manufacturing precision of the crimp quality deteriorates
Solution Approach 1:
The patent employs feedback control for pressure regulation by using a pressure sensing device to monitor the actual crimping force applied. The controller receives pressure information and adjusts the hydraulic pump operation to maintain the desired crimping force, ensuring consistent crimp quality while managing system complexity through electronic control.
Solution Approach 2:
The patent replaces mechanical pressure regulation mechanisms with electronic pressure sensing and control. The pressure sensor provides real-time digital feedback to the controller, which modulates the hydraulic system accordingly, substituting complex mechanical pressure control mechanisms with electronic control for better precision.
3Reliability
If the ram assembly movement is not tracked, then the device complexity is reduced, but the reliability of the crimping process deteriorates
Solution Approach 1:
The patent implements feedback control for reliability by continuously monitoring the ram assembly position throughout the crimping cycle. The position sensing device provides real-time data to the controller, which can detect deviations from the expected movement pattern and take corrective action or flag the operation, thereby enhancing process reliability through intelligent monitoring.
Solution Approach 2:
The patent replaces mechanical indicators of proper operation with electronic position tracking. The position sensor and controller work together to provide digital verification that the crimping operation proceeded correctly, substituting mechanical assurance methods with electronic monitoring to improve reliability without excessive 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
Enables accurate and efficient crimping by ensuring the crimp is applied at the correct location with the appropriate pressure, enhancing the robustness and consistency of the crimping process.
Implementation Method 1
the distance sensor detects a linear displacement of the moveable piston
Data Source
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AI summary
A power tool including a moveable piston, a motor capable of driving the moveable piston to perform work on a work piece, and a distance sensor configured to sense a movement of the moveable piston. The distance sensor operable to provide sensor information indicative of the movement of the piston. A controller receives the sensor information from the distance sensor. The controller operates the motor to perform work on the work piece based in part on the sensor information that the controller receives from the distance sensor.