Memory Positioner Calibration for Precise Crimp Depth Control
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Solution Overview
Problem
Current mechanical crimp tools require high levels of supervision and manual inspection due to potential incorrect positioner adjustments and outdated calibration, leading to operator-dependent errors in wire harness production.
Innovation Solution
A programmable memory positioner and calibration system for crimp tools that includes a memory chip for storing positioner data, a reader for digital communication, and a positioner interface to transmit data to a computer, allowing for automatic adjustment and calibration of crimp depth settings, reducing manual operations and improving traceability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual adjustment and inspection methods are used for crimp tools, then device complexity is reduced, but manufacturing precision and reliability deteriorate due to operator-dependent errors
Solution Approach 1:
The patent replaces manual mechanical adjustment and inspection methods with an automated digital system. A memory chip stores positioner data including crimp depth settings, and a reader automatically retrieves this data to control the positioner mechanism. This substitution eliminates operator-dependent errors while maintaining manageable device complexity through integrated electronics.
Solution Approach 2:
The crimp tool system performs self-calibration and self-adjustment by automatically reading positioner data from the memory chip and configuring the positioner mechanism accordingly. The system includes self-diagnostic capabilities that monitor crimp depth and alert operators when recalibration is needed, reducing the need for manual intervention and maintaining high precision throughout operation.
2Manufacturing precision
If automated memory-based positioner control is implemented, then manufacturing precision improves, but device complexity increases due to additional electronic components
Solution Approach 1:
The memory chip serves multiple functions: storing positioner data, identifying contact types, providing calibration information, and enabling traceability. The reader system similarly performs data retrieval, validation, and transmission to the positioner control. This multi-functionality reduces the need for separate dedicated components, managing electronic system complexity while achieving high crimp depth consistency.
Solution Approach 2:
The system uses digital copies of positioner data stored in the memory chip to control the physical positioner mechanism. Instead of complex mechanical linkages or manual measurement systems, the patent creates a digital replica of the required crimp depth settings and uses this copy to automatically control the positioning, simplifying the electronic system while ensuring precision.
3Reliability
If manual calibration procedures are used, then ease of operation is maintained, but reliability deteriorates due to outdated calibration and lack of traceability
Solution Approach 1:
The system performs preliminary calibration by automatically reading positioner data from the memory chip when the crimp tool is first used or when a new contact type is loaded. This pre-calibration ensures accurate crimp depth settings before production begins, improving reliability without requiring complex manual calibration procedures during operation. The calibration data is stored and automatically applied, maintaining simplicity.
Solution Approach 2:
The system includes feedback mechanisms that monitor crimp depth and track calibration status. When recalibration is needed, the system automatically alerts operators and guides them through the recalibration process using the stored positioner data. This feedback loop maintains high reliability while keeping operations simple, as the system actively manages calibration rather than relying on operator memory or manual tracking.
4Productivity
If digital memory and automated control systems are implemented, then productivity improves through reduced manual operations, but device complexity increases
Solution Approach 1:
The patent merges the memory storage, data reading, positioner control, and crimping functions into an integrated system. The reader is built into the positioner assembly, and the positioner directly controls the crimp depth without separate mechanical adjustment mechanisms. This merging reduces system integration complexity while enabling automated operation that improves crimping speed and productivity.
Solution Approach 2:
The memory chip acts as an intermediary that stores all positioner data and transmits it to the reader system. This intermediary approach allows the system to manage complexity by separating data storage from data execution, enabling fast automated operation while keeping the control architecture manageable. The memory chip mediates between the digital control system and the physical crimping mechanism.
Data Source
AI summary
A crimp tool calibration system for crimping a prepared wire into a corresponding contact wire barrel includes a computer, a positioner having a memory chip storing positioner data, and a tool frame. The tool frame includes a head having a receiving port therethrough, and configured for the positioner to be removably engaged with the receiving port during a crimping operation. The tool frame also includes a plurality of crimping dies positioned around a periphery of the receiving port, an adjustment device to adjust a crimp depth, and a positioner interface coupled to the tool frame. The positioner interface includes a tool memory for storing tool data, a reader, and a transmitter, where the reader is configured to read the positioner data stored on the memory chip or the positioner, and the transmitter is configured to transmit the positioner data and the tool data to the computer.