Mirror-Finished Crimper Press for Stable Wire Termination
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Solution Overview
Problem
Conventional crimping apparatuses experience surface wear during press-fastening operations, leading to unstable crimping and potential adverse effects on mechanical and electrical performance.
Innovation Solution
A crimping apparatus with a mirror-finished or hard chrome-plated press-fastening portion on the crimper, which reduces friction and maintains a smooth surface for extended use, ensuring stable crimping and enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional crimper with standard surface finish is used, then the initial crimping performance is acceptable, but the surface wears quickly leading to unstable crimping and degraded mechanical and electrical performance over time
Solution Approach 1:
The surface finish of the press-fastening portion is changed from a conventional rough finish to a mirror finish with surface roughness Ra of 0.03 μm or less. This parameter change in surface roughness significantly reduces friction during crimping operations, preventing surface wear and maintaining stable crimping performance over extended service life.
Solution Approach 2:
The invention converts the harmful effect of friction-induced surface wear into a benefit by applying a mirror finish. The extremely smooth surface minimizes friction between the press-fastening portion and the crimping piece portions, transforming the wear problem into a durability solution that maintains reliable crimping for thousands of cycles.
2Ease of manufacture
If a rough surface finish is used on the press-fastening portion, then manufacturing is simpler, but friction during crimping increases causing surface wear and unstable crimping performance
Solution Approach 1:
The surface roughness parameter is changed to Ra of 0.03 μm or less through mirror finishing. While this requires more sophisticated surface treatment processes, it ensures consistent and stable crimping performance by minimizing friction variations, thereby achieving high manufacturing precision in the crimping operation.
3Device complexity
If the crimper surface is not protected, then the structure remains simple, but the surface deteriorates due to friction and wear during repeated press-fastening operations
Solution Approach 1:
The surface of the press-fastening portion is treated to achieve a mirror finish with Ra ≤ 0.03 μm. This surface parameter change creates an extremely smooth interface that minimizes friction and wear during crimping, maintaining reliable surface conditions without requiring additional protective structures or components.
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
The apparatus achieves stable crimping over a long period, maintaining mechanical and electrical performance by minimizing surface wear and friction through the use of a mirror finish or hard chrome plating on the press-fastening portion.
Implementation Method 1
since the press-fastening portion of the crimper for striking against the pair of crimping piece portions of the metal terminal has the mirror finish, a friction developing between the press-fastening portion and the pair of crimping piece portions is small
Implementation Method 2
wherein the press-fastening portion is subjected to hard chrome plating
Data Source
AI summary
A crimping apparatus includes an anvil for supporting a metal terminal including a base plate portion for mounting an electric wire thereon and a pair of crimping piece portions extending upwardly respectively from opposite side edges of the base plate portion, and a crimper which has a press-fastening portion for press-fastening the crimping piece portions. The anvil and the press-fastening portion of the crimper cooperate to press-fasten the crimping piece portions for crimping the crimping piece portions to the electric wire mounted on the metal terminal. The press-fastening portion is subjected to a mirror finish.