Motor-Monitored Crimping Punch Control for Stable Crimp Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing handheld devices for producing crimp connections suffer from relative movement of the cable contact in relation to the crimp contact due to device movement, leading to defects such as lower tensile strength.
Innovation Solution
A handheld pulling and compression device with a screw drive and adjustable crimping punch and die, using motor performance data to monitor and control the crimping process, allowing precise alignment and termination at predefined forces for high-quality crimp connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If handheld devices are used for producing crimp connections, then portability and ease of operation are improved, but relative movement between cable contact and crimp contact occurs leading to lower tensile strength
Solution Approach 1:
The device performs preliminary alignment of the cable contact and crimp contact before the actual crimping operation. The housing body positions the crimping die and crimping punch in predetermined locations, and the cable clamping device secures the cable section in place before crimping begins, preventing relative movement during the operation.
Solution Approach 2:
The housing body acts as an intermediary structure that rigidly connects the crimping die, crimping punch, and cable clamping device. This housing structure eliminates relative movement between components by providing a stable reference frame, thereby maintaining alignment throughout the crimping process.
2Device complexity
If manual alignment of cable section to crimp contact is used, then device complexity is reduced, but manufacturing precision and alignment accuracy deteriorate
Solution Approach 1:
The housing body creates a rigid reference frame where all critical components (crimping die, crimping punch, cable clamping device) are positioned in predetermined locations with fixed geometric relationships. This equipotential reference structure ensures that alignment is maintained automatically without requiring complex adjustment mechanisms.
3Productivity
If continuous crimping force is applied, then productivity is improved, but crimp connection quality deteriorates due to inability to correct alignment
Solution Approach 1:
The crimping process is divided into distinct phases: first, the cable clamping device secures the cable section; second, the crimping punch is adjusted toward the crimping die to perform the crimping operation; third, the punch is adjusted back away from the die. This periodic action allows for quality control while maintaining productivity.
Solution Approach 2:
The device incorporates a control unit that monitors the crimping process and can detect alignment issues. When misalignment is detected, the control unit can interrupt the crimping operation, providing feedback that allows for correction before the crimp connection is finalized, thereby ensuring quality without sacrificing productivity.
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
Ensures precise alignment and high tensile strength of crimp connections by interrupting the crimping process at defined motor performance data, ensuring consistent and reliable crimping results.
Implementation Method 1
a screw drive connected to the electric motor and arranged in a housing body for transmitting tensile and compressive forces resulting from the direction of rotation of the electric motor to a coupling unit
Implementation Method 2
the crimping punch being connected to the coupling unit and the crimping die being connected to the housing body... the crimping punch and the crimping die are used to produce a crimp connection
Data Source
AI summary
A method for producing a crimp connection via a handheld pulling and compression device and to a handheld pulling and compression device for carrying out the method. For the handheld pulling and compression device, which enables reliable production of crimp connections, a control unit is provided for controlling the electric motor for adjusting the crimping punch between the crimp position and the open position, and a sensor unit connected to the control unit for monitoring the motor performance data when the crimping punch is adjusted in the direction of the crimp position. The control unit interrupts the adjustment of the crimping punch in the intermediate position when predefined first motor performance data are exceeded and/or undershot, adjusts the crimping punch further in the direction of the crimp position after reactivation and terminates the crimping process when predefined second motor performance data are reached.