Multi-Stage Crimping Dies for Smooth Wire Contacts
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Solution Overview
Problem
Existing crimping tools leave defects such as sharp edges or jagged insulation cuts, which can cause damage to wires in a wiring harness.
Innovation Solution
A system and method for multi-stage crimping using crimping dies that move in two controlled directions, with a first and second die displacing along perpendicular axes to achieve precise crimping and insulation stripping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single-motion crimping tool is used, then the crimping process is simple and fast, but defects such as sharp edges are created on the contact
Solution Approach 1:
The crimping process is divided into two distinct stages: a compression stroke that moves the dies along a first axis to initially form the contact, and a closing stroke that moves the dies along a second perpendicular axis to complete the crimp. This segmentation allows each stroke to perform a specific function, eliminating the sharp edge defect while maintaining process efficiency
Solution Approach 2:
The invention introduces motion in a second dimension (perpendicular axis) to the traditional single-axis crimping motion. The closing stroke along the second axis works in conjunction with the compression stroke along the first axis to create a multi-dimensional crimping action that produces defect-free contacts with smooth edges
2Productivity
If wire stripping is performed with a single-motion blade system, then the stripping process is quick, but jagged insulation edges are created
Solution Approach 1:
The wire stripping operation is segmented into two sequential blade motions: a first motion that initiates the insulation cut, and a second motion that completes the cut cleanly. This two-stage stripping process eliminates jagged edges while maintaining rapid processing speed
Solution Approach 2:
The blade system incorporates motion in two different directions to perform the stripping operation. The first blade motion operates along one axis to start the cut, while the second blade motion operates along a different axis to finish the cut, producing a clean, non-jagged insulation edge
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
Prevents defects by ensuring a smooth crimping process without sharp edges or jagged insulation, enhancing the integrity of the crimped connections.
Implementation Method 1
The first and second crimping dies are displaceable towards each other along a first axis during a compression stroke
Implementation Method 2
The first and second crimping dies are displaceable along a second axis during a closing stroke subsequent to the compression stroke, where the second axis is perpendicular to the first axis
Data Source
Figure 1A~1E
Figure 2A~2E
Figure 3A~3E
AI summary
A system for multi-stage crimping of a contact to a wire includes a first crimping die having a first portion of a selected shape defined therein, and a second crimping die having a complementary second portion of the selected shape defined therein. The system also includes the first and second crimping dies being operable to be displaced towards each other and along a first axis during a compression stroke. The first and second crimping dies are also operable to be displaced along a second axis during a closing stroke subsequent to the compression stroke, where the second axis is generally perpendicular to the first axis. In addition, the system includes the first and second crimping dies cooperating to crimp the contact into the selected shape to the wire upon completion of the closing stroke.