Multicore Cable Crimping Radial Curvature
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Solution Overview
Problem
Conventional terminal crimping methods for flat multicore electric wires result in fork-shaped bends, leading to large intervals between core wires that negatively impact high-frequency characteristics.
Innovation Solution
A multicore cable manufacturing apparatus and method that uses crimping dies with curved faces extending radially from a branch point to connect electric wires and terminals, preventing fork-shaped bends and reducing the interval between wires, thereby minimizing the impact on high-frequency characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If core wires are bent at a predetermined portion to arrange them at a substantially constant interval, then the core wires are arranged uniformly, but fork-shaped bends are created causing large intervals between core wires that negatively impact high-frequency characteristics
Solution Approach 1:
The patent applies curvature by designing the crimping die with a curved face that extends radially from a branch point. This curved geometry guides the core wires to bend along a radial path rather than creating fork-shaped bends, resulting in a more uniform distribution of wires with reduced intervals between them.
Solution Approach 2:
The patent changes the geometric parameters of the crimping process by positioning the curved face of the crimping die at a specific radial distance from the branch point. This parameter adjustment controls the bending radius and distribution of core wires, optimizing the interval between wires to minimize high-frequency characteristic degradation.
2Manufacturing precision
If multiple crimping operations are performed sequentially to connect electric wires and terminals, then connection precision is maintained, but productivity is reduced and control configuration becomes complex
Solution Approach 1:
The patent merges multiple crimping operations into a single simultaneous operation by designing a crimping die with multiple curved faces arranged radially. This allows all electric wires to be crimped to their respective terminals in one action, significantly improving productivity while maintaining connection precision through the standardized curved face geometry.
Solution Approach 2:
The crimping die is designed with multi-functionality by incorporating multiple curved faces that can simultaneously perform crimping operations on multiple electric wires. This universal design enables the single crimping die to replace multiple sequential crimping devices, simplifying the control configuration while maintaining manufacturing precision.
3Ease of manufacture
If conventional crimping dies with linear curved faces are used, then the manufacturing process is simple, but fork-shaped bends are created that increase intervals between wires
Solution Approach 1:
The patent modifies the crimping die geometry by extending the curved face radially from a branch point rather than using a simple linear curve. This radial curvature design prevents fork-shaped bends by guiding the wires along a controlled radial path, thereby reducing the intervals between wires while maintaining ease of manufacture through a standardized die design.
Data Source
AI summary
A multicore cable manufacturing method for manufacturing a multicore cable with reduced influence on high-frequency characteristics is provided. The multicore cable manufacturing method includes a plurality of crimping dies, each crimping die being constituted of a pair of dies to connect, by crimping, each electric wire and each terminal. The plurality of crimping dies is configured to substantially simultaneously connect the plurality of electric wires and the plurality of terminals, and the crimping die is configured to connect a front end portion of each electric wire and each terminal with the front end portions of the plurality of electric wires extending radially centering on a branch point located on a rear side of the front end portion.