Nest Die Lip Geometry for Connector Positioning
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Solution Overview
Problem
Existing crimp tools face difficulties in accurately and reproducibly positioning electrical connectors on conductor wires, making it challenging to maintain the desired location during crimping.
Innovation Solution
The use of nest dies with a conductor receipt area that includes a lip and bottom surface configuration, acting as a travel stop, allows for easy and reproducible seating of electrical connectors along the crimp axis, ensuring the connector is positioned correctly for crimping, with options for positive, negative, or flush depth to set the desired position of the conductor wire relative to the connector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional crimp die sets are used without a nest die structure, then the crimping operation can be performed, but the electrical connector cannot be accurately and reproducibly positioned on the conductor wire
Solution Approach 1:
The nest die structure performs preliminary positioning of the electrical connector on the conductor wire before the actual crimping operation. The conductor receipt area with lip and bottom surface pre-establishes the correct position, eliminating the need for manual positioning adjustments during crimping.
Solution Approach 2:
The nest die acts as an intermediary component between the operator and the crimping process. It provides a standardized interface (conductor receipt area) that automatically positions the connector, mediating the interaction between the operator's loading action and the precise positioning requirement.
2Reliability
If manual positioning of the electrical connector is used, then flexibility in operation is maintained, but reproducibility and consistency of the connector position are poor
Solution Approach 1:
The crimp die set is segmented into two functional parts: the nest die (stationary) and the indent crimp die (movable). The nest die contains the conductor receipt area that handles positioning, while the indent crimp die performs the actual crimping. This segmentation allows each component to be optimized for its specific function.
Solution Approach 2:
The nest die structure is self-positioning through its geometric features (lip and bottom surface). Once the electrical connector is loaded into the conductor receipt area, the structure automatically establishes the correct position without requiring additional adjustment mechanisms or complex alignment procedures.
3Adaptability or versatility
If the conductor wire needs to extend past or be recessed into the connector, then different positioning requirements arise, but traditional dies cannot accommodate multiple positioning scenarios
Solution Approach 1:
The nest die structure provides different local geometries within the conductor receipt area to accommodate different positioning scenarios. The lip and bottom surface can be configured with different depths (positive, negative, or flush) to create specific local conditions for wire extension, flush positioning, or recessed positioning.
Data Source
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AI summary
A nest die for mechanically securing an electrical connector to a conductor wire is provided. The nest die includes a conductor receipt area and a lip. The receipt area has an outer periphery and a bottom surface. The lip is at the outer periphery of the receipt area. The outer periphery is sufficient to receive a free end of the conductor wire abutting the bottom surface and a lower face of the electrical connector on the lip. In this manner, the nest die can be used to easily and reproducibly seat the electrical connector in the die at a predetermined position on the conductor wire.