Off-Center Crimping with Profiled Deformation Tools
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Solution Overview
Problem
Existing crimping methods for manufacturing surge arresters, particularly off-center crimping, result in uneven contact pressure, leading to crushing of glass fiber/matrix materials and reduced mechanical performance, while also being complex and costly.
Innovation Solution
A method and apparatus for crimping load-bearing members and end fittings with varying deformation extent along the perimeter, using profiled deformation tools to achieve uniform gripping pressure, preventing material damage and enhancing mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If off-center crimping is used to manufacture surge arresters, then the mechanical strength and integrity of the assembly is improved, but the contact pressure becomes uneven causing crushing of glass fiber/matrix materials
Solution Approach 1:
The deformation tool is designed with a profiled contact face that applies different deformation extents at different locations around the perimeter of the end fitting. Specifically, the contact face has a varying radius of curvature that compensates for the off-center position of the load-bearing member, ensuring uniform contact pressure distribution across the crimping interface.
Solution Approach 2:
The invention changes the geometric parameters of the deformation tool to match the specific requirements of off-center crimping. The contact face profile is optimized with specific radius variations that transform the uneven pressure distribution inherent in off-center crimping into a uniform distribution, thereby preventing material crushing while maintaining mechanical strength.
2Ease of manufacture
If conventional crimping methods are used, then the manufacturing process is simpler, but the crimp threshold is reduced and material damage occurs
Solution Approach 1:
The profiled contact face of the deformation tool creates localized variations in deformation extent that are specifically tailored to the off-center geometry. This localized quality control ensures that the crimping force is distributed uniformly, maximizing the crimp threshold without requiring complex multi-step processes or additional equipment.
3Ease of operation
If uniform deformation is applied during off-center crimping, then the process is easier to control, but uneven contact pressure results causing material crushing
Solution Approach 1:
Rather than applying uniform deformation, the invention deliberately applies non-uniform deformation through the profiled contact face. The varying radius of curvature creates different deformation extents at different perimeter locations, which compensates for the off-center positioning and achieves uniform contact pressure distribution, preventing material crushing.
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 method provides a stronger, more uniform crimp with increased crimp threshold, preventing material damage and simplifying the manufacturing process, resulting in improved mechanical performance and reduced complexity and cost.
Implementation Method 1
advancing at least one deformation tool to deform a perimeter of the end fitting; and deforming the wall of the aperture into gripping engagement with the load-bearing member
Data Source
AI summary
A method of crimping a load-bearing member and an end fitting together such that the load-bearing member lies displaced from a center of a cross-section of the end fitting. The method includes the steps of inserting the load-bearing member into an aperture in the end fitting and advancing at least one deformation tool relative to the end fitting to deform the wall of the aperture into gripping engagement with the load-bearing member. The extent of the resulting deformation of the wall over a predetermined length thereof varies in dependence on a distance along the length from the load-bearing member.