Portable Wire Crimping Machine Without Pneumatic Compressors
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Solution Overview
Problem
Conventional wire stripping and crimping machines are large, heavy, and require a separate air compressor, limiting their portability and remote monitoring capabilities.
Innovation Solution
A compact and lightweight wire stripping and crimping machine powered solely by electricity, featuring a modular design with motor reducers, toggle mechanisms, and wireless control, allowing for efficient stripping and crimping of wires with reduced weight and volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If conventional wire stripping and crimping machines use cylinders and air compressors, then crimping force is sufficient, but weight increases to 80-100 kilograms and portability is lost
Solution Approach 1:
The patent replaces the traditional pneumatic cylinder system with an electric motor-driven screw mechanism. The motor (11) drives the screw rod (12) which converts rotational motion to linear motion of the crimping head (3), providing sufficient crimping force through mechanical advantage of the screw thread while eliminating the need for heavy air compressors and cylinders.
Solution Approach 2:
The patent eliminates the pneumatic system (air compressor and cylinders) entirely and replaces it with an electric-mechanical system. This substitution removes the heavy pneumatic components while maintaining crimping capability through the motor-screw mechanism, directly resolving the weight-force contradiction.
2Reliability
If conventional machines use cylinders requiring air compressors, then crimping operation is reliable, but portability is reduced and remote monitoring is impossible
Solution Approach 1:
The patent replaces the complex pneumatic system with a simplified electric motor-driven mechanism. The motor (11) connected to the screw rod (12) provides reliable crimping operation through direct mechanical drive, while the compact design enables portability. The electric system also allows for future integration of remote monitoring capabilities.
Solution Approach 2:
The patent divides the machine into modular components: base (2), feeding module (4), wire stripping module (5), crimping module (3), and insulation stripping module (6). This segmentation allows for compact arrangement, easy portability, and potential remote monitoring of individual modules through the control module (7).
3Productivity
If conventional machines focus only on inner insulation stripping and terminal crimping, then those functions are optimized, but outer insulation handling capability is missing
Solution Approach 1:
The patent integrates multiple functions into a single machine: the feeding module (4) handles outer insulation stripping, the wire stripping module (5) removes inner insulation, the crimping module (3) crimps terminals, and the insulation stripping module (6) processes insulation. This multi-functional design maintains high productivity while significantly improving adaptability to handle complete wire preparation processes.
4Ease of operation
If conventional machines use manual adjustments through on-site interface, then operation is simple, but remote monitoring and control are prevented
Solution Approach 1:
The patent incorporates a control module (7) that can be configured for remote monitoring and control. The module receives feedback from machine operations and allows remote adjustment of parameters, maintaining operational simplicity through automated control while enabling remote information access and monitoring capabilities.
Data Source
AI summary
A portable wire stripping and crimping machine, comprising: a base having a housing and an operation front. On the base, from left to right of the operation front, a feeding module, a wire stripping module, a crimping module, and an insulation stripping module are provided, respectively, the crimping module being connected to the feeding module and its bottom side being connected to the wire stripping module; and an operation control module having multiple switch buttons provided on a control side connected to the operation front. The crimping module consists of a first motor reducer, a toggle mechanism, and a crimping mechanism. The wire stripping module consists of a second motor reducer, a wire clamping mechanism, and a die cutter mechanism. The insulation stripping module consists of a third motor reducer and an insulation stripping mechanism.