Progressive Crimping Method for Compression Connectors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for crimping compression connectors are difficult to perform uniformly and consistently, leading to non-uniform crimps and quality that heavily depends on the installer's skill level, resulting in inadequate mechanical strength, high electrical resistance, and susceptibility to moisture and corrosive elements.
Innovation Solution
A progressive crimping method that involves assembling a compression connector with specific crimping depths and using side or center locator crimp dies to ensure uniform crimping, reducing dependency on installer skill and enhancing mechanical strength and sealing properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional crimping method is used, then the crimping process can be completed, but the crimp quality is non-uniform and highly dependent on installer skill level
Solution Approach 1:
The crimping process is divided into multiple sequential stages with different crimp depths. The first stage applies a initial crimp depth to all sections, followed by a second stage that applies a greater crimp depth to specific sections. This segmentation allows each stage to contribute differently to the final crimp quality, ensuring uniformity while simplifying operator requirements.
Solution Approach 2:
The first crimping stage performs a preliminary crimp at a shallower depth across all sections before the final crimping stage. This preliminary action prepares the connector and conductors for the subsequent deeper crimp, ensuring proper alignment and reducing the skill level needed for the final operation while maintaining high crimp quality.
2Strength
If traditional crimping method is used, then the crimping process is quick, but the mechanical strength and electrical performance are inadequate
Solution Approach 1:
The crimping process uses periodic action by applying crimp force in two distinct stages rather than a single continuous action. The first stage applies crimp force to a first depth, then the tool is repositioned for the second stage which applies crimp force to a greater depth. This periodic application of force ensures adequate mechanical strength and electrical performance while maintaining reasonable productivity.
3Object-affected harmful factors
If traditional crimping method is used, then the process is simple, but the sealing against moisture and corrosive elements is insufficient
Solution Approach 1:
The crimping process is segmented into two stages with different crimp depths. The first stage creates an initial seal, and the second stage applies additional crimp force to achieve the final seal quality. This segmentation ensures adequate sealing against moisture and corrosive elements without requiring complex equipment, only a systematic two-stage approach.
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 achieves a simple, repeatable, and verifiable crimping process with uniform crimping, high mechanical strength, low electrical resistance, and moisture sealing, meeting stringent standards like UL 467 and IEEE 837-2002 for direct burial and electrical substation grounding.
Implementation Method 1
crimping the compression connector to a first crimp depth; crimping the first section of the compression connector to a second crimp depth
Implementation Method 2
crimping the compression connector to a first crimp depth; crimping the first section of the compression connector to a second crimp depth
Data Source
AI summary
Certain embodiments of the present invention provide a progressive crimping method. The method includes assembling a compression connector for crimping, the compression connector including a first section and a second section; crimping the compression connector to a first crimp depth; crimping the first section of the compression connector to a second crimp depth; and crimping the second section of the compression connector to the second crimp depth.