Sensor-Guided Hydraulic Crimping Ram Control Without Crimp Dies
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Solution Overview
Problem
Hydraulic crimping tools often result in crimps at undesired locations and with improper pressure, leading to inefficiencies and suboptimal results due to the lack of precise control over the ram assembly's movement during the crimping process.
Innovation Solution
A power tool equipped with a linear sensor to track and identify the movement of the ram assembly, allowing for accurate control of piston displacement and pressure application through a controller that operates based on sensor feedback, ensuring precise crimping actions without the need for traditional crimp dies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional hydraulic crimping tools are used without sensor feedback, then the device complexity is reduced, but the manufacturing precision and reliability of the crimping process deteriorate due to inability to control crimp location and pressure accurately
Solution Approach 1:
The patent applies feedback by implementing a sensor system that monitors the position and movement of the ram assembly during the crimping process. The sensor provides real-time data to a controller, which adjusts the hydraulic pressure and ram movement to achieve precise crimp location and consistent pressure application, thereby resolving the contradiction between manufacturing precision and device complexity
Solution Approach 2:
The patent replaces traditional mechanical position-limiting mechanisms with an electronic control system that uses sensors and a controller to manage ram assembly movement. This substitution allows for more precise and programmable control of crimp parameters without requiring complex mechanical stop mechanisms, thus improving manufacturing precision while managing device complexity
2Reliability
If traditional hydraulic crimping tools are used without sensor feedback, then the device complexity is reduced, but the reliability of the crimping process deteriorates due to improper pressure application
Solution Approach 1:
The sensor system provides continuous feedback on ram assembly position and movement, enabling the controller to monitor and adjust hydraulic pressure in real-time. This feedback mechanism ensures that the correct pressure is applied at the correct stage of the crimping process, significantly improving the reliability of the crimping process while using a manageable level of device complexity
Solution Approach 2:
The system performs preliminary actions by pre-programming the crimping parameters and using the sensor to detect when the ram assembly reaches the correct position before full pressure is applied. This preliminary detection and preparation phase ensures that the crimping action occurs at the optimal moment, improving reliability without requiring overly complex real-time pressure modulation mechanisms
3Manufacturing precision
If a distance sensor and controller are added to track piston movement, then the manufacturing precision and reliability of crimping improve, but the device complexity and cost increase
Solution Approach 1:
The distance sensor provides continuous feedback on piston position, allowing the controller to precisely control the crimping process. This feedback loop ensures consistent crimp location and pressure application across multiple operations, achieving high manufacturing precision while keeping the added device complexity manageable through efficient sensor-controller integration
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
Enables more efficient and robust crimping by ensuring accurate pressure application and consistent crimp location, improving the overall quality and reliability of the crimping process.
Implementation Method 1
the linear sensor comprises a hall effect sensor. For example, the hall effect sensor may detect a contour provided along an outer surface of the moveable piston
Data Source
AI summary
A power tool including a moveable piston, a motor capable of driving the moveable piston to perform work on a work piece, and a distance sensor configured to sense a movement of the moveable piston. The distance sensor operable to provide sensor information indicative of the movement of the piston. A controller receives the sensor information from the distance sensor. The controller operates the motor to perform work on the work piece based in part on the sensor information that the controller receives from the distance sensor.