Single-Point Crimping Die for 1000 kcmil Lugs
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Solution Overview
Problem
Existing crimping tools, such as 12-ton tools, are unable to crimp 1000 kcmil lugs due to physical constraints, requiring separate tools and dies, leading to inefficiencies and high inventory costs.
Innovation Solution
A die set with a single-point indenter profile for use in 12T U-die taking tools, allowing crimping of 1000 kcmil lugs without the need for additional tools, featuring two pyramid indenter dies and one common wedge die, which can replace multiple standard U-dies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional U-dies are used in 12-ton crimping tools, then the tool can crimp standard connectors, but it cannot crimp 1000 kcmil lugs due to physical constraints
Solution Approach 1:
The single-point indenter die is designed to universally accommodate multiple connector types and sizes including 1000 kcmil lugs, eliminating the need for multiple specialized dies. The die can crimp various connector styles (e.g., ring connectors, eye connectors, lugs) across a wide range of conductor sizes, making one die perform the function of many traditional U-dies.
Solution Approach 2:
The die design separates the indenter component from the connector, allowing the indenter to be a standalone replaceable element. This segmentation enables the indenter to be specifically engineered for single-point crimping of large connectors while the connector body remains separate, solving the physical constraint issue.
2Adaptability or versatility
If multiple specialized tools and dies are purchased to handle different connector sizes, then all connector types can be crimped, but inventory costs and complexity increase
Solution Approach 1:
The single-point indenter die serves as a universal solution that can crimp multiple connector types and sizes, replacing the need for maintaining inventories of multiple specialized dies and tools. This single die design consolidates the functionality of many different dies into one component.
Solution Approach 2:
The invention merges the functionality of multiple specialized dies into a single integrated indenter design that handles various connector types, thereby reducing the total quantity of dies and tools needed in the inventory.
3Adaptability or versatility
If separate 15-ton tools with sufficient jaw opening are used, then 1000 kcmil lugs can be crimped, but the cost and complexity of tool inventory increases
Solution Approach 1:
The single-point indenter die enables existing 12-ton tools to universally handle large 1000 kcmil lugs without requiring specialized 15-ton tools. The indenter's design allows it to accommodate large connector dimensions while working within the constraints of standard tool jaw openings.
Solution Approach 2:
The invention changes the crimping parameter from traditional U-die geometry to a single-point indenter profile, which alters how the crimping force is applied. This parameter change allows the same tool to effectively crimp both small and large connectors by changing the die geometry rather than requiring different tool sizes.
Data Source
AI summary
A die set can be provided for use in a crimping tool to crimp a connector onto a conductor. A first die of the die set can include a mating surface and a working surface. The mating surface can selectively mate with the crimping tool. The working surface can include an indenting member that projects away from the mating surface to form an indentation in the connector when the connector is crimped to the conductor by the crimping tool. The indenting member can include a plurality of non-planar faces, each of the plurality of non-planar faces including a concave portion.