Integrated Sleeve Swaging and Testing Apparatus for Steel Wire
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing swaging machines require cumbersome testing procedures to verify the attachment of sleeves to steel wires, often necessitating the movement of the steel wire to a testing apparatus or installation of a cumbersome testing apparatus on location.
Innovation Solution
A multifunctional apparatus that integrates attachment and testing capabilities, featuring a pulling arrangement, swaging rolls, and a holding unit with inclined support units and low friction surfaces, allowing for on-site verification of the sleeve attachment to steel wires using a hydraulic or electric pulling force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate testing apparatus is used to verify sleeve attachment, then testing reliability is improved, but device complexity and operational complexity increase
Solution Approach 1:
The patent combines the swaging apparatus and testing apparatus into a single integrated device. The swaging rolls perform both the attachment function and the testing function by applying force to the sleeve-wire assembly. This merging eliminates the need for separate testing equipment while maintaining verification reliability through the same mechanical force application mechanism.
Solution Approach 2:
The swaging rolls are designed to perform multiple functions: they both attach the sleeve to the wire through crimping and subsequently test the attachment strength by applying pulling force. This multi-functionality reduces the number of separate devices needed while ensuring reliable verification through a unified mechanical system.
2Measurement precision
If steel wire is moved to separate testing apparatus, then testing accuracy is improved, but loss of time and operational complexity increase
Solution Approach 1:
The attachment of the sleeve to the wire is performed first, and the testing capability is already built into the same apparatus. This eliminates the need to move the wire to a separate location, saving time while maintaining testing accuracy through the integrated force application system.
Solution Approach 2:
By combining attachment and testing in one device, the wire remains stationary throughout the process. The swaging rolls stay in position while performing both operations, eliminating transportation time and setup complexity associated with separate testing equipment.
3Adaptability or versatility
If cumbersome testing apparatus is installed on location, then on-site testing capability is improved, but device complexity and installation complexity increase
Solution Approach 1:
The swaging and testing functions are merged into a single portable apparatus that can be brought to installation locations. This integration reduces the complexity of having to install separate testing equipment while providing full on-site capability for both attachment and verification.
Solution Approach 2:
The apparatus is designed as a universal device that performs both swaging and testing functions, eliminating the need for location-specific installation of separate testing equipment. The multi-functional design makes the device portable and adaptable to various on-site conditions.
4Ease of operation
If simple apparatus design is used, then ease of operation is improved, but testing capability may be compromised
Solution Approach 1:
The integration of testing capability into the simple swaging apparatus structure maintains ease of operation while ensuring reliable verification. The same mechanical components used for attachment are used for testing, eliminating the need for complex separate testing systems.
Solution Approach 2:
The apparatus performs self-verification by using its own swaging rolls to apply testing force to the attachment it created. This self-service capability maintains operational simplicity while ensuring reliable verification through direct mechanical testing of the actual attachment.
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 reliable and efficient attachment and verification of sleeve connections directly on-site, simplifying the process and reducing the need for separate testing apparatuses, ensuring consistent attachment quality over time.
Implementation Method 1
The wedges and/or the tracks of the support units may be provided with a low friction surface layer
Implementation Method 2
the holding unit comprises two opposed support units with inclined surfaces arranged to support two wedges for holding the steel wire fixed
Data Source
AI summary
Apparatus for attaching a sleeve comprising a coupling end to a steel wire. The apparatus comprises a pulling end arranged to connect to a sleeve to be attached to a steel wire, a pulling arrangement connected to the pulling end and being configured to pull a sleeve connected to the pulling end, a swaging arrangement comprising two opposed swaging rolls adapted to crimp the sleeve to a close press fit around a loose end of a steel wire. The apparatus further comprises a testing arrangement for testing the strain capacity of the attachment of a sleeve to a steel wire, the testing arrangement including a holding unit configured to effectively hold a portion of the steel wire fixed and allowing the pulling arrangement to pull the sleeve attached to a wire held fixed in the holding unit in order to verify the attachment.