Terminal Assembly Bending and Crimping for Wire Adaptability
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Solution Overview
Problem
Existing terminal assemblies are complex to use and assemble, often requiring multiple steps and components, and may not be compatible with conductors of different sizes, necessitating the use of different terminals for varying conductor sizes.
Innovation Solution
A terminal assembly method involving a terminal body with wings that are bent and crimped onto a wire, using a bending die to form bent portions and a crimping die to secure the wire, allowing for the assembly of terminals that can accommodate various wire sizes with a simplified process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple different terminals are used for various sizes of conductors, then compatibility with different wire sizes is improved, but device complexity and the number of components increase
Solution Approach 1:
The patent describes a terminal design with a receiving portion configured to receive a conductor and wings that can be bent and crimped. The terminal body portion and wing configuration allow a single terminal type to accommodate various conductor sizes through the bending and crimping process, eliminating the need for multiple specialized terminals for different wire gauges.
2Reliability
If a complex assembly process with many steps is used, then secure connection is improved, but ease of operation and assembly time worsen
Solution Approach 1:
The patent describes pre-forming the wings in a specific configuration that is designed to be bent and crimped onto the conductor. The receiving portion is pre-configured to receive the conductor in a specific orientation, and the wings are positioned to wrap around the conductor during the bending process, ensuring secure connection through predetermined geometric relationships rather than complex multi-step assembly procedures.
Data Source
AI summary
A method of assembling a terminal assembly includes providing a terminal. The terminal may include a terminal body portion, a first wing, and/or a second wing. A first wing and the second wing may each include an end portion. The method may include bending an end portion of a first wing and/or an end portion of a second wing that may provide a first bent portion and a second bent portion. The method may include crimping the first bent portion and the second bent portion onto a wire. The terminal may be in a first position during bending and/or the terminal may be rotated to a second position after bending. The terminal may be in the second position during crimping. The first position and the second position may be substantially perpendicular.