Terminal Bending Unit with Segmented Receiving Slots
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Solution Overview
Problem
Manual bending of conductive terminals in electrical connectors is inefficient, inaccurate, and prone to surface scratches, limiting the ability to bend multiple terminals simultaneously and ensuring precise positioning.
Innovation Solution
A terminal bending unit with a pivotally mounted bending tool and driving mechanisms that rotate the tool to bend multiple terminals simultaneously, featuring receiving slots for precise positioning and a resilient reset mechanism to maintain tool accuracy and prevent surface damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual bending of conductive terminals is performed, then the terminals can be bent one by one, but the bending efficiency is very limited and only one terminal can be bent at a time
Solution Approach 1:
The bending tool is divided into multiple receiving slots (first receiving slot, second receiving slot, etc.) that can simultaneously hold multiple terminals. Each slot is independently structured to receive and position a terminal, enabling parallel processing of multiple terminals in one bending operation, thus significantly improving productivity without requiring multiple separate bending devices.
Solution Approach 2:
The patent combines multiple terminal receiving slots into a single bending tool structure that is pivotally mounted on the frame. This merged structure allows multiple terminals to be bent simultaneously by a single rotating motion of the bending tool, eliminating the need for multiple separate bending operations and improving efficiency.
2Manufacturing precision
If manual bending of conductive terminals is performed, then the terminals can be bent, but the bending accuracy is difficult to ensure with large errors in the bended position
Solution Approach 1:
The receiving slots are pre-configured with precise geometric features (side walls, bottom surfaces) that automatically position the terminals in correct orientations before bending. This preliminary positioning ensures that when the bending tool rotates, each terminal is bent at the accurate predetermined position and angle, eliminating positioning errors without requiring complex adjustment operations.
Solution Approach 2:
The bending tool's rotational movement transforms the bending process from manual positioning to a controlled rotational parameter. By rotating the bending tool to a predetermined angle, the bending position and angle are precisely controlled through rotational parameter adjustment, ensuring consistent bending accuracy across all terminals.
3Productivity
If manual bending with tools such as pliers is performed, then the terminals can be bent, but scratches are created on the surface of the conductive terminals degrading the quality
Solution Approach 1:
The receiving slots act as an intermediary structure between the bending tool and the terminals. The slots provide a controlled interface with smooth geometric features (side walls, bottom surfaces) that guide and support the terminals during bending. This intermediary structure prevents direct contact between rough manual tools and the terminal surfaces, eliminating scratches while maintaining bending efficiency.
Solution Approach 2:
The patent replaces the mechanical gripping action of pliers with a rotational pressing mechanism. The bending tool rotates and presses terminals against the receiving slots, substituting the claw-like gripping mechanism of pliers with a smooth rotational pressing action. This substitution eliminates the scratching caused by plier jaws while maintaining the bending function.
4Productivity
If a row of conductive terminals cannot be bent simultaneously, then manual bending can be performed, but the bending efficiency is very limited
Solution Approach 1:
The bending tool is segmented into multiple receiving slots (first receiving slot, second receiving slot, and so on) that can each hold a terminal. This segmentation allows the tool to process multiple terminals in parallel during a single rotational operation, increasing the quantity of terminals bent simultaneously from one to multiple, thereby significantly improving productivity.
Solution Approach 2:
The bending tool is designed with multi-functionality to handle multiple terminals simultaneously. The same bending tool structure with multiple receiving slots can process a row of terminals in one operation, making the tool universal for batch bending operations rather than requiring separate operations for each terminal.
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
Enhances bending efficiency and accuracy, allowing for simultaneous bending of multiple terminals without surface scratches, ensuring precise positioning and maintaining terminal quality.
Implementation Method 1
a linear actuator which is fixedly mounted on the frame and is adapted to urge the slider to slide on the frame
Implementation Method 2
the resilient reset mechanism comprises a spring element
Data Source
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AI summary
The present disclosure discloses a terminal bending unit including: a frame and a bending tool pivotally mounted on the frame. A row of receiving slots is formed in a bottom surface of the bending tool, and terminals to be bent are adapted to be received and positioned in the corresponding receiving slots. The terminals received in the corresponding receiving slots are bent under press of the bending tool when the bending tool is rotated. It is only necessary to turn the bending tool to achieve bending of the terminals, thereby improving the bending efficiency of the terminals. In addition, a row of terminals may be bent simultaneously by the bending tool, which further improves terminal bending efficiency.