Automated Terminal Crimping with Bidirectional Cable Positioning
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Solution Overview
Problem
Current cable crimping technologies lack automation, resulting in poor positioning accuracy, high defect rates, low efficiency, and high labor costs, with existing devices not providing adequate bidirectional positioning or clamping mechanisms, leading to suboptimal crimping quality and efficiency.
Innovation Solution
A fully-automated terminal crimping device incorporating an upper pressing die crimping mechanism, cable positioning mechanisms, a terminal pushing slider mechanism, a terminal clamping mechanism, and an ejection mechanism, which work in coordination to ensure accurate positioning, high automation, and efficient crimping through hydraulic and pneumatic systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual crimping operations are used, then labor flexibility is maintained, but positioning accuracy is poor and productivity is low
Solution Approach 1:
The patent replaces manual mechanical positioning with an automated positioning mechanism that includes a positioning plate, positioning blocks, and a positioning cylinder. This automated system accurately positions the cable and terminal before crimping, eliminating the imprecision of manual operations while maintaining high positioning accuracy through mechanical automation.
Solution Approach 2:
The positioning mechanism is designed to automatically position and clamp the cable and terminal without requiring manual intervention during the crimping process. The positioning cylinder automatically actuates the positioning blocks to secure the workpiece, and the ejection mechanism automatically releases the completed crimped terminal, enabling the system to service itself throughout the operation cycle.
2Manufacturing precision
If simple crimping operations are performed, then device complexity is reduced, but crimping quality is poor and defect rate is high
Solution Approach 1:
The crimping device is segmented into distinct functional modules: an upper pressing die crimping mechanism for applying crimping force, a terminal clamping mechanism for securing the terminal, a cable positioning mechanism for accurate positioning, and an ejection mechanism for releasing completed parts. Each module performs a specific function, allowing the system to achieve high crimping quality through coordinated specialized actions while managing complexity through modular design.
Solution Approach 2:
The patent merges multiple functions into an integrated crimping station: the terminal clamping mechanism and cable positioning mechanism operate simultaneously to secure both components before the pressing die applies crimping force. The ejection mechanism is combined with the positioning mechanism, allowing the same structural elements to perform both positioning and ejection functions, thereby improving crimping quality without proportionally increasing device complexity.
3Productivity
If independent crimping steps are used, then process simplicity is maintained, but productivity is low and labor cost is high
Solution Approach 1:
The crimping device operates in a continuous cycle where the positioning mechanism prepares the cable and terminal, the clamping mechanism secures them, the pressing die applies crimping force, and the ejection mechanism releases the completed product. These actions occur in seamless succession without idle time between steps, maintaining continuous useful action throughout the operation cycle to maximize productivity.
Solution Approach 2:
The positioning mechanism performs preliminary positioning of the cable and terminal before the crimping operation begins. The terminal clamping mechanism also clamps the terminal in advance before the pressing die applies force. These preliminary actions ensure that when the actual crimping occurs, the workpiece is already properly positioned and secured, eliminating the need for repeated adjustments and improving overall productivity.
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
The device achieves high crimping efficiency, improved automation, and enhanced safety and reliability, reducing labor costs and product defects, while being suitable for various cable production enterprises with a simple and long-lasting design.
Implementation Method 1
a hydraulic cylinder, an upper pressing die
Data Source
AI summary
A fully-automated terminal crimping device for facilitating cable positioning includes an upper pressing die crimping mechanism, cable positioning mechanisms, an ejection mechanism, a terminal pushing slider mechanism, and a terminal clamping mechanism, where the terminal pushing slider mechanism is arranged directly below the upper pressing die crimping mechanism, a lower pressing die base is arranged on the terminal pushing slider mechanism, the terminal clamping mechanism and the ejection mechanism are arranged at the left and right sides of the lower pressing die base respectively, and the two cable positioning mechanisms are arranged at the front and rear ends of the lower pressing die base respectively.