Terminal Crimping Device Reducing Projecting Width
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Solution Overview
Problem
The existing method of crimping a terminal to an exposed core part of a wire results in a projecting width that compromises the protective coating's effectiveness, as the compressive force applied to the core crimping barrel can deform and damage the coupling part, leading to inadequate protection performance.
Innovation Solution
A terminal crimping method and device that press the end part of the crimping portion protruding from the upper die surface from above, using a groove-shaped upper die surface and a terminal pressing member with a flat lower end surface, to reduce the projecting width of the terminal when crimped to the exposed core part of the wire end.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a compressive force is applied to the entire core crimping barrel including the vicinity of the end part on the connecting portion side, then the crimping strength is improved, but the coupling part may be deformed and damaged (e.g. cracked)
Solution Approach 1:
The upper die surface is designed with a groove-shaped structure that creates different compression zones: a first compression zone that applies compressive force to the core crimping barrel while excluding the coupling part, and a second compression zone that applies additional compressive force to the end part of the core crimping barrel. This local differentiation allows strong crimping without damaging the coupling part.
2Ease of manufacture
If the core crimping barrel is shaped to gradually expand near the end part on the connecting portion side (bell-mouth shape), then the crimping is facilitated, but the protective film becomes locally thinner at the projecting part and protection performance is insufficient
Solution Approach 1:
The groove depth in the upper die surface is optimized to control the degree of expansion of the core crimping barrel. By adjusting the groove parameters, the expansion is sufficient to facilitate crimping but limited enough to prevent excessive projecting width that would compromise the protective film thickness and its corrosion protection function.
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
This configuration effectively minimizes the projecting width of the terminal, prevents damage to the coupling part, and ensures reliable protection performance by reducing the vertical compression rate and promoting a tapered expansion of the crimping portion, thus enhancing the durability and efficiency of the terminal-equipped wire production.
Implementation Method 1
pressing the end part of the crimping portion protruding from the upper die surface by the terminal pressing member moved in synchronization with the upper die
Implementation Method 2
the end part of the crimping portion protruding from the upper die surface is pressed from above
Data Source
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AI summary
The present invention aims to maximally reduce a projecting width of a projecting part formed on a terminal when the terminal is crimped to an exposed core part of an end part of a wire. To achieve this aim, a method for producing a terminal-equipped wire in which a crimping portion of a terminal is crimped to an exposed core part of an end part of a wire includes a) a step of arranging the exposed core part in the crimping portion, b) a step of sandwiching a part of the crimping portion between a lower die surface of a lower die and an upper die surface of an upper die and crimping the part of the crimping portion to the exposed core part, and c) a step of pressing an end part of the crimping portion protruding from the upper die surface from above.