Toggle Mechanism for Automated Shearing Arm Positioning
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Solution Overview
Problem
Existing powered termination machines require significant operator intervention and are inefficient in producing electrical leads with multiple attached terminals, as they need to be manually adjusted to switch between cutting and non-cutting positions to produce groups of connected terminals.
Innovation Solution
A termination machine with a shearing arm and a toggle mechanism that automatically switches between cutting and non-cutting positions using a powered actuator, allowing for efficient production of electrical leads with multiple attached terminals by selectively severing or leaving intact the bridge segments between terminals during crimp strokes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If the shearing blade is secured in a fixed position relative to the ram, then the structure is simple and reliable, but the machine requires manual adjustment to switch between cutting and non-cutting positions, reducing productivity and increasing operator intervention
Solution Approach 1:
The shearing blade position is changed from fixed to dynamically adjustable. A toggle mechanism with movable linkage allows the shearing blade to automatically shift between cutting and non-cutting positions relative to the ram during operation, enabling automatic switching without manual intervention.
Solution Approach 2:
The termination machine performs self-adjustment of the shearing blade position through the toggle mechanism. The system automatically toggles between cutting and non-cutting modes based on operational requirements without requiring operator deactivation or manual repositioning of the blade.
2Productivity
If the shearing blade is manually adjusted to switch positions, then the device complexity remains low, but significant operator intervention is required and productivity decreases
Solution Approach 1:
The toggle mechanism introduces dynamic positioning capability, allowing the shearing blade to automatically transition between cutting and non-cutting positions during the crimping cycle. This eliminates the need for operator intervention to manually reposition the blade between production batches.
Solution Approach 2:
The system automatically manages the switching between cutting and non-cutting modes through the toggle mechanism, performing the adjustment function itself without requiring external operator action. This self-service capability significantly reduces operator intervention and increases productivity.
3Adaptability or versatility
If the shearing blade remains in cutting position continuously, then the structure is simple, but bridge segments are severed and groups of connected terminals cannot be produced
Solution Approach 1:
The toggle mechanism enables dynamic control of the shearing blade position, allowing the system to adapt between cutting and non-cutting modes. This provides versatility to produce different terminal configurations (single terminals or groups of connected terminals) without changing the physical blade or manual adjustment.
Solution Approach 2:
The same shearing mechanism serves multiple functions: it can both sever bridge segments to produce individual terminals and leave bridge segments intact to produce groups of connected terminals. The toggle mechanism enables this multi-functionality by automatically positioning the blade according to the desired output configuration.
4Productivity
If the machine stops to reset the shearing blade position, then the blade position accuracy is maintained, but production time increases and efficiency decreases
Solution Approach 1:
The toggle mechanism provides dynamic position control that maintains blade accuracy during automatic transitions. The mechanism ensures precise positioning in both cutting and non-cutting modes without requiring machine stops or manual intervention, enabling continuous production with maintained precision.
Solution Approach 2:
The system automatically maintains blade position accuracy through the toggle mechanism's self-correcting design. The mechanism ensures proper blade positioning during automatic mode switching without requiring operator intervention or production stops, thereby maintaining both productivity and manufacturing precision.
Data Source
AI summary
A termination machine includes a ram, a shearing arm, and a toggle mechanism. The ram moves reciprocally relative to a stationary anvil between an extended position and a retracted position during a crimp stroke and crimps a terminal against the anvil while moving towards the extended position. The shearing arm is mounted to the ram and moves with the ram along a portion of the crimp stroke. The shearing arm includes a blade at a distal end thereof and a post projecting laterally from the shearing arm. The toggle mechanism is operatively connected to the post of the shearing arm. The toggle mechanism selectively toggles the shearing arm between a cutting position and a non-cutting position of the shearing arm relative to the ram. The blade of the shearing arm projects farther beyond a crimp end of the ram in the cutting position than in the non-cutting position.