Two-Stage Terminal Shear for Interference-Free Extrusion
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Solution Overview
Problem
During the crimping process, extruded terminal material often interferes with the terminal shear, affecting the consistency and quality of the crimp due to the design constraints of crimping large terminals for high voltage applications.
Innovation Solution
A two-stage shear system is introduced, where a primary shear depressor initially shears the terminal from the strip, and a secondary shear depressor, passively biased by a spring or fluid, further drives the shear tool out of the extrusion area to prevent interference with the crimped material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single-stage shear depressor is used to shear the terminal from the strip, then the device complexity is reduced, but the extruded terminal material contacts the terminal shear during crimping, affecting crimp quality
Solution Approach 1:
The single-stage shear depressor is divided into two distinct stages: a first shear depressor that shears the terminal from the strip, and a second shear depressor that pushes the terminal shear away from the extrusion path. This segmentation allows each stage to perform its specific function independently, preventing material contact while maintaining manageable device complexity
Solution Approach 2:
The second shear depressor performs a preliminary action by positioning the terminal shear away from the extrusion path before the crimping process begins. This preliminary positioning prevents the harmful contact between extruded material and the terminal shear, ensuring crimp quality without requiring complex real-time adjustments
2Length of moving object
If the terminal shear is positioned immediately adjacent to the sheared end of the terminal, then the cut-off tab size is minimized, but the extruded material interferes with the terminal shear during crimping
Solution Approach 1:
The second shear depressor extracts the terminal shear from the extrusion path by pushing it away from the crimping area. This separation removes the harmful factor of material interference while preserving the beneficial positioning for minimal cut-off tab length, as the shear tool returns to its adjacent position only after crimping is complete
3Manufacturing precision
If a two-stage shear depressor system is implemented to prevent material contact, then crimp quality is maintained, but the device complexity increases
Solution Approach 1:
The two-stage shear depressor system operates through self-service mechanisms where the first depressor completes shearing and the second depressor automatically engages to reposition the terminal shear. This self-coordinating action maintains crimp consistency without requiring external control systems, reducing the practical complexity despite the additional component
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 solution ensures that the terminal shear does not contact the extruded material during crimping, maintaining crimp quality and consistency by effectively removing the shear tool from the extrusion path, eliminating interference and enhancing process reliability.
Implementation Method 1
A secondary shear depressor, passively biased by a spring or fluid, further drives the shear tool out of the extrusion area to prevent interference with the crimped material
Data Source
AI summary
A system for separating terminals (e.g., electrical terminals) from a terminal strip includes a shear tool movably mounted to a frame for selectively shearing the terminal from the terminal strip. A primary shear depressor is provided for driving the shear tool from an initial position to an intermediate position during which the terminal is sheared from the terminal strip. A secondary shear depressor is movably mounted to the primary shear depressor for driving the shear tool from the intermediate position after the terminal has been sheared from the terminal strip, to a final position.