Universal Cable Compression Die with Hexagonal Anvil
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Solution Overview
Problem
Conventional crimping tools require multiple die sets for different connector sizes, leading to inefficiencies and the inability to certify proper compression due to flash and sharp edges, which is not acceptable for industry standards.
Innovation Solution
A universal cable compression die assembly with hexagonal-shaped die heads and interchangeable indenters that can accommodate a range of crimp sizes, ensuring proper compression and certification through embossment without creating flash or sharp edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional die sets are used for different connector sizes, then proper compression can be achieved for each specific size, but multiple die sets are required and die changes are needed to accommodate different sized connectors
Solution Approach 1:
The die assembly uses a universal anvil with a hexagonal opening that can accommodate multiple connector sizes (6mm² through 240mm²) without requiring different die sets. The hexagonal geometry allows the connector to be positioned and compressed properly regardless of size, making the same die assembly suitable for all cable sizes within the range.
Solution Approach 2:
The die assembly incorporates an indenter that can be positioned at different locations on the hexagonal anvil surface. By moving the indenter to different positions, the same die assembly can accommodate different connector sizes and apply compression at the appropriate location, providing dynamic adaptability without physical die changes.
2Reliability
If conventional indenter pins are used to emboss die codes, then certification of proper compression is possible, but flash and sharp edges are created which are not acceptable to end users
Solution Approach 1:
The indenter is designed with a rounded or curved tip instead of a sharp pin. This curved geometry allows the indenter to emboss the die code on the connector surface without creating sharp edges or flash. The rounded contact surface distributes the embossing force more evenly, producing a clean impression without damaging the connector exterior.
Solution Approach 2:
The die assembly applies different functions to different parts of the indenter-anvil interface. The indenter tip is optimized for embossing (with a curved surface for clean code impression), while the overall compression force is applied through the hexagonal anvil geometry. This local differentiation allows certification functionality without the harmful effects of sharp indenters.
3Device complexity
If a single universal die assembly is used for all cable sizes, then the need for multiple die sets is eliminated, but the precision of compression for each specific size may be compromised
Solution Approach 1:
The die assembly incorporates an indenter that can be positioned at different locations on the hexagonal anvil surface. By moving the indenter to different positions, the same die assembly can accommodate different connector sizes and apply compression at the appropriate location, providing dynamic adaptability without physical die changes.
Solution Approach 2:
The die assembly is segmented into two functional components: the hexagonal anvil that provides the geometric framework for different sizes, and the movable indenter that can be positioned at different locations. This segmentation allows each component to be optimized for its specific function while working together to achieve precise compression for various cable sizes.
Data Source
AI summary
A cable compression die assembly is used in connection with a compression tool for compressing a stranded cable prior to crimping. The cable compression die assembly includes a pair of cable compression die heads for receiving a stranded cable and a cable connector therebetween. The pair of cable compression die heads defines a hexagonal shaped opening therebetween and is adapted to substantially close the hexagonal shaped opening as the die heads move towards one another.