Virtual Crimp Validation System Using Digital Twins

Solution Overview

Problem

Current crimp validation processes, such as the USCAR-21 specification, are time-consuming and require the destruction of numerous samples, making them inefficient for high-volume manufacturing environments.

Innovation Solution

A virtual crimp validation system that includes a pre-crimp modeler to establish geometry, virtual testing modules to determine physical and electrical characteristics, and a validation module to compare results against predetermined criteria, allowing for digital simulation and validation of crimp quality without physical prototypes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If physical crimp validation testing is performed according to USCAR-21 specification, then crimp quality and reliability are validated, but time consumption and resource requirements increase significantly

Engineering Contradiction:

Improvecrimp quality validationVSAvoidvalidation time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent creates virtual copies of physical crimp components (terminal, conductor, crimp tool) and the crimping process itself through 3D modeling and finite element analysis. These digital twins allow validation testing to be performed in silico, producing results that correlate with physical testing while eliminating the need to manufacture and destroy numerous physical samples, thereby reducing validation time from weeks to hours or days

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The system performs preliminary virtual validation testing before physical prototyping and manufacturing. By simulating crimp geometry, material properties, and process parameters in advance, the system identifies potential issues and optimizes designs virtually, preventing failures before they occur in physical testing and reducing the iterative cycle time

Inventive Principle:

Principle #10Preliminary action

2Reliability

If physical crimp validation testing is performed according to USCAR-21 specification, then crimp quality and reliability are validated, but resource consumption and sample destruction increase

Engineering Contradiction:

Improvecrimp quality validationVSAvoidsample destruction

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent creates virtual copies of physical crimp components (terminal, conductor, crimp tool) and the crimping process itself through 3D modeling and finite element analysis. These digital twins allow validation testing to be performed in silico, producing results that correlate with physical testing while eliminating the need to manufacture and destroy numerous physical samples, thereby reducing validation time from weeks to hours or days

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent replaces physical mechanical testing systems with computational mechanics systems. Instead of physically crimping and destroying samples to measure pull strength, electrical contact, and geometric dimensions, the system uses finite element analysis to compute these properties virtually, substituting computational models for physical destruction while maintaining validation accuracy

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If virtual crimp validation is implemented, then validation time and resource requirements are reduced, but system complexity increases

Engineering Contradiction:

Improvevalidation efficiencyVSAvoidvirtual validation system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent creates a multi-functional virtual validation platform that performs multiple validation functions (geometric analysis, mechanical property prediction, electrical contact simulation, process parameter optimization) through integrated finite element analysis models. This universal system replaces multiple separate physical testing apparatus and procedures with a single computational platform, managing complexity through consolidation while expanding capability

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system manages complexity by parameterizing material properties, geometric dimensions, and process conditions in the virtual models. By defining validation criteria in terms of adjustable parameters rather than fixed physical configurations, the system can efficiently explore design spaces and optimize crimp parameters without requiring complex physical reconfiguration for each test scenario

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS7617066B2Virtual crimp validation system

Publication Date: 2009.11.10 APTIV TECHNOLOGIES AG

AI summary

A system for validating a proposed crimp includes a pre-crimp modeler configured to establish a geometry for the proposed crimp, a plurality of virtual testing modules configured to determine at least one characteristic of the proposed crimp, and a virtual validation module configured to compare results from each of the plurality of virtual testing modules to predetermined criteria.