Wire Clamp with Crisscross Jaws for Terminal Alignment
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Solution Overview
Problem
Existing electrical terminal crimping systems face challenges in maintaining proper alignment and secure holding of wires during crimping operations, especially with varying wire sizes, due to high forces exerted by crimping machines, which can lead to misalignment and safety hazards for operators.
Innovation Solution
A wire clamp with a base and pivotally mounted jaws, biased by a spring, that crisscross to form a mouth to hold the wire in place, allowing for self-adjustment to different wire sizes and maintaining alignment with terminals, enabling safe and efficient crimping without operator intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a user or operator grasps the wire by hand to hold it in place, then the wire alignment is improved, but the safety of the operator deteriorates due to exposure to moving parts and high forces
Solution Approach 1:
The patent introduces a wire clamp as an intermediary device between the operator and the wire. The clamp includes a jaw that mechanically holds the wire in place during crimping operations, eliminating the need for manual wire holding. This intermediary device ensures both proper wire alignment and operator safety by keeping hands away from dangerous moving parts while maintaining precise wire positioning through the clamp's gripping mechanism
2Object-affected harmful factors
If a retractable shield is deployed to guard the crimping machine, then operator safety is improved, but the ability to manually hold the wire deteriorates due to obstruction
Solution Approach 1:
The wire clamp serves as a mechanical intermediary that performs the wire-holding function that would otherwise require manual intervention. The clamp's jaw grips the wire securely, and this function is actuated by a linkage mechanism connected to the crimping machine's moving components. This allows the system to maintain both operator protection behind the shield and effective wire positioning without requiring operators to reach through or around the shield
3Strength
If high crimping forces are applied to the terminal, then the crimping strength is improved, but the wire alignment deteriorates due to wire movement out of position
Solution Approach 1:
The wire clamp performs preliminary action by securing the wire in the correct position before the high-force crimping operation begins. The clamp is positioned to hold the wire against the terminal, and this clamping action is established prior to the crimping ram applying full force. By pre-positioning and securing the wire, the system prevents wire movement during the high-force crimping process, maintaining both alignment and crimping strength
Solution Approach 2:
The wire clamp applies preliminary anti-action by counteracting the potential wire movement that would occur during high-force crimping. The clamp's gripping force on the wire opposes and prevents the wire from being pushed out of position by the crimping forces. This preliminary counter-force ensures that when the full crimping force is applied, the wire remains properly aligned and does not shift
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
The wire clamp effectively secures and aligns wires of various sizes, reducing the risk of misalignment and operator injury by maintaining axial and vertical alignment, allowing for efficient crimping operations while keeping the operator safe from the crimping machine's hazards.
Implementation Method 1
The base includes a spring mounted to the first upright portion. The first and second jaws crisscross each other at an overlap area. The first jaw is coupled to an associated drive shaft that engages the spring. The spring biases the pair of first and second jaws to pivot relative to the base towards a closed position.
Data Source
Figure 1
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Figure 4
AI summary
A wire clamp includes a base and first and second jaws. The first jaw is pivotally mounted to a first upright portion of the base via a first pivot axle, and the second jaw is pivotally mounted to a second upright portion of the base via a second pivot axle. The first and second jaws crisscross each other at an overlap area, and are spring-biased to pivot relative to the base towards a closed position. Respective hook members of the first and second jaws define a mouth above the overlap area that is configured to receive a wire. A size of the mouth adjusts automatically to a size of the wire within the mouth as the first and second jaws pivot towards the closed position. The wire may be held within the mouth in an in-line orientation with a corresponding terminal to which the wire will be crimped.