Wire Ferrule Magazine with Pre-Separation for Accurate Crimping
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Solution Overview
Problem
Existing crimping tools with magazines for wire terminations are cumbersome to handle, often leading to misinsertion of stranded wires and poor crimping connections due to manual operation limitations.
Innovation Solution
A magazine with a cutting device for separating wire terminations and a feed mechanism, such as a spring ratchet arm, allows for automated transportation and positioning of wire terminations, combined with a funnel-shaped conductor feed opening for easy insertion, ensuring efficient and accurate processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If wire terminations are stored in a magazine and fed manually to the crimping tool, then the tool can process multiple wire terminations in succession, but the handling becomes cumbersome and misinsertion of stranded wires occurs frequently
Solution Approach 1:
The magazine pre-separates individual wire terminations from the strip and positions them in advance at the separation position, so that when the crimping tool is actuated, the wire termination is already ready for immediate crimping. This eliminates the need for manual insertion operations during the crimping cycle.
Solution Approach 2:
The magazine acts as an intermediary device between the wire termination strip storage and the crimping tool. It receives the wire termination strip, separates individual terminations, and delivers them to the crimping position, thereby mediating the transfer and eliminating direct manual handling.
2Ease of manufacture
If the magazine is positioned away from the crimping station, then the wire termination strip can be fed into the magazine, but the transport system becomes complex and requires additional components like transport wheels
Solution Approach 1:
The magazine is merged with the crimping tool by positioning it directly on the crimping station. The magazine housing integrates with the tool housing, and the wire termination separation and crimping operations occur at the same location, eliminating the need for separate transport mechanisms.
Solution Approach 2:
The complex transport system including transport wheels and recesses is extracted and removed from the design. Instead of using a rotational transport wheel, the wire terminations are separated and positioned directly at the crimping location through the integrated magazine mechanism.
3Device complexity
If wire terminations are separated and positioned in the same level as the crimping depression, then the process is simplified, but the wire terminations cannot be properly separated from the strip during processing
Solution Approach 1:
The magazine uses two different levels: a first level for storing and separating wire terminations from the strip, and a second level containing the crimping depression. This vertical separation in the third dimension allows both separation and crimping functions to coexist without interference while maintaining structural compactness.
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 solution enhances handling safety and efficiency by allowing seamless insertion and processing of wire terminations, reducing the likelihood of misinsertion and improving the quality of crimping connections.
Implementation Method 1
a feed mechanism, such as a spring ratchet arm
Implementation Method 2
a cutting device for separating wire terminations
Implementation Method 3
a funnel-shaped conductor feed opening for easy insertion
Data Source
AI summary
A magazine (1) for processing wire terminations (2), which are connected to one another via connecting bridges (3) to form a wire termination strip (4), wherein the magazine (1) has a housing (5). The housing (5) has a magazine level in which the wire terminations (2) can be separated from the wire termination strip (4) by a cutting device (6) provided in the magazine level. A feed mechanism (7) is provided in the magazine level, by which mechanism the wire termination strip (4) can be transported in the magazine level, so that the separated wire terminations (2) can be conveyed into a depression level for processing, the magazine level and the depression level being different from one another.