Wire Forming Tool With Rotating Anvil for Precise Connectors
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Solution Overview
Problem
Conventional methods for producing electrical connectors, such as formed wires, are time-consuming, inconsistent, and imprecise, leading to higher costs and reduced performance due to human error.
Innovation Solution
A high production tool for wire forming, comprising a first anvil with a first chamber, a second anvil with a second chamber, and a mandrel with a recess, allows for efficient transformation of wires into precise u-shaped and elbow-shaped connectors through controlled actuation and rotation of the second anvil.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If technicians use calipers and microscopes to create electrical connectors manually, then the electrical connectors can be produced with some level of precision, but the production process is time-consuming and inconsistent
Solution Approach 1:
The patent replaces manual mechanical measurement and forming operations with an automated wire forming tool that uses programmed mechanical movements to precisely form wires into electrical connectors. The system substitutes human operators using calipers and microscopes with an automated mechanism that consistently reproduces precise shapes without manual intervention.
Solution Approach 2:
The patent employs programmable control parameters to define wire forming operations, allowing precise control over bending angles, positions, and sequences. By changing digital parameters rather than relying on manual skill, the system maintains high precision while enabling rapid, consistent production across multiple connectors.
2Adaptability or versatility
If manual methods are used to create formed wires, then flexibility in creating different shapes is maintained, but consistency and precision are reduced due to human error
Solution Approach 1:
The wire forming tool incorporates programmable, dynamic control that allows the same equipment to adapt to different wire forming requirements. The system can be reprogrammed to create various shapes (u-shaped, elbow-shaped, etc.) while maintaining consistent precision through automated control, eliminating the variability inherent in manual operations.
3Productivity
If conventional manual approaches are used for wire forming, then equipment complexity is kept low, but production efficiency and consistency deteriorate
Solution Approach 1:
The wire forming tool is designed with modular components including separate anvils for different forming operations, interchangeable fixtures, and segmented control functions. This segmentation allows the system to achieve high productivity through automation while managing complexity through modularity, making the system more manageable and maintainable.
Data Source
AI summary
A tool for wire forming is provided. The tool for wire forming may include a first anvil having a first chamber. The tool for wire forming further includes a second anvil having a second chamber. The tool for wire forming further includes a mandrel having a first portion disposed in the first chamber, a second portion disposed in the second chamber, and a third portion in between the first portion and the second portion. The third portion may include a recess configured to receive a wire. The second anvil may be configured to be actuated from an open position to a closed position to transform the wire into a formed wire.