Wire Pulling Head Crimp Zone Indicators and Ball Swage
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Solution Overview
Problem
Current wire pulling methods face challenges due to inconsistent crimping and attachment issues between the pulling head body and wire, leading to detachment and costly reattachment processes, necessitating a more precise crimping method and secure connection between the pulling cable and head body.
Innovation Solution
The implementation of a pulling head body with crimp zone indicators on its outer surface to guide optimal crimping positions and a ball swage attachment mechanism that increases friction between the pulling cable and head body, ensuring secure engagement without additional measuring devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If visual estimation or separate measuring devices are used to determine crimping position, then the operator can perform crimping without additional equipment, but the crimping position is inconsistent and imprecise
Solution Approach 1:
The patent applies preliminary action by pre-marking the pulling head body with crimp zone indicators during manufacturing. These indicators are positioned at predetermined locations that correspond to optimal crimping zones for different wire sizes. This allows the operator to simply align the wire with the appropriate indicator and crimp without needing to measure or calculate the correct position, thereby achieving both ease of operation and precise crimping position consistently.
2Manufacturing precision
If the operator uses a separate measuring device to determine crimping position, then the crimping position can be measured accurately, but the process becomes time-consuming and complex
Solution Approach 1:
The patent applies self-service by making the pulling head body self-indicating through integrated crimp zone indicators. The indicators are permanently marked on the head body itself, providing self-guidance to the operator. This eliminates the need for separate measuring devices and the time-consuming process of measurement and calculation, while still achieving accurate crimping position. The system serves itself by providing all necessary positioning information directly on the component being crimped.
3Device complexity
If the pulling cable attachment means is simple, then the device complexity is reduced, but the attachment may fail during wire pulling
Solution Approach 1:
The patent applies local quality by creating a localized high-friction zone at the interface between the pulling cable and the pulling head body. The crimping process deforms the head body material to create a textured, high-friction surface specifically at the cable attachment location. This localized change in surface quality provides enhanced grip and secure attachment without requiring complex attachment mechanisms throughout the entire device. The simple overall design is maintained while the critical attachment zone has enhanced local properties for reliability.
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 provides consistent and precise crimping, reducing detachment issues and improving the reliability of the wire pulling process by ensuring proper attachment and minimizing the need for reattachment, thus reducing time and costs.
Implementation Method 1
a ball swage attachment mechanism that increases friction between the pulling cable and head body
Implementation Method 2
use a crimping device to crimp the pulling head body against the wire
Data Source
AI summary
An enhanced apparatus and method for securing a wire to a pulling cable for pulling wire. Specifically, the pulling cable and wire are attached via a pulling head body. The wire is inserted into an end of the pulling head body and secured by crimping the pulling head body against the wire. Further, crimp zone indicators positioned on the outer surface of the pulling head body indicate the optimal zone of crimping to achieve substantial contact between the pulling head body and the wire. A pulling cable is secured to the pulling head body via a ball swage that comprises a tapped surface.