Wire Termination with Terminal Gripping for Precise Crimp Alignment
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Solution Overview
Problem
Existing crimping systems for securing terminals onto wires, particularly for multi-wire cables like twisted pair cables, face challenges in accurately placing individual wire ends due to limited exposure beyond the cable jacket, leading to difficulties in maintaining wire proximity and signal integrity, and often result in length discrepancies and internal stresses during the crimping process.
Innovation Solution
A wire processing system with a rear-mounted terminal shear and a wire positioning device that grips and repositions the wires to accurately place them between crimping dies, allowing for improved alignment and reduced manual error, featuring a gripper mechanism that moves the terminal from the carrier strip to the crimping position behind the lower die.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If wires are pre-formed into a shape that creates space for crimp tooling, then crimping operation is enabled, but wire spacing becomes greater than final spacing and signal integrity is compromised
Solution Approach 1:
The wire positioning device performs preliminary positioning of the wires before crimping occurs. The positioning device includes positioning features that engage with corresponding features on the connector housing to pre-establish the correct wire spacing and alignment before the crimping operation begins, ensuring signal integrity is maintained while enabling the crimping operation.
2Stability of the object's composition
If wire ends extend only a short distance beyond the cable jacket, then cable assembly requirements are met, but accurate placement of wire ends during crimping becomes difficult
Solution Approach 1:
The wire positioning device acts as an intermediary between the cable assembly and the crimping operation. It includes positioning features such as positioning pins or guide features that engage with corresponding features on the connector housing to accurately locate and hold the wire ends in the correct position during crimping, overcoming the difficulty of placing wires that extend only a short distance beyond the jacket.
3Measurement precision
If wire positioning devices are implemented to accurately position wires, then placement accuracy improves, but compatibility with existing applicator and terminal shear arrangements is lost
Solution Approach 1:
The wire positioning device is designed with multi-functionality to maintain compatibility with existing applicator and terminal shear arrangements. It includes universal mounting features and positioning mechanisms that can work with various crimping tool configurations, allowing accurate wire placement without requiring complete system redesign or sacrificing compatibility with existing equipment.
Data Source
AI summary
A wire processing system comprises a terminal shear having an opening receiving a terminal strip including a plurality of terminals and defining a terminal strip feed path. A crimping tool or die of the system is arranged on a first side of the terminal strip feed path. A terminal gripping device is arranged on a second side of the terminal strip feed path, opposite the first side, and is adapted to grip a terminal of the terminal strip.