Interchangeable Wire Tool Heads With Force Feedback for Reliable Crimping
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Solution Overview
Problem
Existing hand tools for cutting, stripping, and crimping electrical conductors lack process reliability, often requiring users to estimate displacement force, which can lead to incorrect function performance, and do not provide real-time monitoring of crimp quality.
Innovation Solution
A hand-operated machine with a force determiner to measure displacement force and a control unit that adjusts parameters like motor current and torque based on recognized tool heads, allowing for real-time monitoring of displacement force and path to ensure correct execution of functions and detect potential errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If users manually estimate displacement force for each function, then the tool can be operated without complex force measurement systems, but the process reliability deteriorates due to incorrect function performance
Solution Approach 1:
The patent implements a feedback mechanism where the force determiner continuously measures the displacement force during tool operation. The control unit receives this force information and compares it against expected force ranges for different functions. When the measured force falls outside the expected range, the system provides feedback to alert the user or automatically adjust parameters, ensuring correct function performance without requiring manual force estimation by the user.
Solution Approach 2:
The patent replaces manual mechanical force estimation with an automated electronic force measurement and control system. The force determiner uses sensors to electronically measure displacement force, and the control unit processes this information to automatically regulate drive parameters, substituting the manual mechanical estimation process with an automated electromechanical system that improves reliability.
2Manufacturing precision
If the same displacement force is used for all functions, then the tool operation is simplified, but the manufacturing precision deteriorates due to incorrect function execution
Solution Approach 1:
The patent implements dynamic force regulation where the control unit continuously adjusts the displacement force based on real-time measurements from the force determiner. The system adapts the force parameters dynamically during operation to match the specific function being performed (cutting, stripping, or crimping), ensuring precise function execution while automatically handling the complexity of force adjustment so users need not manually configure different forces for each function.
Solution Approach 2:
The patent changes the drive parameters (force, torque, motor current) based on the detected function and measured displacement force. The control unit regulates these parameters dynamically during operation to optimize each specific function (cutting, stripping, crimping), ensuring manufacturing precision while automatically managing parameter adjustments without requiring user intervention.
3Manufacturing precision
If real-time force monitoring is implemented, then the manufacturing precision of crimping is improved, but the device complexity increases due to additional sensors and control systems
Solution Approach 1:
The patent implements a universal force determiner and control system that serves multiple functions: it monitors displacement force for all operations (cutting, stripping, crimping), identifies which function is currently being performed, regulates drive parameters accordingly, and provides feedback for quality control. This multi-functional approach allows real-time force monitoring without requiring separate dedicated systems for each function, thereby limiting the increase in device complexity.
Solution Approach 2:
The patent merges the force measurement, function identification, parameter regulation, and quality monitoring functions into an integrated control system. The force determiner, recognition device, and control unit work as a unified system where a single integrated architecture performs multiple tasks simultaneously, reducing the overall complexity compared to having separate independent systems for each function.
4Adaptability or versatility
If exchangeable tool heads are used for different functions, then the adaptability of the tool is improved, but the reliability deteriorates due to incorrect tool head selection and force estimation
Solution Approach 1:
The patent implements a feedback system where the recognition device identifies the connected tool head type and communicates this information to the control unit. The control unit then uses this identification along with real-time force measurements from the force determiner to verify that the correct function is being performed and adjusts parameters accordingly, ensuring reliable function execution regardless of which tool head is attached.
Solution Approach 2:
The system performs self-identification and self-regulation: the recognition device automatically identifies the connected tool head without user input, the force determiner automatically measures the displacement force, and the control unit automatically adjusts parameters based on this information. This self-service approach ensures reliable function execution with exchangeable tool heads without requiring users to manually estimate forces or configure settings for each tool head.
Data Source
AI summary
A tool set for cutting, stripping and/or crimping an electrical conductor includes: a hand-operated machine handleable manually by a user; a tool interface; a drive; and at least one tool head for carrying out a function, is connectable to the hand-operated machine via the tool interface, and is drivable in a connected position via the drive. The hand-operated machine has a force determiner for determining a displacement force caused by the drive on the at least one tool head connectable to the hand-operated machine.