SK9701Y1 - The crimping tool for connecting damaged wires and the method of crimping - Google Patents

Abstract

The crimping tool for connecting damaged wires contains crimping handles (B) and crimping jaws (D) fitted in them. The crimping jaws (D) include a crimping jaw upper part (A1) and a crimping jaw lower part (A2), wherein the crimping jaw upper part (A1) is rectangular in shape with a chamfered upper corner, and has a round hole located in the center in its upper half ( 1a) to attach the top part of the crimping jaw (A1) to the crimping handles (B), and below it has a unique number (2a) placed on the front to pair with the bottom part (A2) of the crimping jaw, and has at least one cut-out in the lower half, which forms crimping knife (4a), and above it there is a description (5) of the manufacturer's designation on the front, and on the back there is a description (6) of the minimum cross-section of the conductor, and below it there is a description (3a) on the side to indicate the number of the crimping clip (C) . The lower part (A2) of the crimping jaw has the shape of a rectangle with a beveled lower corner, which has a round hole (1b) located in the center for attaching the lower part (A2) of the crimping jaw to the crimping handles (B), and in the upper part it has at least one projection which it forms a crimping anvil (4b) and has a unique number (2b) placed on the front to match the top part (A1) of the crimping jaw, and a marking (3b) of the cross-section of the wires to be connected is placed on the back. The crimping knife (4a) and the opposite crimping anvil (4b) fit together. The upper part (A1) of the crimping jaw and the lower part (A2) of the crimping jaw are fitted in the crimping handles (B) through the round holes (1a) and (1b), where they are inserted into the precise mouths (7) and are secured with screws (8) . The method of crimping using a crimping tool is such that the crimping handles (B) are manually pressed towards each other with the help of a ratchet system, and the crimping clip (C) closes the damaged wires by plastically pressing the material.

Description

The field of technology

The technical solution concerns a crimping tool for connecting damaged wires, mainly in the automotive industry, and a crimping method.

Current state of the art

In the state of the art, several devices used for connecting damaged conductors are known. For example, German utility model DE 201 00031 U1 describes crimping pliers which are used to connect cable connectors by crimping the cable ends. The tool contains inserts with crimping jaws located in the head of the pliers. The crimping jaws are connected by being rotated by activating hand levers.

US 8,533,940 B2 describes a crimping tool with an inclined crimping part and a method of using the crimping tool. The inclined crimping part can be tilted with respect to the crimping tool, it can also be replaced by different inclined crimping parts with different angles. The slanted crimping part is also adjustable at different angles according to the user's needs.

AU 2020104294 A4 describes a device that is used when it is necessary to quickly create an electrical connection between three electrical conductors. A tubular electrical connector can be used to connect three insulated conductors by crimping the body of the electrical connector with a crimping tool. The crimping tool includes opposing jaws with opposing crimping surfaces, wherein one of the opposing crimping surfaces is concave.

For example, VAS 1978 crimping pliers are known from practice, which are an approved repair tool in the cable harness repair kit for the VW Group. Sleeves are used as connecting material together with shrink tubing to insulate the repaired joint.

Advantages of this solution:

The crimping tool is approved as a VW Group repair part.

Disadvantages of this solution:

Crimping pliers VAS 1978 are no longer produced.

The used fasteners have problems with availability on the market.

When using them, the method of repair according to the cross-sections of the wires and the combination of different cross-sections is significantly limited.

The connecting material does not allow continuous connections consisting of several conductors to be connected. Technically, the device allows the connection of only two wires of the same cross-section.

When crimping with VAS 1978 pliers, the crimping process is divided into two steps: crimping one side and then crimping the other side of the connecting material.

Crimping pliers of the hobby category are freely available in various modifications from various manufacturers. The Lear® crimp clip is used as a connecting material.

This tool is not technically suitable for crimping Lear® clips, as when connecting wires using said clip, it is damaged by cutting the material. Clip damage is also caused by two-step crimping. Crimping pliers of this category are intended exclusively for crimping end contacts.

Advantages of this solution:

Ergonomics of crimping pliers

Disadvantages of this solution:

During crimping, the Lear® clip is damaged by cutting the material - this is a result of the narrow jaws of the crimping tool.

Pliers of the hobby category do not allow connecting the connections of large cross-sections of wires, the maximum cross-section of the connected wires is 2.00 mm ² .

Crimping is done in two steps.

When crimping with hobby pliers, the crimping process is also divided into two crimping steps. In this case, it is caused by the insufficient width of the crimping jaws.

The main disadvantage of the solutions known so far is that the crimping takes place in two steps, which complicates and lengthens the production process.

Another disadvantage is the range of used cross-sections of wires, which is limited in existing solutions.

The essence of the technical solution

The shortcomings of the previously known devices for connecting damaged conductors are eliminated by the crimping tool according to the presented solution.

The technical solution makes it possible to connect torn conductors using crimping technology, thus repairing damaged conductors and damaged continuous connections consisting of several conductors. The technical solution can be used to connect damaged wires used in the automotive industry.

The presented method of connecting wires is advantageous because it ensures the maintenance of the mechanical and electrical properties of the repaired wire, which is in line with the constantly increasing requirements for the quality and reliability of the electrical wiring harness system in the automotive industry.

The following technical terms are used in the text:

Crimping jaws - a tool for pressing and plastic (permanent) shaping of material - by bending deformation. The crimping technique ensures the connection of the conductors.

Crimping handles - a hand tool with a ratchet gear, which will allow step crimping with the use of less force.

Crimping clip - connecting material used in crimping, e.g. a Lear® clip is currently available on the market.

Grinding - laboratory test to assess the quality of crimping according to the VW 603 30 standard and the international standard CEI IEC 60352-2. The main indicator of finish is the mechanical and electrical properties of the crimp joint.

Crimp height - a measurable parameter of crimping quality.

Crimping anvil or anvil is a projection located opposite the crimping knife.

The crimping tool for connecting damaged wires consists of crimping handles and crimping jaws mounted in them, which include the upper part of the crimping jaw and the lower part of the crimping jaw. The top of the crimping jaw is rectangular with a beveled top corner and has a round hole in the center of its upper half to attach the top of the crimping jaw to the crimping handles and below it has a unique number located on the front to pair with the bottom of the crimping jaw, in the lower half it has at least one cut-out that forms a crimping knife, above it there is a description of the manufacturer's marking on the front and above it there is a description of the minimum cross-section of the conductor above it, and below it there is a description on the side to indicate the number of the crimping clip.

The lower part of the crimping jaw has the shape of a rectangle with a beveled lower corner, which has a round hole in the middle for attaching the lower part of the crimping jaw to the crimping handles. It has at least one protrusion in the upper part, which is formed by the crimping anvil, under it there is a unique number placed on the front for pairing with the upper part of the crimping jaw, and on the back there is a marking of the cross-section of the wires to be connected.

The upper part of the crimping jaw and the lower part of the crimping jaw are fitted through round holes in the crimping handles, where they are inserted into precise mouths and are secured with screws. Damaged wires are connected with the resulting crimping pliers, while a crimping clip is used as a connecting material.

The crimping knife and the opposing crimping anvil fit together.

Crimping jaws are divided into two types depending on the cross-section of the connected wire:

- crimping jaws for connecting conductors of the overall cross-section and subsequent multiples of cross-section conductors from 0.7 mm ² to 1.5 mm ² (small conductor cross-sections)/jaws I,

- crimping jaws for connecting conductors of the overall cross-section and subsequent multiples of cross-section conductors from 1.5 mm ² to 4.0 mm ² (medium and large cross-sections of conductors)/jaws II.

Crimping jaws of both types are mounted in crimping handles when in use.

The upper part of the crimping jaw and the lower part of the crimping jaw are fitted through round holes in the crimping handles, where they are inserted into precise mouths and are secured with screws, as shown in figure no. 3.

SK 9701Υ1

Crimping handles are a hand tool with a ratchet gear, which ensures that less force is used when crimping by hand. Jaws I or jaws II are inserted into the crimping handles in precise mouths, which are then secured with screws.

The method of crimping using crimping jaws according to this technical solution is as follows:

Damaged wires are first cleaned, straightened and stripped, and then the ends of these wires are inserted into a crimp clip as a connection material. The type of crimping clip is determined according to the total cross-section of the wires to be connected. The crimping clip is then placed on the crimping anvil and its correct position is determined with the crimping knife in the first locked position of the ratchet system of the crimping handles. Then, the crimping handles are manually pressed towards each other using a ratchet system, while the crimping clip closes the damaged wires by plastically pressing the material. Crimping takes place in one step.

The joint of damaged conductors connected by the crimping technique meets the mechanical and electrical requirements for conductors used for the needs of the automotive industry.

Each crimping knife and the corresponding crimping anvil are geometrically precisely designed for a specific clip.

The crimp clip is shown in figures 4a, 4b and 4c in different views.

Each jaw is suitable for connecting certain conductor cross-sections.

The main advantages of the new technical solution:

1. a significant difference in the resulting quality of the joint,

2. saving time in the crimping process itself, as the crimping jaws according to the presented solution crimp the clip in only one step, and

3. the jaws allow a variable range of used connected cross-sections of conductors.

The following table shows the use of the type of jaws in conjunction with the appropriate crimping clip according to the overall cross-section of the conductors.

Table no. 1

Crimp clip number Type of jaws The total cross-section of the conductors N 101 677 01 Jaws 1 0.7-1.5 mm ² N 102 796 01 Jaws II 1.5 - 2.5 mm ² N 103 301 01 Jaws II 2.5-4.0 mm ²

In fig. 7 shows the range of possible combinations that can be connected using the crimping jaws according to this solution.

Bright points indicate the possibility of carrying out the repair also with VAS 1978 pliers, dark points indicate the possibility of carrying out the repair also with hobby type pliers.

The limited possibilities of competing solutions (VAS 1978 and hobby pliers) are clearly shown. The numerical columns express a specific combination of connected wires, e.g. 2 x 0.13 + 0.5 expresses the combination of the connection of two wires with a cross section of 0.13 mm ² with a wire with a cross section of 0.5 mm ² .

Overview of images on drawings

fig. la Crimping jaws, top, left side view

fig. lb Crimping jaws, top, right side view

fig. 2a Crimping jaws, lower part, left side view

fig. 2b Crimping jaws, lower part, right side view

fig. 3 The crimping tool contains crimping jaws mounted in crimping handles

fig. 4a Crimp clip, views, side view of clip

fig. 4b Crimping clip, views, cross-sectional view of the clip

fig. 4c Crimping clip, views, top view of clip

fig. 5 Crimping procedure using crimping jaws according to this solution

fig. 6 The range of possible combinations that can connect the crimping jaws according to this solution.

Implementation examples

Example 1

The crimping tool for connecting damaged wires consists of crimping handles B and crimping jaws D installed in them. Crimping jaws D contain the upper part of the crimping jaw A1 and the lower part of the crimping jaw A2.

The upper part of the crimping jaw A1 is rectangular in shape with a chamfered upper corner, in its upper half, it has a round hole 1a located in the center for attaching the upper part of the crimping jaw A1 to the crimping handles B, below it, it has a unique number 2a placed on the front for pairing with the lower part A2 crimping jaw and in the lower half has one cut-out, which forms a crimping knife 4a, and above it there is a description 5 of the manufacturer's mark on the front, and on the back there is a description 6 of the minimum cross-section of the conductor, and below it there is a description 3a on the side to indicate the number of the crimping clip C.

In fig. 1a are crimping jaws, upper part A1, left side view, and in fig. 1b are crimping jaws, top A1, right side view.

The lower part of the crimping jaw A2 has the shape of a rectangle with a beveled lower corner, which has a round hole 1b located in the middle for attaching the lower part of the crimping jaw A2 to the crimping handles B. It has one protrusion in the upper part, which forms a crimping anvil 4b, below it, it has a front placed a unique number 2b to match the top A1 of the crimping jaw and behind it is placed a marking 3b of the cross-section of the wires to be joined.

The crimping knife 4a and the opposite crimping anvil 4b fit into each other.

The upper part A1 of the crimping jaw and the lower part of the crimping jaw A2 are through round holes, hole 1a for attaching the upper part of the crimping jaw A1 and hole 1b for attaching the lower part of the crimping jaw A2, located in the crimping handles B, where they are inserted into the precise mouths 7 and are secured with screws 8 as shown in figure no. 3. In practice, any suitable type of B handles can be used, regardless of the manufacturer of these handles.

Crimping clip C from the manufacturer Lear® is used as a connecting material during crimping, views of crimping clip C are shown in figure no. 4.

The upper part A1 of the crimping jaw and the lower part of the crimping jaw A2 are easily exchangeable in the crimping handles B with one screw.

The crimping method is carried out in one step and is as follows.

Damaged wires are first cleaned, straightened and stripped, and then the ends of these wires are inserted into the crimping clip C as a connection material. The type of crimping clip C is determined according to the total cross-section of the wires to be connected. The crimping clip C is then placed on the crimping anvil 4b and its correct position is determined by the crimping knife 4a in the first locked position of the ratcheting system of the crimping handles B. Then the crimping handles B are manually pressed towards each other using the ratcheting system, while the crimping clip C is plastically pressed by the material closes damaged wires. Crimping takes place in one step.

The joint of damaged conductors connected by the crimping technique meets the mechanical and electrical requirements for conductors used for the needs of the automotive industry.

Clips vary depending on the overall cross-section of the connected wires.

Figure 6 shows crimping in one step using crimping jaws D according to this solution.

In this case, crimping jaws D type I are used - they are intended for connecting conductors of the total cross-section and subsequent multiples of cross-section conductors from 0.7 mm ² to 1.5 mm ² (for small conductor cross-sections).

Evaluation of the capability of the device - technical solution: the purpose of the capability test of the technical solution of the crimping jaws D was to determine whether the device is capable of producing products (crimp clips) in the required parameters with sufficient certainty. The monitored selected parameter was the height of the crimp.

Table no. 2

Statistical evaluation of the capability of the device when monitoring the crimp height on 50 samples of a combination of 3 x 0.35 mm ² and using crimping jaws D type I

SK 9701Υ1

Emblem Crimp height Requirement for Lear® crimp clip and combination of 3 x 0.35 mm ² conductor cross sections (total cross section 1.05 mm ² ) 1.40 mm Upper tolerance 1.45 mm Lower tolerance 1.35 mm

Serial number Measured value Serial number Measured value 1 1,416 26 1,415 2 1,415 27 1,428 3 1,421 28 1,422 4 1,423 29 1,416 5 1,419 30 1,426 6 1,426 31 1,422 7 1,423 32 1,417 8 1,427 33 1,428 9 1,415 34 1,419 10 1,417 35 1,411 11 1,419 36 1,423 12 1,422 37 1,422 13 1,423 38 1,429 14 1,426 39 1,415 15 1,415 40 1,419 16 1,422 41 1,426 17 1,417 42 1,428 18 1,426 43 1,427 19 1,419 44 1,417 20 1,428 45 1,415 21 1,427 46 1,422 22 1,415 47 1,426 23 1,423 48 1,423 24 1,428 49 1,417 25 1,419 50 1,427

The test results are presented in table no. 3.

Average 1.4214 Standard deviation 0.0048 What 2.00 Cm 5.01 Cm 3.51 Cmk 2.00

Cmk is the equipment capability index, which expresses the ability of the equipment to produce within the required tolerances. The value of the minimum capability index is Cmk >1.67.

Based on the test results, it can be concluded that by using the device according to example 1, the ability of the device to connect wires within the required tolerances was confirmed.

Example 2

Crimping tool for connecting damaged conductors as in example 1, with the difference that the crimping jaws D are type II and are intended for connecting conductors of the total cross-section and subsequent multiples of cross-section conductors from 1.5 mm ² to 4.0 mm ² .

The cutouts that make up the crimping knife 4a are 2 in number, and the protrusions that make up the crimping anvil 4b are in the number of 2.

The cutouts of the crimping knife 4a are of different sizes and the protrusions of the crimping anvil 4b are of different sizes.

In fig. 2a are crimping jaws, lower part A2, left side view, and in fig. 2b are crimping jaws, lower part of A2, right side view.

Crimping jaws D are made of high-alloy tool steel, heat-treated to HRC 55 ±3 by multi-stage electroerosive machining and subsequent polishing.

The crimping method is performed in one step and is the same as in Example 1.

Industrial applicability

The crimping tool for connecting damaged wires and the method of crimping according to the presented technical solution ensures, after the repair of the wires, the mechanical and electrical properties of the wires, which are in line with the constantly increasing requirements for the quality and reliability of the electrical wiring harness system, especially in the automotive industry.

List of relationship tags

A1 - the upper part of the crimping jaw

A2 - lower part of the crimping jaw

B - crimping handle

C - crimp clip

D - crimping jaws

1a - hole for attaching the upper part of the crimping jaw to the crimping handles

1b - hole for attaching the lower part of the crimping jaw to the crimping handles

2a - unique number to pair with the lower part of the crimping jaw

2b - unique number to pair with the top of the crimping jaw

3a - designation of the number of the crimping clip

3b - designation of the cross-section of the connected wires

4a - crimping knife

4b - crimping anvil

- description of the manufacturer's marking

- description of the minimum cross-section of the conductor

- the mouth of the crimping handles

- screws

Claims (9)

1. Crimping tool for connecting damaged conductors containing crimping handles (B) and crimping jaws (D) mounted therein, characterized in that the crimping jaws (D) include the upper part (A1) of the crimping jaw and the lower part (A2) of the crimping jaw, while the upper part (A1) of the crimping jaw has the shape of a rectangle with a chamfered upper corner, and in its upper half has a round hole (1a) located in the center for attaching the upper part of the crimping jaw (A1) to the crimping handles (B), and below it has a unique number (2a) placed on the front to match the lower part (A2) of the crimping jaw, and in the lower half it has at least one cut-out formed by the crimping knife (4a), and above it a description (5) of the manufacturer's mark is placed on the front, and on the back is above a description (6) of the minimum conductor cross-section placed by it, and below it a description (3a) placed on the side to indicate the number of the crimping clip (C), the lower part (A2) of the crimping jaw has the shape of a rectangle with a beveled lower corner, which has in the middle located a round hole (1b) for attaching the lower part (A2) of the crimping jaw to the crimping handles (B), and in the upper part it has at least one projection, which is formed by the crimping anvil (4b) and below it has a unique number (2b) placed on the front for pairing with the upper part (A1) of the crimping jaw, and behind it there is a marking (3b) of the cross-section of the connected wires, while the crimping knife (4a) and the opposite crimping anvil (4b) fit into each other, while the upper part (A1) of the crimping jaw and the lower part (A2) of the crimping jaw are fitted in the crimping handles (B) through the round holes (1a) and (1b), where they are inserted into the precise mouths (7) and are secured with screws (8). 2. A crimping tool for connecting damaged wires according to claim 1, characterized in that the upper part (A1) of the crimping jaw and the lower part (A2) of the crimping jaw are replaceable in the crimping handles (B) by means of one screw. 3. Crimping tool for connecting damaged conductors according to claim 1, characterized in that the crimping jaws (D) are made of high-alloy tool steel, heat-treated to HRC 55 +/-3 by multi-stage electroerosive machining and subsequent polishing. 4. Crimping tool for connecting damaged conductors according to claim 1, characterized in that the number of cutouts that form the crimping knife (4a) is 2 and the number of protrusions that form the crimping anvil (4b) is 2. 5. Crimping tool for connecting damaged conductors according to claim 4, characterized in that the individual cutouts of the crimping knife (4a) have a different size from each other and the individual protrusions of the crimping anvil (4b) have a different size from each other. 6. Crimping tool for joining damaged conductors according to claim 1, characterized in that the crimping jaws (D) are adapted for joining conductors of the overall cross-section and subsequent multiples of cross-section conductors from 0.7 mm ² to 1.5 mm ² . 7. Crimping tool for joining damaged conductors according to claim 1, characterized in that the crimping jaws (D) are designed for joining conductors of the overall cross-section and subsequent multiples of cross-section conductors from 1.5 mm ² to 4.0 mm ² . 8. A crimping method using a crimping tool according to claim 1, characterized in that damaged wires are cleaned, straightened, stripped, and then the ends of these wires are inserted into a crimping clip (C) as a connecting material, wherein the type of crimping clip (C) is determined according to the total cross-section of the wires to be connected, the crimping clip (C) is then placed on the crimping anvil (4b) and its correct position is determined with the crimping knife (4a) in the first locked position of the ratchet system of the crimping handles (B), and then the crimping handles are (B) manually pressed towards each other by means of a ratchet system, and the crimping clip (C) closes the damaged wires by plastically pressing the material, while the crimping takes place in one step. 9. Crimping method according to claim 8, characterized in that the damaged conductors are conductors used in the automotive industry.