EP4550592A1 - Crimping device - Google Patents

Abstract

The invention relates to a crimping device (1) for crimping a conductor of a predetermined cable (7) with a predetermined contact sleeve (8) having the features:
the crimping device (1) has at least two suitable pressing elements (5) for providing a crimp with a predetermined crimping height (H), which are mounted so as to be reversibly movable relative to a central crimping zone (40) of the crimping device (1);
the crimping device (1) has a drive (2) suitable for the intended operation of the pressing elements (5), wherein the drive (2) is operatively connected to the pressing elements (5) via a suitable mechanism (3);
the drive (2) is an electrically driven, essentially flat-cylindrical coreless motor (2), and
the pressing elements (5) and the mechanics (3) are arranged inside the cylindrical motor (2).

The invention further relates to a controller (10) for controlling the operation of the crimping device (1), as well as a method (VK) for calibrating the crimping device (1) and a method (V) for controlling the operation of the crimping device (1).

Description

The invention relates to a crimping device with, in particular, a drive suitable for operating a crimping device, as well as a control system suitable for the operation and a method for controlling a crimping device.

During crimping, two components are joined together by plastic deformation using a forming tool and a pressing force. This creates a crimp, i.e., a mechanical connection that is difficult to break between a conductor and a connecting element, such as a contact sleeve.

When crimping, a high quality crimp is desirable to ensure a permanent mechanically and electrically stable connection between the crimped components, whereby a contact sleeve suitable for a predetermined application and a predetermined conductor is crimped to the conductor.

State of the art

A conventional crimping device suitable for stationary industrial operation is, for example, from the WO 2020/147888 A1 known, which is particularly directed to a method for monitoring the condition of the crimping device and to a device suitable for carrying out the method. The known crimping device is an indent crimping device whose pressing elements are designed as opposing, tapered mandrels. Setting a suitable crimp height for a predetermined contact sleeve and a predetermined cable, namely the setting of a The minimum distance between two opposing mandrels, up to which the mandrels are moved toward each other during crimping, is disadvantageously laboriously determined using adjusting mandrels with a suitable adjustment mechanism. In this process, an adjustable mechanical stop is set for a lever, via which a pneumatic pressure device is operatively connected to the crimping device. The device comprising the pressure device, lever, and crimping device has a correspondingly disadvantageously high space requirement and a disadvantageously heavy weight, making it particularly unsuitable for a mobile hand tool.

From the DE 10 2018 130 564 A1 A crimping tool is known which also has a disadvantageous lever, referred to as a crimp body actuation control surface arm, which is movable between an unactuated position and an actuated position in order to actuate four crimp bodies to crimp a terminal. The crimping tool includes a complex drive assembly which is movable along a drive spindle between a retracted position and an advanced position. The drive assembly, which has a correspondingly disadvantageously large space requirement, has a drive nut on the drive spindle and a coupling body which is operatively coupled between the drive nut and the crimp body actuation control surface arm. To set a desirable correct crimp height, a mechanical stop for the crimp body actuation control surface arm is provided, which is also disadvantageously complex to adjust.

Task

The object of the invention is therefore to provide a reliable crimping device with a compact design that is suitable for many applications. In particular, the object is to provide a to provide a drive suitable for a crimping device according to the invention as well as a method and a suitable control system suitable for operating the crimping device.

The problem is solved by the features of the independent claims.

Advantageous embodiments of the invention are specified in the subclaims and/or the following description.

The invention particularly relates to a crimping device for crimping a conductor of a predetermined cable with a predetermined contact sleeve. To provide a crimp with a predetermined crimp height, the crimping device comprises at least two suitable pressing elements that are mounted for reversible movement relative to a central crimping zone of the crimping device. For the intended operation of the pressing elements, the crimping device comprises a suitable drive that is operatively connected to the pressing elements via a suitable mechanism.

The drive is particularly advantageously designed as an electrically driven, substantially flat-cylindrical coreless motor, which allows the pressing elements and the mechanics to be arranged within the cylindrical motor, whereby an advantageously compact crimping device can be provided which is suitable for many applications, such as a crimping device of a stationary industrial device and in particular also for a crimping device of a mobile hand tool.

Coreless motors and thus also the crimping device according to the invention can be particularly advantageously designed to be compact and have a Outer diameter in the range of 80mm to 100mm and advantageously from 60mm to 80mm and particularly advantageously in the range of 50mm to 60mm.

Coreless motors are also characterized by their very high torque and compact size, which is particularly advantageous for operating a crimping device. Furthermore, they allow for very dynamic and rapid speed changes, which are particularly advantageous for the precise adjustment or control of a predetermined crimp height. A suitable coreless motor can be provided, in particular, with a stepper motor or servo motor.

A mechanism particularly suitable for operating a coreless motor and the crimping device can be designed as a gear that interacts with the motor and the pressing elements and can be designed particularly advantageously as a cycloidal gear that is operatively connected to the motor and the pressing elements, wherein the central crimping zone and the pressing elements can advantageously be arranged within the gear, and the gear is arranged together with the central crimping zone and the pressing elements within the motor.

With this advantageous design and arrangement, the particularly compact design of the crimping device described above is retained. Furthermore, a cycloidal gear allows for a particularly advantageous mechanical design and arrangement. The cycloidal gear can be particularly advantageously designed and arranged such that the gear generates a predetermined transmission ratio i of a speed of the motor to the gear operatively connected to the pressing elements, which is much greater than 1, so that the mechanism generates a predetermined reduction i which is particularly advantageous for the operation of a crimping device, and in doing so also generates an advantageous corresponding increase in a maximum transmittable torque, namely the output torque.

The gear unit with its features described below can be suitably designed such that the reduction ratio i is in a range from 50 to 1,000 and advantageously in a range from 60 to 600 and, for the application of the crimping device in a mobile hand tool, particularly advantageously in the range of approximately i = 100, and an advantageous output torque in the range from 100 Nm to 400 Nm and advantageously of approximately 200 Nm is possible.

For this purpose, the cycloidal gear can suitably comprise a cam disc and a mandrel control for controlling the pressing elements, which are arranged adjacent to one another and interact mechanically.

The cam disc can have an outer contour that is designed and arranged to correspond to an inner contour of a rotor of the motor such that a predetermined rotation of the rotor can be transmitted to the cam disc. The cam disc can also suitably have an inner contour with cycloidal toothing that interacts with the mandrel control.

When reference is made here and in the entire context of the application to the inner contour of the rotor, the cam disc and the mandrel control, this refers to the contour facing the central crimping zone, while the contour opposite the inner contour The outer contour is the contour facing away from the crimping zone and facing the motor.

The mandrel control suitably has an outer contour, also with cycloidal toothing, which is designed and arranged to correspond to the inner contour of the cam disc such that a predetermined rotation of the cam disc can be transmitted to the mandrel control. To drive the pressing elements, the mandrel control has an inner contour designed as a control cam for the pressing elements for a transmission output. This inner contour is designed and arranged such that a rotation of the mandrel control by a predetermined angle produces a predetermined position of the pressing elements radially perpendicular to a central axis of a central crimping zone of the crimping device.

The control cam of the mandrel control described above can be suitably designed and arranged in such a way that, in particular, even in the event of possible wear of the gear mechanism and/or the pressing elements, an advantageous recalibration of the crimping device is easily possible.

A crimping device according to the invention described above can advantageously be designed as an indent crimping device with mandrel-like pressing elements and particularly advantageously as a 4-indent crimping device, the pressing elements of which are guided radially perpendicular to the center axis of the central crimping zone in a mandrel carrier arranged centrally within the motor. A cycloidal gear particularly suitable for the operation of a 4-indent crimping device can be suitably designed such that a rotation of the mandrel control through an angle of, as described below with reference to the accompanying drawings, naturally less than 90° and suitably at least 20° and advantageously about 60° causes a maximum deflection of the pressing elements from their rest position or zero position without any deflection.

A crimping device as described above can also have a sensor system suitable for operating the crimping device by means of a hardware- and software-supported control system, which comprises at least one sensor for angle measurement and/or torque measurement and/or force measurement and/or identification of a contact sleeve. The control system can be configured, in particular, to also regulate the motor speed in accordance with the crimping height, in particular also in a pulsating manner. The control system can be configured to determine the crimping force from the motor current consumption.

Suitable sensors mentioned above can be provided, for example, by means of suitably arranged Hall sensors, strain gauges and optical sensors.

The invention therefore also relates in particular to a control system for operating a crimping device, as described below, as well as to a method for calibrating a crimping device and a method for controlling the operation of a crimping device, which are also described below.

As mentioned above, the invention also relates in particular to a hardware and software-supported control for operating a crimping device with an electric drive and a transmission ratio i of much greater than 1, the advantages of which are described above in connection with the crimping device according to the invention.

The control system is suitably connected to a suitable operating device and/or display device and/or storage device in terms of signals and/or data, wherein first, second and third data are suitably available on the storage device for controlling the crimping device.

The first data suitably comprise, in particular, the exact transmission ratio i of the rotational speed of a rotor of the drive to a rotational speed of the gear output of a gear cooperating with the drive, said gear output cooperating with pressing elements of the crimping device, and also the functional relationship of the angle of rotation of the drive and the angle of rotation of the gear output to a force acting on the pressing elements and to the position of the pressing elements, in particular also during operation at idle of the crimping device from the rest position or zero position of the pressing elements to the position of their maximum deflection.

The second data comprise data suitable for crimping a contact sleeve with a conductor of a cable for identifying the contact sleeve, and in particular also technical properties and features of a plurality of different contact sleeves and in particular the outer diameter and the crimp height of an individual contact sleeve suitable for crimping.

The third data includes the functional relationship of the angle of rotation of the drive and the angle of rotation to a force acting on the pressing elements during idle operation of the crimping device from the rest position or zero position of the pressing elements to the position of their maximum deflection.

The control is advantageously configured to adjust the crimping height when crimping a contact sleeve with a conductor of a cable by regulating, in particular in a pulsating manner, the rotational speed of the drive corresponding to the crimping height in accordance with, in particular, the first and second data.

For controlling and monitoring the operation of the crimping device, the control system is suitably connected by signal and/or data technology to a sensor system of the crimping device, which comprises at least one sensor for angle measurement and/or torque measurement and/or force measurement and/or identification of a contact sleeve.

For its operation and for its use in the method for calibrating a crimping device described below and the method for controlling the operation of a crimping device also described below, the controller can suitably also be connected in terms of signals and/or data to an operating device and/or a display device, wherein the operating device and/or the display device and/or the storage device can each suitably be a remote device which is connected in terms of signals and/or data to the controller in a network-supported manner.

Of course, the control system described above is advantageously configured and particularly suitable for controlling the operation of the crimping device described at the beginning.

As mentioned above, the invention also relates in particular to a method for calibrating a crimping device and a method for controlling the operation of a crimping device, wherein the two Procedures for their intended implementation suitably use the control described above.

It is clear that the two methods can be carried out particularly advantageously using a crimping device as described above.

The method for calibrating a crimping device suitably comprises the following two steps, namely step one and step two.

In step one, a suitable calibration of the crimping device is carried out, wherein in particular the above-mentioned first and third data are suitably determined by the control system, in particular when the crimping device is idling, from signals from the sensors described above and the design of the control cam likewise described, and can be suitably checked using at least one suitable limit gauge. In particular, the exact transmission ratio i of the speed of the rotor of the drive to the speed of the gear output of the gear interacting with the drive, which cooperates with the pressing elements of the crimping device, and the known functional relationship between the angle of rotation of the drive and the angle of rotation of the gear output to the position of the pressing elements, in particular when the crimping device is operating at idle, from the rest position or zero position of the pressing elements to the position of their maximum deflection, can be suitably checked and corrected if necessary using the at least one suitable limit gauge or at least one suitable calibration mandrel.

The determined first and third data are used together with other relevant data from the calibration of the crimping device for its Use in a method described below for controlling the operation of a crimping device is recorded on the memory device. Step one is suitably carried out at the factory by the crimping device manufacturer after manufacture of the crimping device.

In step two, step one is repeated when the crimping device is first put into operation and as required, with an updated calibration being carried out each time, and the updated calibration being compared with the original factory calibration and/or the last recorded calibration, and any deviation determined being recorded on the storage device together with the current calibration.

As mentioned above, the invention also relates in particular to a method for controlling the operation of a crimping device using the control described above, wherein the method in particular comprises the following first, second, third and fourth steps and may further comprise the likewise following fifth, sixth and seventh steps.

In contrast to the steps one and two of the calibration procedure described above, for the sake of clarity and comprehensibility, the steps mentioned in the procedure for controlling the operation of a crimping device are consistently referred to as the first step, second step, etc.

In the first step of the method for controlling the operation of a crimping device, a hardware- and software-supported identification and/or an operator-assisted identification of a contact sleeve intended for crimping is carried out.

In the second step, the parameters relevant for crimping the contact sleeve for the control system, in particular the crimp height suitable for the contact sleeve and the outer diameter of the contact sleeve, are determined from the second data, whereby for this purpose the data are compared with the identification carried out in the first step.

In the second step, taking into account the determined outer diameter of the contact sleeve, a second rest position or first working position or insertion position of the pressing elements for the contact sleeve can be provided in a particularly advantageous manner, so that a simple, safe and correct insertion of the contact sleeve into its intended position for carrying out a crimping, as centrally as possible in the central crimping zone of the crimping device, is ensured.

This measure is particularly advantageous for identifying a contact sleeve that may be too large and for ensuring simple and correct insertion and positioning of small contact sleeves.

In the third step, the crimping of the contact sleeve is carried out using the parameters determined in the second step, wherein a drive of the crimping device is controlled in particular in a pulsating manner such that pressing elements of the crimping device are brought from their rest position or their zero position or from the second rest position or first working position or insertion position provided above in the second step into a position which corresponds to a crimping height corresponding to the contact sleeve.

In the fourth step, the drive of the crimping device is controlled in such a way that the pressing elements of the crimping device are returned to their rest position or zero position or, in particular in the case of a successive crimping of a large number of similar contact sleeves, possibly also to the second rest position or first working position or insertion position described above.

In the above third step, a position of the pressing elements corresponding to the crimping height can be dynamically controlled in a particularly advantageous manner, in particular by continuously reducing a first high speed of the drive in a suitable manner until the position corresponding to the crimping height is reached at a speed = 0.

In the third step mentioned above, a rotation angle of the rotor and/or a rotation angle of the mandrel control and a crimping force corresponding to the aforementioned rotation angles can also be determined during crimping. The force can be determined using a suitable sensor and, in particular, also from the motor current consumption.

After the third and fourth steps have been carried out, in the fifth step the values determined in the third step are advantageously compared with the first, second and third data, checking for their agreement and returning a yes or no result.

In a sixth step, the contact sleeve is tested for compliance with the identification carried out in the first step with the result Yes or No, whereby the sixth step is carried out upon the result No in the fifth step. In particular, a first increase in the above crimping force corresponding angle of rotation of the mandrel control and a corresponding position of the pressing elements with an outer diameter of the contact sleeve are checked for their agreement.

The procedure is completed in a seventh step, which is carried out upon the result of the fifth step being Yes.

If the result of the sixth step is No, at least the first, second, third, fourth, and fifth steps are repeated. Otherwise, the seventh step is performed and, appropriately, step two of the above method for calibrating a crimping device is performed.

The features of the crimping device and the control, as well as the steps of the two methods, have been described abstractly above. For a better understanding of the features of the crimping device in particular, reference is made here to the following description of an advantageous embodiment, which is accompanied by schematic drawings and which is directed to an advantageous 4-indent crimping device.

The crimping device, the control system and the two methods are particularly suitable for reliable and, in particular, efficient crimping, particularly also sequentially performed, of a large number of, in particular, turned contact sleeves of different design and/or function, in particular since the crimping height is not adjusted mechanically but particularly efficiently with the aid of hardware and software, and since, in particular, quality control and error correction are also possible. The crimping device, the control system and the two processes are therefore particularly suitable for crimping the contacts of hybrid connectors in particular.

Examples of implementation

Fig. 1A

eine schematische Darstellung einer Crimpeinrichtung nach einer Ausführung der Erfindung;

Fig. 1B

einen vergrößerten Dorn der Crimpeinrichtung von Fig. 1A

Fig. 1C

ein Kabel mit einer Kontakthülse, lose und miteinander vercrimpt;

Fig. 2A

die Crimpeinrichtung von Fig. 1A aus einer anderen Perspektive;

Fig. 2B

weitere Beispiele von Kontakthülsen;

Fig. 3A

eine perspektivische Darstellung des Dornträgers zusammen mit der Dornsteuerung der Crimpeinrichtung von Fig. 1A;

Fig. 3B

eine perspektivische Darstellung der Kurvenscheibe der Crimpeinrichtung von Fig. 1A;

Fig. 4A

eine weitere schematische Darstellung der Dorne der Crimpeinheit von Fig. 1A in ihrer Ruheposition bzw. Nulllage, zusammen mit einer bestimmungsgemäß zum Vercrimpen angeordneten Kontakthülse und einem Kabel;

Fig. 4B

die Dorne von Fig. 4A in einer ersten Position;

Fig. 4C

die Dorne von Fig. 4A und 4B in einer weiteren Position;

Fig. 4D

die Dorne von Fig. 4A, 4B und 4C in einer weiteren Position;

Fig. 5A

eine schematische Darstellung zur Erläuterung des Betriebs der Crimpeinrichtung unter Verwendung einer geeigneten Steuerung; und

Fig. 5B

ein schematisches Flußdiagramm eines Kalibrierverfahren und eines Verfahrens zur Crimpung eines Kabels mit einer Kontakthülse nach einer Ausführung der Erfindung.

Embodiments of the invention are illustrated in the drawings and explained in more detail below. They show:

Fig. 1A

a schematic representation of a crimping device according to an embodiment of the invention;

Fig. 1B

an enlarged mandrel of the crimping device of Fig. 1A

Fig. 1C

a cable with a contact sleeve, loose and crimped together;

Fig. 2A

the crimping device of Fig. 1A from a different perspective;

Fig. 2B

further examples of contact sleeves;

Fig. 3A

a perspective view of the mandrel carrier together with the mandrel control of the crimping device of Fig. 1A ;

Fig. 3B

a perspective view of the cam disc of the crimping device of Fig. 1A ;

Fig. 4A

another schematic representation of the mandrels of the crimping unit of Fig. 1A in its rest position or zero position, together with a contact sleeve arranged as intended for crimping and a cable;

Fig. 4B

the thorns of Fig. 4A in a first position;

Fig. 4C

the thorns of Fig. 4A and 4B in another position;

Fig. 4D

the thorns of Fig. 4A, 4B and 4C in another position;

Fig. 5A

a schematic diagram to explain the operation of the crimping device using a suitable control; and

Fig. 5B

a schematic flow diagram of a calibration method and a method for crimping a cable with a contact sleeve according to an embodiment of the invention.

The figures contain partially simplified, schematic representations. In some cases, identical reference symbols are used for identical, but possibly not identical, elements. Different views of identical elements may be scaled differently. Not all reference symbols are shown in all drawings.

Fig. 1A shows a schematic representation of a crimping device 1 according to an embodiment of the invention in a front view, Fig. 1B shows an enlarged mandrel 5 of the crimping device 1 and Fig. 1C shows a cable 7 with a contact sleeve 8, each loose and crimped together. The contact sleeve 8 is a turned contact sleeve 8 with a sleeve section 80 for accommodating the strand of the stripped cable 7 and a contact section 81. Further such contact sleeves 8 are shown schematically in Fig. 2B shown, wherein the contact section 81 of one of the contact sleeves 8 is designed as a signal transmission contact 81, while the contact sleeve 8 shown in the middle and on the right in the drawing is designed as a first and second embodiment of a power contact 81.

The crimping device 1 is an indent crimping device 1 and in particular a four-mandrel crimping device or 4-indent crimping device 1, whose pressing elements 5 are designed like mandrels. The crimping device 1 has a mandrel carrier 4, which houses four pressing elements 5 designed as mandrels 5, which are particularly suitable for crimping a stranded wire or a conductor of a stripped single-core cable 7 with a turned contact sleeve 8. The mandrel carrier 4 is in Fig. 1A different from the perspective representation the crimping device 1 of Fig. 2A , which shows its back, is shown semi-transparently.

The mandrel carrier 4 has a central crimping zone 40 with a central axis A and a cylindrical guide for each of the four mandrels 5, in which guide the mandrels 5 are mounted so as to be movable radially in the direction R perpendicular to the central axis A. The mandrels 5 have a central cylindrical section with a conically tapered tip 51 and a head 50, each of which interacts with a return spring 6 such that the mandrels 5 are pressed radially in the opposite direction to the central crimping zone 40 by the return springs 6.

Fig. 4A shows a further schematic representation of the mandrels 5 of the crimping device 1 of Fig. 1A in its rest position P0 or zero position P0 without any deflection, together with a contact sleeve 8 arranged as intended for crimping in the crimping zone 40 of the crimping device 1 and a cable 7. The tips 51 of the mandrels 5 of the crimping device 1 are arranged concentrically with the contact sleeve 8 arranged centrally in the crimping zone 40.

A displacement of the tips 51 of the mandrels 5 from their rest position P0 to a position P takes place against the force of the return spring 6 using a predetermined torque M. In the position P of Fig. 4B the mandrels 5 of the crimping device 1 just touch the surface of the contact sleeve 8 and are in a position P which corresponds approximately to the outer diameter of the contact sleeve 8 and which, moreover, essentially corresponds to the position described at the outset and also below with reference to Fig. 5B in connection with step S2 of the method V corresponds to position P, namely an advantageous second rest position P or first working position P or insertion position P of the pressing elements 5 to ensure a simple and correct insertion and positioning of small contact sleeves 8 in particular in the central crimping zone 40.

Fig. 4C shows the mandrels 5 of the crimping device 1 at the position P, at which the tips 51 of the mandrels 5 are arranged on a circle with a diameter H, which corresponds to a predetermined crimping height H. A minimum adjustable crimping height H corresponds to the position Pmax, in which the mandrels 5 are maximally deflected from their rest position P0, and the maximum adjustable angle of rotation αmax of the mandrel control 31. Suitably, the minimum adjustable crimping height H and the corresponding maximum adjustable angle of rotation αmax can be selected such that the tips 51 of the mandrels 5 just touch each other. The mandrels 5 of the crimping device 1 at their position Pmax are shown schematically in Fig. 4D The adjustment of the crimping height H of the crimping device 1 is described below with reference to Fig. 5A and 5B described.

An electric motor 2 is provided as the drive 2 of the crimping device 1, which is particularly advantageously designed as a coreless motor 2 or frameless motor 2 and which suitably interacts with a cycloidal gear 3. Coreless motors 2 are characterized by a compact design and, in particular, by a very high torque with a small size, and allow for very dynamic and rapid speed changes.

The motor 2 has a stator 20 and a rotor 21 and, in particular, is essentially flat-cylindrical in design with its stator 20. The mandrel support 4, with its crimping zone 40 and its central axis A, is arranged centrally within the cylindrical motor 2 and is surrounded by the gear 3, which is arranged between the mandrel support 4 and the motor 2. For the intended use of the Crimping device 1 can be provided with suitable fastening elements such as threads and screws on the static mandrel carrier 4.

The gear 3, advantageously designed as a cycloidal gear 3, has a cam disk 30 with an internal cycloidal toothing 300 and a mandrel control 31 with an external cycloidal toothing 311. An outer contour of the cam disk 30 is designed to correspond to an inner contour of the rotor 21 such that the cam disk 30 is driven by the rotating rotor 21 such that it executes a wobbling rotary movement about the axis A of the stationary mandrel carrier 4 and about the mandrel control 31.

To provide the wobbling rotary movement of the cam disk 30 driven by the rotor 21, the cam disk 30, as described above, has an outer contour 301 corresponding to the inner contour of the rotor 21. Furthermore, recesses 304 are provided on the cam disk 30 for this purpose, which interact with cylindrical pins 404 of the mandrel support 4 and are designed and arranged correspondingly to the pins 404.

Fig. 3A shows a perspective view of the mandrel support 4 surrounded by the mandrel control 31, which has cylindrical pins 404 which, adjacent to one another, form a ring around the central crimping zone 40 and extend in the axial direction A. The on a drawing sheet in conjunction with the mandrel support 4 and the mandrel control 31 of Fig. 3A in Fig. 3B The perspectively shown cam disc 30 has a central recess which corresponds to the central crimping zone 40 in such a way that the crimping zone 40 is positioned for its intended purpose is freely accessible during operation. The cam disc 30 also has recesses 304 which, adjacent to one another, form a ring around the central recess and are designed and arranged in correspondence with the pins 404 in such a way that the above-described wobbling rotational movement of the cam disc 30 around the central crimping zone 40 is enabled.

To provide the above rotary movement of the cam disk 30, at least three and suitably five pins 404 or recesses 304 are provided on the mandrel carrier 4 and the cam disk 30. The cam disk 30, with its inner cycloidal toothing 300, is also designed and arranged to correspond to the outer cycloidal toothing 311 of the mandrel control 31 such that the above wobbling rotary movement of the cam disk 30 generates a rotation by a predetermined angle of rotation αi of the mandrel control 31, after which the mandrel control cam 310 formed on the inner contour 310 of the mandrel control 31 interacts as intended with the heads 50 of the mandrels 5 and adjusts their radial R positioning as well as the position P of their tips 51.

A crimping device 1 described above, with its drive 2, gear 3, and mandrel support 4, and in particular their advantageous joint arrangement around a central crimping zone 40, is particularly compact and advantageously suitable for many applications, both in a stationary industrial operation and in a mobile hand tool. Furthermore, the crimping device 1 also has an advantageously low weight.

Suitably, the crimping device 1 can have a diameter ø of 80mm to 100mm and advantageously of 60mm to 80mm and particularly advantageously in the range of 50mm to 60mm.

In the embodiment shown in the drawings, a maximum angle of rotation αimax of the mandrel control cam 31 is approximately 20° for the sake of clarity and for better understanding, whereby the maximum angle of rotation αimax of a 4-indent crimping device 1 is naturally limited due to the dimensions of the mandrels 5 and is accordingly less than 90° and can advantageously be approximately 60° in particular to enable advantageous recalibration.

In accordance with their diameter ø with the above advantageous dimensions, the motor 2 with in particular the inner contour of its rotor 21, the gear 3 with the outer contour 301 of its cam disk 30, the inner contour 310 of the mandrel control 31, as well as their inner 300 and outer 311 cycloid toothing can be designed such that, as described above, a transmission ratio i of the speed of the drive 2 to the speed of the mandrel control 31 to provide a maximum angle of rotation αimax of the mandrel control cam 31 desirable for a 4-ident crimping device 1 in the range of approximately 20° to approximately 60°, suitably in a range i of 50 to 1,000 and advantageously in a range of 60 to 600 and for the use of the crimping device 1 in a mobile hand tool particularly advantageously in the range of approximately i = 100.

The transmission ratio i, namely i = speed of the rotor 21 / speed of the mandrel control cam 31 corresponds to the design of the cycloidal gear 3, namely the ratio of the number of teeth Z311 of the cycloidal toothing 311 to the difference between the number of teeth Z300 of the cycloidal toothing 300 and the number of teeth of the cycloidal toothing 311 and is thus given by the equation i = Z311 / (Z300 - Z311).

Since, of course, only integer teeth can be implemented technically, with the advantageous above gear ratio of i = 100, for example, a number Z311 of 100 teeth of the cycloidal toothing 311 and a number Z300 of 101 teeth of the cycloidal toothing 300 come into consideration for a corresponding design of the cycloidal gear 3.

Assuming a linearly sloping control curve contour 310, the relationship A50(αimax) = -1/15 * αimax + 22 results, for example, where A50(αimax) is the distance between the center axis A of the crimping center 40 and the contact point of the head 50 of a mandrel 5 on the mandrel control curve 310.

The position Pmax of the mandrel tip 51 relative to the central axis A of the crimping center 40 corresponds, as described above with reference to Fig. 4A to 4D described, with the minimum crimp height H, resulting in the following equation, namely Pmax = P(αimax) = A50(αimax) - L5,
where L5 corresponds to the length of the crimping mandrel 5.

This ultimately results in the relationship between the position P of the tip 51 of a crimping mandrel 4 and the angle of rotation α of the drive motor 2, namely Pmax = P(αmax) = -1/15 * αmax * 100 + 22. The position P, namely the distance of the tip 51 of a mandrel 5 to the central axis A of the crimping center 50, corresponds, as also described above with reference to Fig. 4A to 4D described, in addition to half the crimp height H, namely P = H/2.

The above design of the transmission ratio i of approximately 100 allows a particularly simple and precisely controllable angle of rotation α with a correspondingly advantageously exact controllable positioning P of the mandrels 5 and thus allows in particular an advantageously exact control of a predetermined crimping height H. In addition, an above advantageous reduction of in particular i = 100 enables an advantageous corresponding increase in the output torque M to approximately 200Nm and thus a desirable operation of the crimping device 1 with the coreless motor 2 as the drive, which, as mentioned above, has a desirably high torque with a small size and allows a desirably dynamic and rapid speed change.

It is clear that the crimping device 1, which was advantageously designed as a 4-indent crimping device 1 above, can also be modified to be a 2-indent crimping device 1 or an 8-indent crimping device 1. It is also clear that instead of an indent crimping device 1 with a mandrel carrier 4 and the mandrels 5, suitable jaw pliers can also be provided for providing the pressing elements 5, which can also be driven by a coreless motor 2 and a cycloidal gear 3, which may be desirable for selected applications.

Fig. 5A shows a schematic diagram to explain the operation of the crimping device 1 using a suitable controller 10, and Fig. 5B shows a schematic flow diagram of a method VK for calibrating a crimping device 1 and a method V for crimping a cable 7 with a contact sleeve 8 according to an embodiment of the invention.

For a desirably simple and efficient operation of the crimping device 1, the crimping device 1 can be controlled by a suitable hardware and software-supported control 10, wherein the crimping device 1 can have a suitable sensor system 11, which Sensors for angle measurement and/or torque measurement and/or force measurement and/or identification.

At least one exemplary Hall sensor suitable for measuring the distance and thus for determining the angle and as a distance sensor can be suitably provided at least one suitable position of the motor 2 for detecting the rotation of its rotor 21 and/or at least one suitable position of the mandrel carrier 4 for detecting the angle of rotation αi of the mandrel control 31.

In addition, at least one strain gauge suitable for force measurement and as a force sensor can be provided in a suitable manner at at least one suitable position of the inner contour 310 of the mandrel control 31, which interacts with the head 50 of the mandrel 5 during crimping, wherein the at least one force sensor detects the essentially constant restoring force of the spring 6 acting on the head 50 of the mandrel 5 and thus on the mandrel control cam 310 when the crimping device 1 is idle.

It is clear that the controller 10 is also configured with suitable hardware and software, in particular, for controlling the motor 2 and for detecting and evaluating the signals from the sensor system 11, as well as for detecting the motor current consumption. Furthermore, the controller 10 can be suitably connected to a suitable operating device 12 and/or a suitable display device 13 and/or storage device 14 via signals and/or data. In particular, the storage device 14 can be a remote storage device 14 that is connected to the controller 10 via signals and/or data via a network.

In order to control a suitable drive of the crimping device 1, first data D1 for controlling the crimping device 1 can be stored on the storage device 14 in a particularly advantageous manner and can be retrievably stored thereon. The first data D1 suitably comprise, in particular, the exact transmission ratio i of the rotational speed of a rotor 21 of the drive 2 to a rotational speed of the gear output of a gear 3 interacting with the drive 2, said gear output interacting with pressing elements 5 of the crimping device 1, and the functional relationship of the angle of rotation α of the drive 2 and the angle of rotation αi of the gear output to a force acting on the pressing elements 5 and to the position P of the pressing elements 5, in particular also during operation at idle of the crimping device 1 from the rest position P0 of the pressing elements 5 to the position Pmax of their maximum deflection.

Furthermore, second data D2 of the individual properties of a plurality of different contact sleeves 8 can particularly advantageously be available on the storage device 14, also in particular for setting the crimping height H suitable for a predetermined individual contact sleeve 8 and its predetermined use. In addition to the type of contact sleeve 8, its intended use, its individual article designation, and also the serial number and/or alphanumeric coding assigned to the contact sleeve 8 for machine identification, etc., the second data D2 can advantageously include technical data D2, such as in particular material, dimensions, ie in particular the outer and inner diameter of the contact sleeve 8, and the individual crimping height H suitable for crimping the contact sleeve 8 with a conductor of a predetermined cable 7.

The above second data D2, in particular the individual optimal crimping height H, can be suitably determined by the manufacturer of the contact sleeve 8 through suitable test series using, in particular, a crimping device 1 of identical construction. The second data D2 can be routinely maintained and, in particular, updated by the manufacturer, wherein the second data D2 can be suitably made available by the manufacturer in a network-supported manner for use by the controller 10 of the crimping device 1.

Furthermore, third data D3 can advantageously be available for the control 10 on the storage device 14, which data describe the functional relationship between the provided force and/or the torque M and the speed and/or the angle of rotation α of the rotor 21 and/or the angle of rotation αi of the mandrel control 31, in particular when the crimping device 1 is running idle from the rest position P0 of the mandrels 5 and the mandrel control 31 to their maximum deflection or

Rotation αimax. The third data D3 also originate, appropriately, initially from an initial calibration of the crimping device 1 and can be checked during routine idle measurements and, if necessary, updated using limit gauges.

Using the first data D1 and third data D3, the controller 10 can also advantageously detect and quantitatively record a drift, in particular of the mechanical properties of the crimping device 1, for example due to wear, in particular on the tips 51 of the mandrels 5 or the cycloidal toothings 300 and 311, and of course also store or update this drift in a suitable manner on a storage device 14 together with the third data D3.

The above quantitatively recorded drift can also be suitably taken into account in the method VK for calibrating a crimping device 1 and method V for controlling the operation of a crimping device 1 described below.

As described above, the controller 10 is suitably configured to adjust the crimping height H when crimping a contact sleeve 8 with a conductor of a cable 7 by regulating, in particular, the rotational speed of the drive 2 corresponding to the crimping height H in accordance with, in particular, the first D1 and second D2 data.

The method VK for calibrating a crimping device 1 is suitably carried out using the control 10 described above.

In a first step S1 of the calibration method VK, the crimping device is first calibrated, in particular by determining the first D1 and third D3 data as described above, in a suitable manner, in particular using at least one limit gauge, and then the first D1 and third D3 data, in particular, are recorded on the storage device 14, together with further relevant data of the calibration of the crimping device 1, such as location, date, ID of the crimping device 1, etc. Step S1 is suitably carried out at the factory after the crimping device 1 has been manufactured.

A repetition of step S1 is carried out in a second step S2 when the crimping device 1 is first put into operation and if required carried out, whereby an updated calibration is carried out in each case, and wherein the updated calibration is suitably compared with the original factory calibration and/or the last recorded calibration, and a determined deviation is recorded together with the current calibration.

Like the method VK, the method V for controlling the operation of a crimping device 1 is also suitably carried out using the controller 10.

In a first step S1 of the method V, a hardware- and software-supported identification and/or an identification carried out by an operator of a contact sleeve 8 intended for crimping is carried out.

Following the first step S1, in a second step S2, the parameters relevant for crimping the contact sleeve 8 for the controller 10 are determined, in particular the crimping height H suitable for the contact sleeve 8 and the outer diameter of the contact sleeve 8, from the second data D2 and the identification determined in the first step S1.

In the second step S2, taking into account the outer diameter of the contact sleeve 8, a second rest position P or first working position P or insertion position P of the pressing elements 5 can be provided, which corresponds to a distance between the tips 51 of the pressing elements 5 that is slightly larger than the outer diameter of the contact sleeve 8, so that a simple, safe and correct insertion of the contact sleeve 8 into its intended position for carrying out a crimping, as centrally as possible in the central crimping zone 40 of the crimping device 1, is ensured. This measure As described at the beginning, this is particularly advantageous for the early identification of a contact sleeve 8 that may be too large and for ensuring simple and correct insertion and positioning of small contact sleeves 8.

In a third step S3, crimping of the contact sleeve 8 is carried out using the parameters determined in step S2, wherein a drive 2 of the crimping device 1 is controlled in a suitable manner, in particular also in a pulsating manner, such that the pressing elements 5 of the crimping device 1 are brought from their rest position P0 or zero position P0 or from their second rest position P or first working position P or insertion position P provided above in step S2 into a position P which corresponds to a crimping height H corresponding to the contact sleeve 8.

In a subsequent final step S4, the drive 2 of the crimping device 1 is controlled such that the pressing elements 5 of the crimping device 1 are returned to their rest position P0 or zero position P0 or initially to the second rest position P or first working position P or insertion position P.

In the method V for controlling the operation of a crimping device 1, in the third step S3, a position P of the pressing elements 5 corresponding to the crimping height H can advantageously be dynamically controlled, in particular by continuously reducing a first high rotational speed of the drive 2 in a suitable manner until the position P is reached at a rotational speed = 0, wherein in the third step S3, during the crimping, a rotational angle α and/or a rotational angle αi and a force corresponding to the rotational angle α and/or the rotational angle αi can also be determined.

Furthermore, in a fifth step S5 of the method V, a comparison of the values measured in the third step S3 with the first D1, second D2 and third D3 data and a check for their agreement with the result Yes or No y/n can be carried out in a suitable manner.

In a sixth step S6, moreover, a check of the contact sleeve 8 can be carried out for agreement with the identification carried out in the first step S1 with the result Yes or No y/n, wherein the sixth step S6 is carried out under the assumption that the result of the comparison in the fifth step S5 is No n.

Finally, the method V can be terminated in a seventh step S7 under the condition that the result of the comparison in the fifth step S5 is Yes y.

Provided that the result of the test in the sixth step S6 is No n, at least the above steps S1 to S5 are repeated, and if, on the other hand, the result of the test in the sixth step S6 is Yes y, the method is terminated in the seventh step S7, and the second step S2 of the method VK described above and an advantageous recalibration are also carried out.

Although various aspects or features of the invention are shown in combination in the figures, it will be apparent to those skilled in the art—unless otherwise stated—that the illustrated and discussed combinations are not the only possible ones. In particular, corresponding units or feature complexes from different embodiments can be interchanged.

List of reference symbols

1

Crimping device

10

steering

11

Sensor technology

12

Control device

13

Display device

14

storage device

2

Drive, Motor, Stepper Motor, Servo Motor, Coreless Motor, Frameless Motor

20

stator

21

rotor

3

Drive mechanism, gears, cycloidal gears

30

Cam disc, gearbox input

300

inner contour, cycloidal toothing

301

External office

304

recess

31

Mandrel control

310

inner contour, mandrel control curve

311

Outer contour, cycloidal toothing

4

Mandrel carrier

40

Crimp zone

404

cones

5

Mandrel, pressing element

50

Head

51

Great

6

spring, return spring

7

Cable

8

Contact sleeve

80

Sleeve section, crimp section

81

Plug-in section, contact section

A

central axis

A50

Distance

D1, D2, D3

Data

H

Crimp height

L5

length

M

torque

N

Number

n

No as a value of an examination

P, P0, Pmax

position

R

Direction

S1, S2, S3, S4, S5, S6, S7

Step

i

Translation, subdivision

V, VK

Proceedings

y

Yes as the value of an exam

Z300, Z311

Number of teeth

O

diameter

α, αmax

Rotor rotation angle

αi, αimax

Rotation angle mandrel control

Claims (20)

Crimping device (1) for crimping a conductor of a predetermined cable (7) with a predetermined contact sleeve (8) with the features: - the crimping device (1) has at least two suitable pressing elements (5) for providing a crimp with a predetermined crimping height (H), which are mounted so as to be reversibly movable relative to a central crimping zone (40) of the crimping device (1); - the crimping device (1) has a drive (2) suitable for the intended operation of the pressing elements (5), wherein - the drive (2) is operatively connected to the pressing elements (5) via a suitable mechanism (3); - the drive (2) is an electrically driven, essentially flat-cylindrical coreless motor (2), and - the pressing elements (5) and the mechanics (3) are arranged inside the cylindrical motor (2). Crimping device (1) according to claim 1, having the features: - the mechanism (3) is designed as a cycloidal gear (3) and is operatively connected to the motor (2) and the pressing elements (5); - the central crimping zone (40) and the pressing elements (5) are arranged within the gear (3). Crimping device (1) according to claim 2, having the features: - the motor (2) has a stator (20) and a rotor (21); - the cycloidal gear (3) has a cam disc (30) and a mandrel control (31) which are arranged adjacent to one another and interact mechanically; - the cam disc (30) has an outer contour (301) which is designed and arranged to correspond to an inner contour of the rotor (21) in such a way that a predetermined rotation of the rotor (21) can be transmitted to the cam disc (30); - the cam disc (30) has an inner contour (300) with cycloidal toothing (300); - the mandrel control (31) has an outer contour (311) with a cycloid toothing (311) which is designed and arranged to correspond to the inner contour of the cam disc (30) in such a way that a predetermined rotation of the cam disc (30) can be transmitted to the mandrel control (31); - the mandrel control (31) has an inner contour (310) designed as a control curve (310) of the pressing elements (5), which is designed and arranged such that a rotation of the mandrel control (31) by a predetermined angle (α) produces a predetermined position (P) of the pressing elements (5). Crimping device (1) according to one of the preceding claims, having the features: - the mechanism (3) is designed in such a way that the mechanism (3) applies a predetermined transmission ratio i of a speed of the motor (2) to the gears operatively connected to the pressing elements (5) causes a mandrel control (31) which is much greater than 1, so that a predetermined reduction i is generated by the mechanism (3). Crimping device (1) according to claim 4, wherein the reduction ratio i is in a range from 50 to 1,000 and advantageously in a range from 60 to 600 and particularly advantageously in the range of approximately i = 100. Crimping device (1) according to one of the preceding claims, wherein
the crimping device (1) with in particular the motor (2) and the mechanism (3) is designed such that an output torque in the range of 100Nm to 400Nm and advantageously of about 200Nm is provided. Crimping device (1) according to one of the preceding claims, wherein
the cylindrical motor (2) has an outer diameter (ø) in a range of 80mm to 100mm and advantageously in a range of 60mm to 80mm and particularly advantageously in a range of 50mm to 60mm. Crimping device (1) according to one of claims 3 to 7, having the features: - the control cam (310) of the mandrel control (31) is designed and arranged in such a way that, in particular, recalibration of the crimping device (1) is possible even in the event of possible wear of the mechanism (3) and/or the pressing elements (5). Crimping device (1) according to one of claims 3 to 8, having the features: - the crimping device (1) is an indent crimping device (1) with mandrel-like pressing elements (5) and in particular is designed as a 4-indent crimping device (1); - the pressing elements (5) are guided in a mandrel carrier (4) arranged centrally within the motor (2) radially perpendicular to a central axis (A) of the central crimping zone (40); - the cycloidal gear (3) of the 4-indent crimping device (1) is designed such that a rotation of the mandrel control (31) by an angle (α) of at least 20° and particularly advantageously approximately 60° causes a maximum deflection of the pressing elements (5) from their rest position (P0) into the position (Pmax). Crimping device (1) according to one of claims 4 to 9,
with the features: - the crimping device (1) has a sensor system (11) suitable for operating the crimping device (1) by means of a hardware and software-supported control system (10), which comprises at least one sensor for angle measurement and/or torque measurement and/or force measurement and/or identification of a contact sleeve (8), wherein - the control (10) is designed, in particular, to also regulate the speed of the motor (2) in accordance with the crimping height (H). Crimping device (1) according to one of claims 1 to 10, wherein the motor (2) is a stepper motor or a servo motor. Hardware and software-supported control (10) for operating a crimping device (1) with an electric drive (2) and a transmission ratio i of much greater than 1, having the features: - the controller (10) is connected to a suitable operating device (12) and/or display device (13) and/or storage device (14) by means of signals and/or data; - first data (D1), second data (D2) and third data (D3) are available on the memory device (14) for the control (10) of the crimping device (1); - the first data (D1) comprise in particular the exact transmission ratio i of the rotational speed of a rotor (21) of the drive (2) to a rotational speed of the gear output of a gear (3) cooperating with the drive (2), said gear output cooperating with pressing elements (5) of the crimping device (1), and in particular the functional relationship of the angle of rotation (α) of the drive (2) and the angle of rotation (αi) of the gear output to a force acting on the pressing elements (5) and to the position (P) of the pressing elements (5), in particular also during operation at idle of the crimping device (1) from the rest position (P0) of the pressing elements (5) to the position (Pmax) of their maximum deflection; - the second data (D2) comprise data suitable for crimping the contact sleeve (8) with a conductor of a cable (7) for identifying the contact sleeve (8), and in particular also technical properties and features of a plurality of different contact sleeves (8) and in particular the outer diameter and the Crimp height (H) of an individual contact sleeve (8) suitable for crimping; - the third data (D3) comprise the functional relationship of the angle of rotation (α) of the drive (2) and the angle of rotation (αi) to a force acting on the pressing elements (5) during idle operation of the crimping device (1) from the rest position (P0) of the pressing elements (5) to the position (Pmax) of their maximum deflection; - the control (10) is configured to adjust the crimping height (H) when crimping a contact sleeve (8) with a conductor of a cable (7) by regulating, in particular, the rotational speed of the drive (2) corresponding to the crimping height (H) in accordance with, in particular, the first (D1) and second (D2) data. Controller (10) according to claim 12, having the features: - the controller (10) is connected in terms of signals and/or data to a sensor system (11) of the crimping device (1) for controlling and monitoring the operation of the crimping device (1), which sensor system comprises at least one sensor for measuring angle and/or torque and/or force and/or identifying a contact sleeve (8). Controller (10) according to claim 12 or 13, having the features: - the operating device (12) and/or the display device (13) and/or the storage device (14) is a remote device which is connected to the controller (10) in a network-supported manner by means of signals and/or data. Controller (10) according to one of claims 12 to 14, wherein the controller (10) is suitably configured to operate a crimping device (1) according to one of claims 1 to 11. Method (VK) for calibrating a crimping device (1) using the controller (10) according to one of claims 12 to 15, comprising the steps: - Step (S1): Carrying out a calibration of the crimping device (1) with, in particular, determining the first (D1) and third (D3) data and recording, in particular, the first (D1) and third (D3) data on the storage device (14), wherein step (S1) can be carried out using at least one limit gauge, and wherein
Step (S1) is carried out after the crimping device (1) has been manufactured at the factory; - Step (S2): Repeating step (S1) when the crimping device (1) is first put into operation and as required, performing an updated calibration each time, and comparing the updated calibration with the original factory calibration and/or the last recorded calibration, and a determined deviation is recorded together with the current calibration on the storage device (14). Method (V) for controlling the operation of a crimping device (1) using the controller (10) according to one of claims 12 to 15, comprising the steps: - Step (S1): Hardware and software-based identification and/or operator-assisted identification of a component intended for crimping Contact sleeve (8); - Step (S2): Determination of the parameters relevant for crimping the contact sleeve (8) for the control (10), in particular the crimping height (H) suitable for the contact sleeve (8) and the outer diameter of the contact sleeve (8) from the second data (D2), and positioning of the contact sleeve (8) at its intended position for carrying out a crimp in the central crimping zone 40 of the crimping device 1, wherein
for this purpose, the pressing elements (5) are moved from their rest position (P0) or zero position (P0) into a suitable first working position (P) or insertion position (P); - Step (S3): Carrying out the crimping of the contact sleeve (8) using the parameters determined in step (S2), wherein a drive (2) of the crimping device (1) is controlled in such a way that pressing elements (5) of the crimping device (1) are brought from their rest position (P0) or zero position (P0) or the first working position (P) or insertion position (P) into a position (P) which corresponds to a crimping height (H) corresponding to the contact sleeve (8); - Step (S4): The drive (2) of the crimping device (1) is controlled in such a way that the pressing elements (5) of the crimping device (1) are returned to their rest position (P0) or zero position (P) or to the first working position (P) or insertion position (P). Method (V) according to claim 17, comprising the steps: - in step (S3), a position (P) of the pressing elements (5) corresponding to the crimping height (H) is dynamically controlled, in particular by a first high speed of the drive (2) is continuously reduced in a suitable manner until the position (P) is reached at a speed = 0; - in step (S3), a rotation angle (α) and/or a rotation angle (αi) and a force corresponding to the rotation angle (α) and/or the rotation angle (αi) are also determined during the crimping; - Step (S5): Carrying out a comparison of the values measured in step (S3) with the first (D1), second (D2) and third data (D3) and checking their agreement with the result Yes/No (y/n); - Step (S6): Checking the contact sleeve (8) for compliance with the identification carried out in step (S1) with the result Yes/No (y/n); - Step (S7): Termination of the procedure (V); where: - Step (S7) is performed on the result Yes (y) in step (S5); - Step (S6) is performed on the result No (n) in step (S5); - if the result is No (n) in step (S6), at least steps (S1) to (S5) are repeated; - upon the result Yes (y) in step (S6), step (S7) is carried out and, in addition, step (S2) of the method (VK) according to claim 16 is carried out. Method (V) according to claim 17 or 18, wherein step (S3) is controlled and carried out in a pulsating manner, and the force corresponding to the angle of rotation (α) and/or the angle of rotation (αi) in step (S3) is determined from the motor current consumption of the motor (2). Carrying out the method (VK) according to claim 16 and the method according to one of claims 17 to 19 using the crimping device (1) according to one of claims 1 to 11.

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