Patent Publication Number: US-11398709-B2

Title: Crimping machine

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a national stage of, and claims priority to, Patent Cooperation Treaty Application No. PCT/EP2018/071409, filed on Aug. 7, 2018, which application claims priority to German Application No. DE 10 2017 118 968.8, filed on Aug. 18, 2017, which applications are hereby incorporated herein by reference in their entireties. 
     DESCRIPTION 
     The disclosure relates to a crimping machine as disclosed herein. 
     Such a crimping machine is known, for example, from the patent specification DE 44 40 835 C1 to the applicant and serves for crimping wire ferrules with a stripped cable end, for example. The wire ferrules are wound, in the known solution, as a webbing onto a drum magazine and are conveyed from there via a transport unit toward a crimping head. As an alternative, the wire ferrules or contact elements may also be received singled in a storage and may then be conveyed, in a defined position, to the crimping head via an appropriate feeding device. Such feeding device is described, for example, in DE 198 31 588 A1. 
     In the known solutions, the wire ferrule to be crimped is put onto the stripped cable end by means of a holding unit and is then crimped via the crimping head. The stripping of the cable end can be either external or via a stripping head integrated in the crimping machine. 
     The design of a transport unit for conveying the wire ferrules arranged on a webbing or any other electric components is described, for example, in the applicant&#39;s document G 93 08 266.5. A similar transport unit is also disclosed in DE197 14 964 C1. 
     In series production it is necessary to crimp different cable cross-sections and electric components/contact elements to one another and then to install them in a subsequent mounting step, for example when mounting a switch cabinet. For this, there are basically two options: In one variant, the crimping machine is retooled for crimping different cable cross-sections and/or contact elements (wire ferrules), or else plural crimping machines are provided for processing the different cable cross-sections/contact elements. The former solution requires long setup times and considerable personnel costs. This drawback is overcome in the latter solution by a plurality of crimping machines—however, the investment costs are considerable. 
     In the document DE 10 2004 057 818 B3, a machine (in the form of a stripper, crimper) is disclosed by which different cable cross-sections and wire ferrules can be processed. Accordingly, for each wire ferrule type a drum magazine and a related crimping unit are provided to which a joint drive is assigned which can optionally be operatively engaged in one of the crimping units. Such solution requires high apparatus effort, as a plurality of crimping units has to be provided and controlled. 
     DE 10 2015 119 217 A1 to the applicant illustrates a crimping machine by which the afore-mentioned drawbacks are eliminated. The crimping machine has a storage arrangement including plural drum magazines to which a joint transport unit and a joint crimping head are assigned so that the apparatus effort is significantly reduced as compared to the afore-described solution. 
     DE 10 2015 102 060 A1 also to the applicant illustrates a crimping machine in which different wire ferrules are provided in a storage arrangement including plural drum magazines. A transport unit via which the respective pre-selected wire ferrule is transported into a transfer position is assigned to each of the drum magazines. The wire ferrule is separated there and then guided to a joint crimping head by means of a shuttle. 
     This crimping machine excels by high productivity. However, a certain drawback is perceived in the fact that the shuttle required has a comparatively complex design and requires corresponding space and no stripping is possible. 
     As compared to this, the object underlying the disclosure is to provide a machine suited for stripping and crimping by which flexible manufacture is possible with a comparatively simple design. 
     This object is achieved by a crimping machine comprising features as disclosed herein. 
     The disclosed crimping machine serves for crimping contact elements with an end section of a conductor, for example a cable end. The crimping machine has a storage arrangement including plural magazines, wherein a transport unit for transporting the contact element, for instance a wire ferrule, to a cutting device is assigned to each magazine. The crimping machine moreover includes a centering device for positioning the conductor end section with respect to a crimping head via which the contact element is crimped with the end section of the conductor (cable end). In accordance with the disclosure, a guiding device via which the separated contact element is guided toward the crimping head is arranged between the crimping head and the cutting device. The guiding device has a plurality of inputs each of which is assigned to a transport unit and, respectively, a contact element cross-section. The inputs open into an output on the crimping head side via channels along which the contact element to be crimped is guided. At the output, the contact element is taken over and inserted into the crimping head. 
     The contact element to be crimped is thus directly guided into the operating area of the crimping head without interconnecting a complex shuttle or the like. The guiding is realized with minimum apparatus effort by the described guiding device, which works substantially without any movable components and conveys the contact element by the effect of gravity, only supported by applying compressed air or the like, if at all. 
     In an example, the guiding device is funnel-shaped, with the inputs being configured to be located next to each other on the one side. From the inputs, the channels then extend to converge to the opposite joint output. 
     As already mentioned in the foregoing, the channels are orientated in the crimping machine preferably in the direction of gravity, i.e. in the vertical direction, so that the transport of the contact elements within the guiding device is at least supported by gravity. 
     In one example, the transport can be accelerated when a suitable accelerating device is provided via which the movement of the contact element within the guiding device is supported. Such accelerating device may include, for example, a compressed air channel, via which a compressed air jet is directed to the contact element. Accordingly, a compressed air channel can be assigned to each channel or a joint compressed air channel can be assigned to all channels. 
     The operating safety can be further improved when in the area of the output of the guiding device a sensor detecting the approach of a contact element is disposed. Then the crimping head and the related functional elements are controlled by means of a control unit via the then generated sensor signal. 
     In another example, a stripper is further integrated in the crimping machine. 
     The crimping machine may be provided with a control panel/display via which the cable cross-section/contact element type is selected. In response to such entry, the transport unit and the cutting device, the stripping unit and the crimping head as well as other functional elements are controlled via the control unit. 
     The crimping machine is preferably pneumatically operated. Basically, also a motor-driven operation can be realized, however. 
     The actual structure of the transport unit, the stripping unit and the crimping head is known from the state of the art to the applicant, especially DE 44 40 835 C1 and DE 10 2015 102 060 A1 as well as the state of the art cited there, so that in the following a detailed description of these units known per se will be renounced and in this respect the disclosure of the mentioned documents which belong to the disclosure of the present application will be referred to. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       Examples are illustrated in detail in the following by way of schematic drawings, wherein: 
         FIG. 1  shows a three-dimensional view of a crimping machine according to the disclosure; 
         FIG. 2  shows a rear view of the crimping machine from  FIG. 1 ; 
         FIG. 3  shows a front view of the crimping machine with a partly opened housing and merely a partial representation of the functional units; 
         FIG. 4  shows an individual representation of a transport unit and a cutting device of the crimping machine according to  FIGS. 1 to 3 ; 
         FIG. 5  shows a view of the unit according to  FIG. 4  when viewed from above; 
         FIG. 6  shows a three-dimensional representation of the transport unit comprising a guiding device according to the disclosure; 
         FIG. 7  shows the guiding device from  FIG. 6  when viewed from below; and 
         FIG. 8  shows a representation of the crimping machine with the housing being opened. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  illustrates a three-dimensional view of a crimping machine  1  by which five different wire ferrules or other contact elements and corresponding cable cross-sections can be processed. Each of the wire ferrules  2  is provided as a webbing. In the shown example, the webbings are wound onto five drum magazines  4   a ,  4   b ,  4   c ,  4   d  and  4   e  which are rotatably supported on a housing  8  of the crimping machine  1  via a magazine holder  6 . Each webbing including the wire ferrules  2  then is wound off the drum magazine  4  via a respective transport unit, wherein the transport units are combined into a transport module  10  mounted on the housing  8 . 
     At the housing front, visible in  FIG. 1 , there is arranged a display  12 , for example in the form of a touch display, so that appropriate entries for selecting the cable cross-section or the like can be made. 
     Approximately in the middle of the shown front side, a centering and guiding device  14  is provided which bulges inwardly in about funnel shape and via which the cable ends  16  to be processed can be supplied. As stated in the foregoing, five different cable cross-sections can be processed by the shown crimping machine  1 . As a matter of course, the crimping machine  1  can also be designed for processing more or fewer cable cross-sections and a corresponding number of wire ferrules. 
       FIG. 2  illustrates a rear view of the crimping machine  1  according to  FIG. 1 . This representation shows the five drum magazines  4   a ,  4   b ,  4   c ,  4   d ,  4   e , wherein the webbings are not shown. The latter then run from the drum magazines  4   a ,  4   b ,  4   c ,  4   d  and  4   e  into the transport module  10  which is mounted on the housing  8 . The described crimping machine  1  is operated by compressed air. An appropriate compressed air supply  18  is arranged on the rear side shown in  FIG. 2 . On the rear side of the housing  8 , an electrical connection  20  having an ON/OFF switch as well as further sockets/terminals for signal transmission and, respectively, energy supply are additionally provided. 
       FIG. 3  illustrates the crimping machine according to  FIGS. 1 and 2  when the housing  8  is partly opened, wherein this representation shows merely in the housing interior a guiding device  22  via which a wire ferrule to be processed is guided toward a crimping head not shown and a stripper unit as well as the related functional elements, for example sleeve holding pliers and conductor holding pliers not shown to simplify matters. The basic structure of these elements is known—as explained in the beginning—from the cited state of the art. 
       FIG. 4  shows an individual representation of the transport module  19  which is provided, in the representations according to  FIGS. 1 to 3 , with an enclosure—the enclosure is omitted in the representation according to  FIG. 4 . A cutting device  24  via which a wire ferrule  2  to be processed can be separated from the respective webbing is assigned to the transport module  10 . As previously described, the transport module  10  includes five transport units  26   a ,  26   b ,  26   c ,  26   d ,  26   e  whose basic structure is known per se. In this respect, the patent DE 44 40 835 C1 to applicant (FIGS. 10a, 10b) is referred to. Such transport unit  26  consequently has a pneumatically actuated transport pawl  28   a ,  28   b ,  28   c ,  28   d  and  28   e  biased into a home position which engages, by a transport projection, in the area between two wire ferrules  2  adjacent on the webbing and, by appropriate control, displaces the wire ferrules in the transport direction (see arrow T), wherein each stroke corresponds to the diameter of a wire ferrule. During the transport, the respective webbing is guided in a guiding groove whose geometry is adapted to that of the webbing. The transport pawl  28  acts upon the respective plastic sleeves of the wire ferrules. In the representation according to  FIG. 4 , the opening areas of the afore-mentioned guides  30   a ,  30   b ,  30   c ,  30   d  and  30   e  are shown, wherein the plastic collars of the wire ferrules are guided in the pawl-side area of the guides  30   a ,  30   b ,  30   c ,  30   d  and  30   e  at the top in  FIG. 4  and, correspondingly, the actual metal sleeves of the wire ferrules are guided in the constricted area. Corresponding to the cable cross-sections to be processed, also the inside diameter of each of the respective guides  30   a ,  30   b ,  30   c ,  30   d  and  30   e  is designed to be different. In the representation according to  FIG. 4 , the size of the wire ferrules to be processed is reduced from the right to the left. 
     The transport units  26   a ,  26   b ,  26   c ,  26   d  and  26   e  can be individually controlled so that, in accordance with the pre-selected cable cross-section, only the related transport unit  26  is actuated. 
     The wire ferrule  2  displaced into the opening area shown in  FIG. 4  due to a stroke of the transport unit  26  then is separated from the webbing by means of the cutting device  24 . In the shown example, the cutting device  24  is configured to have five sleeve separating blades  32   a ,  32   b ,  32   c ,  32   d ,  32   e  which are fastened to a joint cutting bar  34  which can be operated by means of a pneumatic cylinder  35 . The pneumatic cylinder  35  extends for separating the wire ferrule  2  so that the cutting bar  34  including the sleeve separating blades  32  moves upwards in the representation according to  FIG. 4  and separates the front wire ferrule. In so doing, all of the five sleeve separating blades  32  are simultaneously operated—but as just one wire ferrule is located in the operating area, the other four sleeve separating blades so-to-speak perform an idle stroke without any cutting engagement. 
     The representation according to  FIG. 4  further shows by the reference numerals  36   a ,  36   b ,  36   c ,  36   d  and  36   e  pneumatic cylinders for operating the transport unit  26 , more exactly speaking the transport pawls  28 . The pneumatic cylinders  36  are double-acting cylinders that are controlled via a related pneumatic valve. 
       FIG. 5  illustrates a top view onto the transport module  10 , wherein a cover  38  indicated in  FIG. 4  is not shown. In this view, five guiding plates  40   a ,  40   b ,  40   c ,  40   d  and  40   e  of the transport units  26  with the associated transport pawls  28   a ,  28   b ,  28   c ,  28   d  and  28   e  and the related bearing as well as including tension springs  42   a ,  42   b ,  42   c ,  42   d  and  42   e  via which the transport pawls  28   a ,  28   b ,  28   c ,  28   d  and  28   e  are biased to their engaging position are visible. Also visible in this representation are pivot-mounted pawls  44   a ,  44   b ,  44   c ,  44   d  and  44   e  which are operatively engaged in the respective webbing during transport so as to hold or guide the webbing in the predetermined transport position. 
     At the bottom of  FIG. 5 , the cutting device  24  including the pneumatic cylinder  35  as well as the cutting bar  34  and the sleeve separating blades  32   a ,  32   b ,  32   c ,  32   d  and  32   e  is evident. The wire ferrule  2  separated by operation of the cutting device  34  then falls downwards in the direction of gravity into the guiding device  22  already shown in  FIG. 3 . The guiding device  22  is orientated in the direction of gravity so that the separated wire ferrule  2  is conveyed by gravity. 
     In the representation according to  FIG. 6 , the guiding device  22  has an approximately funnel-shaped structure tapering away from the transport module  10 . Each of the guides  30   a ,  30   b ,  30   c ,  30   d  and  30   e  shown in  FIG. 4  opens into an input  46   a ,  46   b ,  46   c ,  46   d  and  46   e  whose cross-section is selected such that the wire ferrules  2  may enter into the guiding device  22  with minimum friction. Each of the inputs  46  then opens into a respective channel  48   a ,  48   b ,  48   c ,  48   d  and  48   e , which channels are downwardly convergent and merge in an output  50 . The central channel  48   c  extends in the direction of gravity directly from the related input  46   c  to the output  50 . The two adjacent channels  48   b  and  48   d  in the central area converge into the channel  48   c . The two outer channels  48   a  and  48   e  open, in the area of the output  50 , into the central channel  48   c . In other words, the channels  48  are meandering, when viewed from the output  50 , toward the inputs  46 , with the geometry being optimized with regard to the minimum friction during transport/falling of the wire ferrules  2 . 
     For supporting the transport movement, a compressed air channel  52   a ,  52   b ,  52   d ,  52   c  opens into each of the curved outer channels  48   a ,  48   b ,  48   d ,  48   e , via which compressed air channels a compressed air jet can be introduced, upon controlling a respective compressed air valve, for supporting the transport movement, with the control being carried out, as a matter of course, such that the wire ferrules are accelerated in the transport direction. For the central channel  48   c  this is not necessary as this channel has no deflection. In the end area of the funnel-shaped guiding device  22  a light barrier  55  indicated in  FIG. 6  is located for monitoring the falling of the wire ferrule  2  and transmitting a corresponding control signal to the control unit. 
       FIG. 7  illustrates the guiding device  22  including the afore-mentioned inputs  46   a ,  46   b ,  46   c ,  46   d  and  46   e , the joint output  50  and the related channels  48   a ,  48   b ,  48   c ,  48   d  and  48   e  in a different view, wherein a cover plate  54  transparently shown in  FIG. 6  is not shown. In the representation according to  FIG. 7 , the opening areas of the outer channels  48   a ,  48   b ,  48   d  and  48   e  into the central channel  48   c  orientated in the direction of gravity and the opening areas of the compressed air channels  52   a ,  52   b ,  52   d ,  52   e  into the respective assigned channels are clearly evident. 
       FIG. 8  illustrates a partial view of the crimping machine  1  with the housing  8  being opened so that some of the described functional elements are visible. Evident at the top is the transport module  10  including the integrated cutting device  34 . The funnel-shaped guiding device  22  orientated in the direction of gravity which in this view is covered by the cover plate  54  is connected to the transport module  10 . 
     The output  50  of the guiding device  22  opens into a guiding plate  56  also indicated in  FIG. 3 . Along this guiding plate  56 , supported by the compressed air jet, the separated singled wire ferrule  2  is guided toward sleeve holding pliers  58  which in turn are supported on a swivel plate. The sleeve holding pliers  58  take over the isolated wire ferrule  2 . 
     In parallel to the singling and to the transport of the wire ferrule  2  toward the input  46 , the insulation of the cable end is cut in via a stripping unit  60  guided on an adjustable tool carriage  62 . 
     After a fallen wire ferrule  2  has been reported via the light barrier  55 , the tool carriage  62  is moved backward. By this movement the insulation is removed from the cable end. A swivel plate pivot-mounted on the tool carriage  62  moves the sleeve holding pliers  58  and thus the separated wire ferrule  2  into a position in which the cable end and the wire ferrule  2  are arranged coaxially to each other. In a following step, the tool carriage  62  moves forward so that the wire ferrule is pushed onto the stripped cable end held by conductor holding pliers. In a subsequent working cycle, the wire ferrule is crimped to the cable end via a crimping head and the conductor holding pliers are opened so that the wire ferrule and the cable end crimped thereto can be removed. 
     If a different cross-section is to be processed, a corresponding entry is made on the touch display  12 . Then the same afore-described working cycle is run, wherein, depending on the entry, a different transport unit  26  is driven via the corresponding pneumatic valve and the assigned pneumatic cylinder. 
     In the shown example, the crimping machine  1  is designed for processing wire ferrules for wire cross-sections of 0.5 mm 2 , 0.75 mm 2 , 1.0 mm 2 , 1.5 mm 2  and 2.5 mm 2 ; as a matter of course, the machine can also be designed for processing other cross-sections. 
     Disclosed is, a crimping machine comprising a conveying device via which a separated wire ferrule is guided from a transport unit toward a crimping head. 
     LIST OF REFERENCE NUMERALS 
     
         
           1  crimping machine 
           2  wire ferrule 
           4  drum magazine 
           6  magazine holder 
           8  housing 
           10  transport module 
           12  display 
           14  centering/feeding device 
           16  cable end 
           18  compressed air supply 
           20  electrical connection 
           22  guiding device 
           24  cutting device 
           26  transport unit 
           28  transport pawl 
           30  guide 
           32  sleeve separating blade 
           34  cutting bar 
           35  pneumatic cylinder 
           36  cylinder 
           38  cover 
           40  guiding plate 
           42  tension spring 
           44  pawl 
           46  input 
           48  channel 
           50  output 
           52  compressed air channel 
           54  cover plate 
           55  light barrier 
           56  guiding plate 
           58  sleeve holding pliers 
           60  stripping unit 
           62  tool carriage