Patent Description:
Cable processing apparatuses comprising a crimping device loadable with crimp cassettes are known in the art. A crimp cassette comprises part of a crimping tool, as well as a magazine (a reel) of crimp contacts or the like. The crimping tool part as a component of a crimp cassette can be arranged, typically automatically arranged, on the crimping device of the cable processing apparatus. Some crimping tools for crimping devices are divided, i. they have a stationary tool part and a movable tool part. The stationary and movable tool parts are configured to act together in a crimping operation of the crimping device.

The tool parts of a divided crimping tool can become misaligned, e. during a tool exchange operation. There is a desire to counteract such a misalignment which causes incorrect and/or unreliable crimps.

Document <CIT> describes a crimping machine for different crimping and pressing processes having a crimping station that comprises a crimping tool. The crimping tool is formed in two parts.

Document <CIT> describes a crimping press having a cassette that can be inserted from the rear of the press.

It is an object of the present disclosure to provide a method of aligning a crimp cassette in a cable processing apparatus having a crimping device loadable with the crimp cassette where positioning or alignment of the cassette inside the crimping device, as well as an alignment of the tools parts of a divided crimping tool, are improved.

In view of the above, a method according to claim <NUM> is provided.

Further aspects, advantages, and features of the present disclosure are apparent from the dependent claims, the description, and the accompanying drawings. The aspects discussed below may be freely combined with each other, as appropriate.

According to one aspect of the disclosure, a crimping cassette for a crimping device of a cable processing apparatus has a crimping tool having a stationary tool part and a movable tool part, wherein the stationary and movable tool parts are configured to act together in a crimping operation of the crimping device. The crimping cassette further comprises a holding device for attaching to a mounting part, the mounting part being directly or indirectly fixed to the stationary tool part. The holding device has a position for allowing an adjustment movement of the stationary tool part within a spatially limited adjustment range. The holding device may comprise at least two claws for attaching to the mounting part in a mounting area of the claws. The position for allowing the adjustment movement of the stationary tool part within the spatially limited adjustment range may be referred to as an unlocked closed position, and the claws may loosely grip the mounting part in the unlocked closed position. The holding device may further have a locked closed position in which the claws are firmly clamped to the mounting part, and an open position in which the claws release the mounting part such that the stationary tool part is separable from the holding device.

In the locked position, the claws are firmly clamped to the mounting part of the mounting part. When in the unlocked closed position, the mounting part is not yet released in a manner which would allow a complete detachment of the stationary tool part. However, an adjustment of the stationary tool part relative to the movable tool part in a limited adjustment range is possible in the unlocked closed position. Hence, the movable and stationary tool parts are easily aligned relative to each other.

The adjustment range, typically in a plane which is perpendicular to a crimping operation movement of the movable tool part relative to the stationary tool part, is limited to a range which is sufficient for performing an efficient alignment operation, e. within a range, in the two directions of the plane, of less than <NUM> or less than <NUM>.

In the open position, the claws release the mounting part and allow the stationary tool part to be separated from the holding device. This allows for an easy exchange of the crimping cassette in a cable processing apparatus or by hand.

The cable processing apparatus further comprises a tensioning device for the mounting part adapted to apply a tensioning force to the mounting part relative to an attachment surface provided on the crimping device. Thereby, a reliable and tight fixation is possible.

According to the method of aligning a crimping tool of a crimping cassette in the cable processing apparatus (aligning method or alignment method), the method comprises releasing the tensioning device; inserting the stationary tool part of the crimping tool into a tensioning area of the tensioning device; moving the moveable tool part towards the stationary tool part slightly before the moveable tool part touches the stationary tool part; moving the moveable tool part towards the stationary tool part until a pressing force between the moveable tool part and the stationary tool part is reached or exceeded, such that an alignment within the adjustment range takes place between the moveable tool part and the stationary tool part; and applying a tension with the tensioning device.

The method may comprise - before releasing the tensioning device - bringing the holding device in the unlocked closed position; and - before moving the moveable tool part towards the stationary tool part until a pressing force between the moveable tool part and the stationary tool part is reached or exceeded, such that an alignment within the adjustment range takes place between the moveable tool part and the stationary tool part - bringing the holding device into the open position. The method may further comprise - as a final step - bringing the holding device into the locked closed position.

According to certain aspects of the embodiment, the attachment surface is provided with at least one supporting element, typically supporting roller, adapted to lower a friction between the mounting part and the attachment surface. Thereby, a movement of the mounting part on the attachment surface, prior to tightening and/or after releasing, is facilitated.

In embodiments, a closing spring is provided and arranged such as to close the gripping of the claws in the unlocked closed position. In other words: The closing spring acts on the claws to keep a sufficient clamping force, in the unlocked closed position, to prevent a premature release of the stationary tool part from the holding device, yet allowing for an efficient alignment operation.

In embodiments, the crimping tool is configured to perform a tool part alignment operation in which, when the holding device is in the unlocked closed position, the movable tool part is moved towards the stationary tool part, typically to a greater extent than when performing a crimping operation, such as to mechanically shift the stationary tool part within the spatially limited adjustment range.

Corresponding shapes of the surfaces of the movable and stationary tool parts which are involved in such an alignment operation may be beneficially shaped to ensure a reliable alignment. Hence, the movable tool part and the stationary tool part may each comprise an alignment face, wherein the alignment faces are shaped such as to interact in the tool part alignment operation to self-align the stationary tool part relative to the movable tool part.

In embodiments, the holding device further comprises a mandrel. The mandrel has a back face shaped such that when it is pushed against a corresponding face of the claws, the claws are tightened, in the mounting area, to the mounting part; and a front face shaped such that when it is pushed against a corresponding face of the claws, the claws are spread.

The mandrel is moveable into an idle state in which none of the back face or the front face pushes against the claws to facilitate a tool part alignment operation in the unlocked closed position of the holding device. Hence, in the idle state, the mandrel does not hinder an aligning movement of the stationary tool part relative to the movable tool part.

In embodiments, the crimping cassette further comprises an operating device adapted to operate the holding device at least between the locked closed position and the unlocked closed position.

The operating device may comprise an unlocking push button and an unlocking lever coupled to each other. A linear movement of the unlocking push button may be transformed, via the unlocking lever, into a linear movement of the mandrel into the idle state. Then, an alignment operation is easily possible.

In embodiments, the crimping tool further comprises a coupling device for releaseably coupling the movable tool part with the stationary tool part. The coupling device may be fixed to the movable tool part. The coupling device may comprise a conical end face which is adapted to be engaged with a corresponding conical bore provided on the stationary tool part.

In embodiments relating to the cable processing apparatus, the cable processing apparatus further comprises a locking device for releaseably locking a loaded crimping cassette. The locking device is configured to operate the operating device of the crimping cassette.

In embodiments, the cable processing apparatus further comprises a mounting device configured to mount the moveable tool part of the crimping tool of a loaded crimping cassette.

In embodiments, the mounting device comprises a gripper which is configured and arranged to be moveable according to a gripping trajectory to grip a gripping counterpart of the moveable tool part, the gripping trajectory comprising, in a movement of the gripper to grip the gripping counterpart, a linear trajectory and a subsequent pivoting trajectory.

With a succession of a linear trajectory and a pivoting trajectory, an automated fixation and alignment operation of the tool parts relative to each other is further facilitated.

In embodiments, the gripper is arranged and shaped such as to be moved according the gripping trajectory upon applying a force to an operating face of the gripper. The force has a constant direction throughout the movement of the gripper according to the gripping trajectory. According to a further aspect, the cable processing apparatus further comprises an actuator, typically a pneumatic cylinder, to open the gripper, and a spring arrangement to close the gripper.

Thereby, with a simple linear arrangement of actuators and/or spring elements, a reliable gripping operation, involving an advanced trajectory, is possible by acting on a single face of the gripper.

In embodiments, the cable processing apparatus further comprises a lifting device adapted to lift the moveable tool part towards the mounting device. However, according to an alternative embodiment, the mounting device itself may be moveable towards the moveable tool part.

In embodiments, the cable processing apparatus further comprises a pressure detector arranged to detect a pressing force between the movable tool part and the stationary tool part, and a stroke limiting device connected to the pressure detector, wherein the stroke limiting device is adapted to limit a stroke of the movable tool part relative to the stationary tool part upon detection of a pressing force which exceeds a predetermined maximum pressing force.

According to an aspect of the disclosure, prior to the alignment method above, a loading method of the crimping cassette in the cable processing apparatus according may be performed. The loading method comprises moving the locking device towards the crimping cassette to be loaded; operating the operating device to bring the holding device into the unlocked closed position; attaching the crimping cassette to the locking device; releasing the moveable tool part from the stationary tool part; moving the moveable tool part relative to the mounting device such as to approach the moveable tool and the mounting device; and gripping the gripping counterpart of the moveable tool part.

With the aspects and embodiments described herein, a crimping device such as a crimping press may perform any or all of the functions of lateral insertion of a crimping cassette with an intermediate position; opening a coupling device between the movable and stationary tool parts; taking over and holding the movable tool part, e. on a slide of the crimping device; opening the holding device in two stages (the unlocked closed position and the open position), and taking over the stationary tool part into the crimping device; aligning the tool parts, optionally by moving the tool parts together; and clamping the stationary tool part on the crimping device.

The subject matter of the disclosure will be explained in more detail with reference to preferred exemplary embodiments which are illustrated in the accompanying drawings. In the drawings, like reference numerals are assigned to like or corresponding parts.

<FIG> is a perspective view of a crimping cassette <NUM> and a crimping device <NUM> of a cable processing apparatus used in an embodiment of the present disclosure.

The crimping device comprises a mounting device <NUM> and a lifting device. In <FIG>, the mounting device <NUM> is configured as a press slide, and the lifting device is configured as a lifting fork <NUM>. A locking device <NUM> is provided on the crimping device for releasably locking a loaded crimping cassette <NUM>, as described in more detail below.

In <FIG> which is a close-up view of <FIG>, a holding device of the crimping cassette <NUM> is shown in more detail. The holding device comprises a bracket having two claws 21a, 21b which are normally pushed together, via a spring to be described further below, into a clamping position or locked position. An unlocking push button <NUM> is coupled to an unlocking lever <NUM> to release the claws 21a, 21b and described in more detail below.

A crimping tool assembly comprises a base plate <NUM> on which a stationary crimp tool part <NUM> is fixed. The claws 21a, 21b clamp the base plate <NUM>. Furthermore, the crimping tool assembly comprises a coupling <NUM> which is configured such that a movable crimping tool part can be releasably coupled to the stationary crimp tool part. The crimp tool parts <NUM>, comprise a crimp anvil and a crimp indentor, respectively (see also <FIG>). In order to protect the sensitive crimp anvil 32a and crimp indentor 33a, the stationary and movable tool parts are shifted in a lateral direction.

<FIG> shows a schematic side view of the holding device. Corresponding schematic top views of the holding device in a locked position, in an unlocked closed position, and in an open position are respectively shown in <FIG>.

In the locked position and in the unlocked closed position, the claws 21a, 21b are pushed into a clamping or closed state by a closing spring <NUM>. In the locked position (<FIG>), the claws 21a, 21b are firmly clamped to a mounting part of the base plate. In the unlocked closed position (<FIG>), the claws 21a, 21b loosely grip the mounting part for allowing an adjustment movement of the stationary tool part within a spatially limited adjustment range. In the open position (<FIG>), the claws 21a, 21b are released from the mounting part.

In order to supplement the behavior in the respective positions, a mandrel <NUM> is provided at the holding device. Upon operation of the unlocking push button <NUM>, the unlocking lever <NUM> is pivoted and moves the mandrel <NUM> linearly. A back face 23a of the mandrel <NUM> is shaped such that when it is pushed against a corresponding face of the claws 21a, 21b, the claws 21a, 21b are tightened to the mounting part. A front surface 23b of the mandrel <NUM> is shaped such that when it is pushed against a corresponding face of the claws 21a, 21b, the claws 21a, 21b are spread open. In the shown example, the mandrel <NUM> pushes against rollers <NUM>, which in turn spread the claws 21a, 21b.

In an idle state in the unlocked closed position (<FIG>), the mandrel substantially does not touch any of the faces on the claws 21a, 21b, thus allowing a limited spatial aligning movement of the tool parts.

In the perspective view of <FIG>, the locking device is shown. The locking device comprises, in addition to parts for attaching to the crimping cassette <NUM>, elements for unlocking and opening the claws. A lever <NUM> is passively pivoted by a pulling force of a spring <NUM> at a time where the locking device is moved out as a whole (<FIG>). Independent from the operation of the lever <NUM>, an opening lever <NUM> may be actuated by a pneumatic cylinder <NUM> (<FIG>).

Both the lever <NUM> and the opening lever <NUM> act on the unlocking push button <NUM> of the holding device. The unlocking push button <NUM> is then flush with the housing of the crimping cassette <NUM> and cannot be pushed in to such an extent that the claws 21a, 21b are opened entirely.

<FIG> is a perspective view of a coupling device <NUM> arranged at the crimping device. In <FIG>, the coupling device <NUM> is fixed at the movable tool part and comprises a conical end face which is adapted to be engaged with a corresponding conical bore provided on the stationary tool part. A latch bolt <NUM> is provided which is pushed sidewards when the end face of the coupling device <NUM> is inserted into the bore. The latch bolt <NUM> is then reset into its initial position by a spring (not shown) and fixes the end face of the coupling device <NUM>.

In <FIG>, the mounting device <NUM> comprises a gripper <NUM> which is pivotable around a rotation axis 53a. A pulling rod <NUM> can be actuated by a pneumatic cylinder (not shown) which pushes the pulling rod <NUM>, which in turn moves a yoke <NUM> at which the pulling rod <NUM> and the gripper <NUM> are fixed, into the downwards direction. Upon release of the pneumatic cylinder, this movement is counteracted by a push spring which pulls up the gripper <NUM> into an upper position.

The gripper <NUM> is inserted into the yoke <NUM> and has contact parts with two elements. The rotation axis 53a is one of the elements, and the rotation axis 53a allows for a rotational movement of the gripper <NUM>. A bolt 53b, as the other one of the elements, is another contact element of the gripper <NUM>.

Two mounting pieces each comprising a push spring and a spring holder are provided on each lateral sides of the rotation axis 53a. The mounting pieces are held within a groove on the mounting device <NUM> and allow for a slight linear movement of the gripper. A trajectory outline <NUM> is provided as an auxiliary measure to make sure that the gripper performs a linear movement in the first place. Under normal conditions, the gripper is not in contact with the trajectory outline <NUM>; however, in the exemplary case that an irregular movement occurs which would lead to a rotary or pivoting movement of the gripper, the gripper is guided along the trajectory outline <NUM>.

When the pneumatic cylinder (not shown) is in its retracted position, the spring pulls the yoke <NUM> into the uppermost position (<FIG>). The shape of the trajectory outline <NUM> prevents a pivoting movement of the gripper <NUM>.

Upon moving the pneumatic cylinder outwardly, the yoke <NUM> is moved down. In a first stage, the mounting pieces make the gripper <NUM> move linearly downward (<FIG>). At the end of the first stage, the linear movement is limited by the grooves <NUM>. Since the rotation axis 53a is fixed, the gripper <NUM> moves, along the trajectory outline <NUM>, in a pivotal manner (<FIG>).

A gripping operation of the movable crimp tool part by the gripper is shown in an illustrative manner in <FIG>.

<FIG> show a crimping press during alignment of the movable and stationary tool parts. The base plate <NUM> is provided with pressure sensors 40a, 40b. In the shown example, a third pressure sensor is provided but not shown in <FIG>. The disclosure is not limited to a particular amount of pressure sensors 40a, 40b, and in general, one, two, three, or more pressure sensors 40a, 40b can be provided, dependent on the constructive measures and/or a desired accuracy. The pressure sensors 40a, 40b help to detect when the crimp anvil and the crimp indentor touch each other and prevent an excessive pressure from being exerted to the crimp anvil and the crimp indentor.

On an attachment surface <NUM> of the base plate <NUM>, supporting rollers <NUM> are provided to lower a friction between a mounting part and the attachment surface <NUM>. In the shown example, the mounting part comprises a clamping element <NUM> and mounting cylinders <NUM>. The supporting rollers <NUM> are optional parts and may be omitted; in particular, when using crimping contacts having a certain minimum size, the alignment may be performed without supporting rollers <NUM>.

In an unloaded state, the supporting rollers <NUM> protrude slightly from the attachment surface <NUM> in the shown example. A spring mechanism (not shown) bears the supporting rollers <NUM> such that each of the supporting rollers <NUM> may be pressed downwards by a load acting thereon, i. to be at least flush with the plane of the attachment surface <NUM> in the case of a sufficient load. Thereby, the stationary tool part rests entirely on the attachment surface <NUM> and is virtually unaffected by the supporting rollers <NUM>.

For performing an alignment operation, the clamping element <NUM> is loosened, then the stationary tool part is inserted. Then, the movable tool part is lowered, and the alignment surfaces of the crimp anvil and the crimp indentor touch each other. This operation is monitored using the pressure sensors 40a, 40b. Depending on the applied forces, the optional supporting rollers <NUM> are pushed downwards, to make the stationary tool part rest entirely on the attachment surface <NUM>. After the alignment is performed, the clamping element <NUM> is tightened.

<FIG> show different stages of a loading operation of the crimping cassette <NUM> in a crimping device of a cable processing apparatus.

In <FIG>, the cassette <NUM> is in an initial position. In <FIG>, the locking device of the crimping device moves outward, and the gripper <NUM> is opened. If present, the lifting fork <NUM> is lowered.

In <FIG>, the cassette <NUM> is moved to the right, and the unlocking push button <NUM> is operated. The stationary tool part can be aligned relative using the mounting cylinders <NUM>. In the shown example, the alignment is performed by an aligning movement of a slit in the base plate <NUM> relative to a periphery of the mounting cylinder <NUM> and, in addition, relative to a periphery of the mounting cylinder below the clamping element <NUM> (cf.

In <FIG>, the movable tool part has been moved to the mounting device <NUM>, and the cassette is moved further to the right. The coupling is open since the latch bolt <NUM> has been operated by an abutment <NUM>.

In <FIG>, the movable tool part is gripped by the gripper <NUM>. Thereafter, the moveable tool part is lifted, through the lifting fork <NUM>, to the mounting device <NUM>. In an alternative embodiment without a lifting fork <NUM>, the mounting device <NUM> is lowered towards the moveable tool part. In either case, the movable tool part is moved relative to the mounting device <NUM>, such that the movable tool part and the mounting device <NUM> approach each other.

Subsequently, the locking device is moved inwards, the cassette <NUM> is further moved to the right and clamped, and the movable tool part is lowered (<FIG>). Then the claws 21a, 21b are opened by pivoting the opening lever (<FIG>), whereby the stationary tool part is released.

Subsequently, the above-described alignment process may be performed.

Claim 1:
A method of aligning a crimping tool of a crimping cassette in a cable processing apparatus,
wherein the crimping cassette (<NUM>) comprises a crimping tool having a stationary tool part and a movable tool part, wherein the crimping cassette (<NUM>) further comprises a holding device having at least two claws (21a, 21b) for attaching to a mounting part in a mounting area of the claws (21a, 21b), the mounting part being directly or indirectly fixed to the stationary tool part, wherein the holding device has:
a locked closed position in which the claws (21a, 21b) are firmly clamped to the mounting part;
an unlocked closed position in which the claws (21a, 21b) loosely grip the mounting part for allowing an adjustment movement of the stationary tool part within a spatially limited adjustment range;
an open position in which the claws (21a, 21b) release the mounting part such that the stationary tool part is separable from the holding device,
wherein the cable processing apparatus comprises a tensioning device for the mounting part adapted to apply a tensioning force to the mounting part relative to an attachment surface provided on the crimping device,
wherein the stationary and movable tool parts of the crimping cassette (<NUM>) are configured to act together in a crimping operation of the crimping device of the cable processing apparatus,
wherein the method comprises:
Bringing the holding device into the unlocked closed position;
Releasing the tensioning device;
Inserting the stationary tool part of the crimping tool into a tensioning area of the tensioning device;
Moving the moveable tool part towards the stationary tool part slightly before the moveable tool part touches the stationary tool part;
Bringing the holding device into the open position;
Moving the moveable tool part towards the stationary tool part until a pressing force between the moveable tool part and the stationary tool part is reached or exceeded, such that an alignment within the adjustment range takes place between the moveable tool part and the stationary tool part;
Applying a tension with the tensioning device.