Optimization of Mechanical Crimping in the Terminal Crimping Process Using a Response Surface Methodology

Jongwuttanaruk, Kaona; Thavornwat, Chalermsak

doi:10.1155/2022/6508289

Cited by 7 publications

(5 citation statements)

References 26 publications

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“…Response surface methodology (RSM) is a test design method proposed by Box et al It is an optimization method that integrates test design and mathematical modeling [22][23][24][25][26][27]. By performing tests on representative local points, the functional relationship between factors and results in the global scope is regressed and fitted, and the optimal level value of each element is obtained.…”

Section: Response Surface Methodology and Its Application In Dance He...mentioning

confidence: 99%

“…In recent years, the progress of computer and information technology [18][19][20][21][22][23] has also provided a powerful tool for the dance health and training safety analysis of this study. In order to promote the safety of dance teaching and competition, this study adopts response surface methodology [22] to study the accidental injuries and characteristics in dance teaching and competition, analyzes the causes, and puts forward corresponding safety precautions to reduce the incidence of injuries in safety measures.…”

Section: Introductionmentioning

confidence: 99%

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Application of Response Surface Methodology in Dance Health and Training Safety

Zhang

2022

Mathematical Problems in Engineering

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In order to analyze and optimize the influencing factors of dance health and training safety, response surface methodology is applied to dance health and training safety in this study. Response surface methodology is an optimization method that integrates experimental design and mathematical modeling. It can effectively reduce the number of experiments, provide visual contour maps and three-dimensional diagrams, and investigate the interaction between influencing factors. This paper introduces the basic definition, model construction principle, and characteristics of the response surface method and expounds the test scheme design, model establishment, model inspection, model optimization, and other aspects of the response surface method combined with an example of analysis of influencing factors of dance health and training safety. The results show that the response surface method is an optimization method of comprehensive experiment design and mathematical modeling, which can effectively reduce the number of experiments for the analysis of influencing factors of dance health and training safety and can investigate the interaction between influencing factors.

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Section: Response Surface Methodology and Its Application In Dance He...mentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Application of Response Surface Methodology in Dance Health and Training Safety

Zhang

2022

Mathematical Problems in Engineering

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“…However, the tool utilized applies non-uniform pressure to the surface of the terminal during crimping, so crimped terminals often have many defects. Moreover, this tool is controlled by a worker, so achieving uniform-quality crimped terminals is very difficult [2][3][4].…”

Section: Introductionmentioning

confidence: 99%

“…For these reasons, the determination of a proper process for achieving high-quality crimped terminals has been intensively studied. Jongwuttanaruk and Thavornwat [3] used response surface methodology optimization of the mechanical crimping process to solve the problem wherein loose wire strands are present. Optimal crimping conditions for the terminal 064 series, which has open wings with cores exposed, were selected; in terms of tensile mechanical properties, a pull-out force of more than 0.07 kN was achieved.…”

Section: Introductionmentioning

confidence: 99%

Selection of Magnetic Pulse Crimping Process Conditions to Improve Crimped Terminal Quality

Kim,

Shim

2023

Metals

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The crimping of copper terminals via hand-operated and hydraulic compressors is used to generate a compressive force between a terminal and a wire, generally on a worksite. However, this equipment often causes compression defects because non-uniform pressure is applied to the terminal surface in the radial direction during crimping. When the crimped terminal is connected to electrical parts such as the power transmission system, a low-quality crimped terminal can separate from the wire strands, increasing resistance to current flow through the terminal, energy loss, and the risk of fire due to overheating. For this reason, Magnetic Pulse Crimping (MPC), which can yield highly durable crimped terminals with uniform quality, has recently been developed. This process uses only the magnetic force generated by high electromagnetic interaction between the crimping coil part and the surface of the terminal, without physical contact. The objective of this research was to confirm the superiority of the MPC process over the conventional crimping process and then analyze the effects of the main process parameters, including the crimping length and the charge energy on the crimping part, so that this new process can be applied at worksites. To realize these goals, copper terminals and 35 mm2 copper wire strands were employed, and various types of crimping parts were manufactured under different crimping conditions. In particular, the distribution of electromagnetic force on the crimped parts were analyzed via numerical analysis. The crimping part performance was improved when the MPC process was applied to terminal crimping. In particular, decreasing the crimping length led to increased crimping quality, while increasing the charge energy caused increases in the compression ratio and pullout strength. However, excessively high charge energy caused the edge to break the wire strands; therefore, it is important to select the proper charge energy.

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“…Recently, Jongwuttanaruk et al [ 15 ] reported on the use of response surface methodology to optimize the mechanical crimping process. Yu et al [ 16 ] designed an electromagnetic pulse crimping device, which uses a strong pulsed magnetic field to act on the metal workpiece to produce plastic deformation to complete the joint connection.…”

Section: Introductionmentioning

confidence: 99%

Study on the Application of Modified Sn-Based Solder in Cable Intermediate Joints

Zhang

Luo

et al. 2022

Materials

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With the increasing use of underground cables, the quantity and quality of intermediate joints demanded are also increasing. The quality of the traditional crimping intermediate joint is easily affected by the actual process of the operator, which may lead to the heating of the crimping part of the wire core, affecting the insulation performance of the cable, and finally causing the joint to break. However, aluminothermic reactive technology has some problems, such as a high welding temperature and an uncontrollable reaction. In order to solve these problems, according to the brazing principle and microalloying method, the optimal content of In in Sn-1.5Cu-based solder was explored, and then the connection of the middle joint of a 10 kV cable was completed using a connecting die and electrical connection process. The contact resistance and tensile strength of the joint were tested to verify the feasibility of this method. The results show that the maximum conductivity of the solder with 3.8% and 5% In content can reach 3.236 × 106 S/m, and the highest wettability is 93.6%. Finally, the minimum contact resistance of the intermediate joint is 7.05 μΩ, which is 43% lower than that of the aluminothermic welded joint, and the tensile strength is close to that of the welded joint, with a maximum of 7174 N.

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Optimization of Mechanical Crimping in the Terminal Crimping Process Using a Response Surface Methodology

Cited by 7 publications

References 26 publications

Application of Response Surface Methodology in Dance Health and Training Safety

Application of Response Surface Methodology in Dance Health and Training Safety

Selection of Magnetic Pulse Crimping Process Conditions to Improve Crimped Terminal Quality

Study on the Application of Modified Sn-Based Solder in Cable Intermediate Joints

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