Robust crimps

Robust design optimization of crimp connections at TE Connectivity

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The automated Optimus robust design optimization process is suitable for complex barrel development. Optimus contains all necessary functions to automatically execute Taguchi methods from start to end, considerably saving development time and cost. Mr. Kazushige Sakamaki of Tyco Electronics Japan G.K., a TE Connectivity company

Development teams at TE Connectivity (TE) in Japan (formerly known as Tyco Electronics) engineer B-type barrel designs to further enhance the gastight solder-free connection between barrel and stranded wire. The electrical and mechanical connection characteristics are tested and simulated to accurately model the barrel design.

An automated process for barrel design simulation

TE engineers use Optimus software to coordinate and automate crimp and tensile analyses in search of optimized design variants combining highest crimp connection quality and robustness. Optimus automatically drives the execution of ANSYS Workbench and LS-DYNA when performing design of experiments (DOE) and design optimization studies.

Automated execution of the Taguchi robust design optimization process, enabling faster turnaround.

The automated simulation process enables TE engineers to identify robust optimum barrel design variants and speed up the development cycle. The TE development team applied the L81 Taguchi design table to generate the signal/noise (SN) ratio values for each design variable, and have them displayed in Optimus column effect plots for easy interpretation.

“Using these plots, we decided on the combination of design parameters that enable them to most effectively increase barrel design robustness,” Sakamaki explains.

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