Method of operating a hydraulic crimping tool to crimp connectors

Abstract

A method for operating a hydraulic crimping tool to crimp a connector, the method comprising: starting a crimping action; starting a motor to increase the hydraulic tool pressure in a hydraulic circuit; moving a piston toward a crimping head; monitoring the hydraulic tool pressure; detecting a threshold pressure when the piston contacts an outer surface of the connector to be crimped; measuring an outer diameter of the connector; determining target crimping information based on the outer diameter of the connector; and increasing the hydraulic tool pressure to move the piston toward the crimping head to complete the crimping action on the connector.

Description

[0001] This application is a divisional application of a patent application with application number 201780074123.1, application date October 2, 2017, and title “Power Tools”.

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS

[0003] This application claims priority to U.S. patent application Ser. No. 15 / 722,765, filed on Oct. 2, 2017, entitled “POWER TOOL,” which claims priority to U.S. provisional patent application Ser. No. 62 / 402,535, filed on Sept. 30, 2016, entitled “POWER TOOL,” which are incorporated herein by reference as if fully set forth in this specification. Technical Field

[0004] The present disclosure generally relates to power tools. More specifically, the present disclosure relates to a dieless power crimping tool that utilizes a linear sensor to track and identify the movement of a punch assembly. The crimping power tool enables a user to apply appropriate crimping pressure and enables precise linear movement of a piston during the crimping process. Background Art

[0005] Hydraulic crimpers and cutters are different types of hydraulic power tools used to perform work (e.g., crimping or cutting) on ​​a workpiece through a work head (such as a crimping head or a cutting head). In such tools, a hydraulic tool including a hydraulic pump is used to pressurize a hydraulic fluid and transfer it to a cylinder in the tool. The cylinder causes an extendable piston or punch assembly to shift toward the work head. In the case where the power tool includes a hydraulic crimper, the piston applies a force on the crimping head of the power tool, which crimping head may typically include opposing crimping dies having certain crimping features. The force applied by the piston can be used to close the crimping die to crimp or compress the workpiece at the desired crimping position.

[0006] Crimping can result in crimping at undesirable crimp locations and can also result in crimping with an inappropriate amount of pressure applied during the crimping process.Therefore, there is a general need for a hydraulic crimping tool that can achieve a more efficient and powerful final crimp. Summary of the invention

[0007] According to one exemplary arrangement, a power tool includes a movable piston, a motor capable of driving the movable piston to perform work on a workpiece, and a distance sensor configured to sense movement of the movable piston. The distance sensor is operable to provide sensor information indicative of movement of the piston. A controller is configured to receive the sensor information. The controller operates the motor to perform work on the workpiece based in part on the sensor information received by the controller from the distance sensor. In one arrangement, the distance sensor is configured to continuously sense movement of the movable piston.

[0008] According to one exemplary arrangement, the distance sensor detects the linear displacement of the movable piston. When the power tool is working on the workpiece, the distance sensor can detect the linear displacement of the movable piston. For example, when the power tool performs a crimping action, the distance sensor can detect the linear displacement of the movable piston.

[0009] According to one exemplary arrangement, the distance sensor detects the linear displacement of the movable piston during the crimping action. In one arrangement, during the crimping action, the distance sensor generates an output signal that is transmitted to the controller. The output signal may represent the distance traveled by the movable piston from a reference position. In one arrangement, the reference position includes a home position of the movable piston. In one arrangement, the reference position includes a retracted position of the movable piston. This retracted position may be a fully or completely retracted position.

[0010] In one arrangement, the output signal indicates the direction of movement of the movable piston. For example, the direction of movement of the piston may include the direction of the movable piston towards the working head of the power tool. In one arrangement, the direction of movement of the movable piston includes the direction of movement away from the working head.

[0011] In one arrangement, the working head of the power tool comprises a crimping head. For example, the crimping head of the power tool may comprise a dieless crimping head. In one arrangement, the working head of the power tool comprises a cutting head.

[0012] In one arrangement, the linear sensor comprises a Hall Effect sensor.For example, the Hall Effect sensor may detect a profile disposed along an outer surface of the movable piston.

[0013] In one arrangement, the power tool further includes a pump and a gear reducer, wherein the electric motor is configured to drive the pump via the gear reducer.

[0014] In one arrangement, the distance sensor is mounted in a cylindrical bushing of the power tool.For example, the cylindrical bushing may be mounted in a frame of the power tool.

[0015] The features, functions, and advantages can be achieved independently in various embodiments of the present disclosure or may be combined in yet other embodiments in which further details can be seen with reference to the following description and drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The novel features believed characteristic of the illustrative embodiments are set forth in the appended claims. However, the illustrative embodiments together with the preferred mode of use, further objects and description thereof will be best understood by reference to the following detailed description of one or more illustrative embodiments of the disclosure when read in conjunction with the accompanying drawings, wherein:

[0017] Figure 1 shows a perspective view of a hydraulic tool according to an exemplary embodiment;

[0018] Figure 2 Shows Figure 1 A block diagram of certain components of the hydraulic tool shown in ;

[0019] Figure 3 Shows Figure 1 Another perspective view of the hydraulic tool shown in ;

[0020] Figure 4 Shows Figure 1 Another perspective view of the hydraulic tool shown in ;

[0021] Figure 5 A flow chart showing an exemplary crimping method using a hydraulic tool according to an exemplary embodiment is shown;

[0022] Figure 6 A flow chart showing an exemplary crimping method using a hydraulic tool according to an exemplary embodiment; and

[0023] Figure 7 An alternative hydraulic tool 130 is shown, which includes a ram-type crimping head;

[0024] Figure 8 is a plan side view of a crimping tool head in a closed state according to an exemplary embodiment;

[0025] Fig. 9 is based on Figure 8 A plan side view of an exemplary embodiment of a crimping tool head in an open state;

[0026] Fig.10 is based on Figure 8 An exploded view of a crimping tool head of an exemplary embodiment of the present invention;

[0027] Fig.11A A hydraulic circuit that may be used with a hydraulic tool is shown;

[0028] Fig. 11B Shows Fig.11A A portion of a hydraulic circuit shown in;

[0029] Fig. 11C Shows Fig.11A A portion of a hydraulic circuit shown in;

[0030] Fig.12 Shows Fig.11A A portion of the hydraulic circuit shown in ; and

[0031] Fig.13 An exemplary operator panel that may be used with a hydraulic tool is shown. DETAILED DESCRIPTION

[0032] The following detailed description describes various features and functions of the disclosed systems and methods with reference to the accompanying drawings. The illustrative system and method embodiments described herein are not meant to be limiting. It can be easily understood that certain aspects of the disclosed systems and methods can be arranged and combined in a variety of different configurations, all of which are contemplated herein.

[0033] In addition, unless the context indicates otherwise, the features shown in each figure may be used in combination with each other. Therefore, the figures should generally be regarded as part of one or more overall implementations, and it should be understood that not all of the features shown are necessary for each implementation.

[0034] In addition, the enumeration of any elements, frames or steps in this specification or claims is for the purpose of clarity. Therefore, such enumeration should not be interpreted as requiring or implying that these elements, frames or steps follow a specific arrangement or are executed in a specific order.

[0035] The term "substantially" means that the features, parameters or values ​​described need not be achieved precisely, but deviations or variations (including, for example, tolerances, measurement errors, measurement precision limitations and other factors known to those skilled in the art) may not preclude the features from occurring in the amounts intended to be provided.

[0036] Figure 1 Certain components of a hydraulic tool 100 are shown according to an exemplary embodiment. Although the exemplary embodiments described herein refer to an exemplary crimping tool, it should be understood that the features of the present disclosure may be implemented in other similar tools, such as a cutting tool. In addition, components or materials of any suitable size, shape, or type may be used. As an example only, the hydraulic tool 100 shown includes a work head that utilizes a hexagonal or six-sided crimping head 114. However, alternative forms of crimping heads may also be used. As an example only, stamped or dieless crimping heads may also be used. For example, Figure 7 An alternative hydraulic tool 130 is shown that includes a ram-type crimping head 132 .

[0037] Return to Figure 1, the hydraulic crimping tool 100 includes a motor 102, which is configured to drive a pump 104 through a gear reducer 106. The pump 104 is configured to provide pressurized hydraulic fluid to a hydraulic circuit 124 including a hydraulic actuator cylinder 108, which includes a piston slidably received therein. The motor 102 is configured to drive the pump 104 through the gear reducer 106. The pump 104 is configured to provide pressurized hydraulic fluid to the hydraulic actuator cylinder 108, which includes a piston or a plunger slidably received therein.

[0038] The hydraulic tool also includes a controller 50. For example, Figure 2 Shows Figure 1 and Figure 7 1 and 130. Figure 2 As shown, the tool 100, 130 includes a fluid reservoir 214 that is in fluid communication with the hydraulic circuit 124 and the pump 104. The hydraulic circuit 124 and the pump 104 provide certain operating information and operating data to the controller 50, wherein the pump 104 is operated through the gear reducer 106.

[0039] The controller 50 may include a processor, a memory 80, and a communication interface. The memory 80 may include instructions that cause the controller 50 to operate the tool 100 when executed by the processor. In addition, the memory 80 may include a plurality of value lookup tables. For example, at least one stored lookup table may include workpiece information or data, such as connector data. As an example, such connector data may include a connector type (e.g., an aluminum or copper connector), and may also include a preferred crimping distance for certain types of connectors and certain sizes of connectors. Such a preferred crimping distance may include the distance that the piston 200 and therefore the movable crimping die 116 move toward the crimping target area 160, so as to achieve a desired crimping for a specific connector type with a specific size.

[0040] In one arrangement, the controller communication interface enables the controller 50 to communicate with various components of the tool 100, such as the user interface component 20, the motor 102, the memory 80, the battery 212, and various components of the hydraulic circuit 124 (e.g., the pressure sensor 122 and the linear distance sensor 150) (see, e.g., Figure 3 ).

[0041] The battery 212 may be removably connected to a portion of the hydraulic tool, such as the base 134 of the hydraulic tool. Figure 7 As shown, the battery 212 may be removably connected to the base 134 of the hydraulic tool 130 remote from the work head 132. However, the battery 212 may be removably mounted to any suitable location, portion, or position on the frame of the hydraulic tool 130.

[0042] like Figure 2 As shown, the hydraulic tool 100 may also include a user interface component 20 that provides input to the power tool, such as a controller 50 of the power tool. As will be described, such a user interface component 20 can be used to operate the hydraulic tool 100. For example, such a user interface component 20 may include an operating panel, one or more switches, one or more buttons, one or more interactive indicator lights, a soft touch screen or panel, and other types of similar switches (such as a trigger switch). As just one example, and as will be described in detail below, the hydraulic tool 100 may be configured to provide an input to the power tool 100. Figure 7 As shown, the user interface 136 may be located on a top surface of the hydraulic tool 136. The hydraulic tool may also include a trigger switch 138 mounted along the bottom of the hydraulic tool, proximate to the battery 212.

[0043] Fig.13 It shows that it can be used with hydraulic tools (such as Figure 7 13. The exemplary operation panel 1300 for use with a hydraulic tool (shown in FIG. 13). In the operation panel arrangement 1300, the operation panel includes a plurality of soft-touch operation buttons 1310 located below a display 1320, such as a liquid crystal display (LCD). In the illustrated arrangement, four buttons are provided: a first button 1312 including a scan button, a second button 1314 including an increase button 1314, and a third button including a decrease button 1316.

[0044] A fourth button 1318 including a button for selecting a connector type may also be provided. For example, before crimping, a user may use the fourth button 1318 to select a copper (Cu) connector, an aluminum (Al) connector, or other connector type. The operation panel 1300 also includes a first LED 1340 and a second LED 1350. The first LED may be some other color in addition to the second LED. For example, the first LED 1340 may include a green LED and the second LED may include a red LED. Alternative LED configurations may also be used.

[0045] Figure 3 Shows Figure 1 Another perspective view of the hydraulic tool shown in, Figure 4 Shows Figure 1 Another perspective view of the hydraulic tool shown in FIG. Figure 3 and Figure 4, located near the piston 200 is a distance sensor 150. In the illustrated arrangement, the linear distance sensor 150 is mounted within a cylindrical bushing 126 surrounding the piston rod 203A of the piston 200. During the crimping action, the linear distance sensor 150 will operate to detect the linear displacement of the piston 200. Specifically, based on the movement of the piston 200 during the crimping action, the linear distance sensor 150 will generate an output signal that is transmitted to the controller 50. The output signal represents the distance that the piston 200 has moved from a specific reference point position of the punch or piston 200. In a preferred arrangement, the specific reference point will be the position of the piston 200 when the piston 200 has been fully retracted to the proximal position (e.g., the home position), as shown in FIG. Figure 1 and Figure 3 shown.

[0046] The linear distance sensor 150 also provides information about the direction of movement of the piston 200. That is, the linear distance sensor 150 can determine whether the piston 200 is moving or extending toward the crimping target or whether the piston 200 is moving away from the crimping target or retracting from the crimping target. This directional movement information can also be transmitted to the controller 50. The controller 50 can operate the tool based in part on this information, such as controlling the position of the piston during the crimping procedure. For example, the controller 50 can use this information to retract the movable punch to a predetermined position so that the controller controls the return position of the punch, so that subsequent crimping can be performed without full punch retraction, returning to the original position. In addition, the controller 50 can use this information to drive or move the movable punch to a predetermined position, for example, to keep the connector at a given position before the crimping procedure.

[0047] Exemplary linear distance sensors include, but are not limited to, linear variable differential transformer sensors, photoelectric distance sensors, optical distance sensors, and Hall effect sensors. For example, such a Hall effect sensor may include a transducer that changes its output voltage in response to a magnetic field generated by the outer contour of the outer surface 213 of the movable piston 200. As just one example, grooves, slots, and / or protrusions 215 may be machined, etched, engraved, or otherwise provided along the outer surface 213 of the piston 200 (e.g., by serving as a label).

[0048] In the illustrated example of a hydraulic tool, the frame and bore of the tool 100 form a hydraulically actuated cylinder 108. The cylinder 108 has a first end 109A and a second end 109B. The piston is coupled to a mechanism 110 that is configured to move a movable crimping head 116 of a crimping head 114. The first end 109A of the cylinder 108 is proximate to the crimping head 116, while the second end 109B is opposite the first end 109A.

[0049] When the piston is retracted, the movable head 116 can be pulled back to the fully retracted or original position, such as Figure 1 and Figure 3 Optionally, the movable head 116 may be pulled back to a partially retracted position.

[0050] When pressurized fluid is provided to the cylinder 108 by the pump 104, the fluid pushes the piston 200 into the cylinder 108, so that the piston 200 extends toward the crimping target placed in the working area 160. As the piston 200 extends through the cylindrical bushing 126, the linear sensor 150 senses the movement of the piston 200 and provides this information to the controller 50.

[0051] In one preferred arrangement, the linear sensor 150 continuously senses the movement of the piston 200. As just one example, as the punch assembly moves toward the crimping head, performs crimping, and then retracts, the linear sensor 150 may continuously sense the movement of the piston 200 during one or more periods throughout the crimping process. However, as one of ordinary skill in the art will appreciate, alternative sensing devices may also be used. As just one example, in some arrangements, the controller may utilize the linear sensor 150 to sense the movement of the piston 200 only during a specified period of time (e.g., only when the piston rod 200 is driven toward the workpiece or only during the crimping action). In yet another optional arrangement, the linear sensor 150 may be used to sense the movement of the piston 200 only periodically.

[0052] When the piston 200 is extended, the linkage 110 moves the movable crimping head 116 toward the fixed head 115, and thus can cause the working heads 115, 116 to act on or crimp the connector that is already located in the crimping working area 160. When the crimping operation is performed, the controller 50 can provide instructions to the hydraulic circuit 124 to stop the motor 102, thereby releasing the high-pressure fluid back to the fluid reservoir 214, as described in more detail herein.

[0053] As described above, in order to improve the efficiency of the hydraulic tool 100, it may be desirable to have a tool in which the piston 200 can move at a non-constant speed and apply different loads based on the state of the tool, the crimping operation, and / or the type of crimping required. For example, the piston 200 can be configured to advance rapidly while traveling within the cylinder 108 before the movable crimping head 116 reaches the connector to be crimped. Once the movable crimping head 116 reaches the connector, the piston 200 can be decelerated, but so that the movable crimping head 116 applies a large force to perform the crimping operation. Described next is an exemplary hydraulic circuit 124 that is configured to control the crimping operation of the hydraulic tool 100.

[0054] return Figure 3 and Figure 4, the tool 100 includes a partially hollow piston 200 movably accommodated in a cylinder 108, and the cylinder 108 is formed by a frame 201 and a hole 202 of the tool 100. The piston 200 includes a piston head 203A and a piston rod 203B extending from the piston head 203A along the central axis direction of the cylinder 108. As shown in the figure, the piston 200 is partially hollow. In particular, the piston head 203A is hollow and the piston rod 203B is partially hollow, so that a cylindrical cavity 230 is formed in the piston 200.

[0055] The motor 102 drives the pump 104 to provide pressurized fluid to the extension cylinder 206 through the check valve 204. The extension cylinder 206 is arranged in a cylindrical cavity formed in the partially hollow piston 200. The piston 200 is configured to slide axially around the outer surface of the extension cylinder 206. However, the extension cylinder 206 is fixed to the cylinder 108 at the second end 109B, so the extension cylinder 206 does not move with the piston 200.

[0056] The piston 200, in particular the piston rod 203B, is further connected to a punch 208. The punch 208 is configured to connect to and drive the movable crimping head 116.

[0057] The piston head 203A divides the interior of the cylinder 108 into two chambers: a first chamber 210A and a second chamber 210B. The first chamber 210A is formed between the surface of the piston head 203A facing the punch 208, the surface of the piston rod 203B, and the wall of the cylinder 108 at the first end 109A. The second chamber 210B is formed between the surface of the piston head 203A facing the motor 102 and the pump 104, the outer surface of the extension cylinder 206, and the wall of the cylinder 108 at the second end 109B. When the piston 200 moves linearly in the cylinder 108, the corresponding volumes of the first chamber 210A and the second chamber 210B change. The second chamber 210B includes a portion of the extension cylinder 206.

[0058] The pump 104 is configured to draw fluid from the fluid reservoir 214 to pressurize the fluid and deliver the fluid to the extension cylinder 206 after the user initiates a crimp command. This crimp command can be initiated by the user through the user interface assembly 20 (see Figure 2 ) to input such a command. For example, the user can use the user interface 136 or the toggle switch 136 (such as Figure 7 Enter the crimp command as shown to start the crimp command.

[0059] The reservoir 214 may include fluid at a pressure close to atmospheric pressure, such as a pressure of 15-20 pounds per square inch (psi). Initially, the pump 104 provides low pressure fluid to the extension cylinder 206. The fluid has a path through the check valve 204 to the extension cylinder 206. The fluid is blocked at the high pressure check valve 212 and the release valve 216, which is connected to the controller 50 and can be actuated by the controller 50.

[0060] The fluid delivered to the extension cylinder 206 exerts pressure on a first area A1 within the piston 200. As shown, the first area A1 is the cross-sectional area of ​​the extension cylinder 206. The fluid causes the piston 200 and the punch 208 connected thereto to advance rapidly. In particular, if the flow rate of the fluid entering the extension cylinder 206 is Q, the piston 200 and the punch 208 move at a speed equal to V1, where V1 can be calculated using the following equation:

[0061]

[0062] Furthermore, if the pressure of the fluid is P1, the force F1 applied to the piston 200 can be calculated using the following equation:

[0063] F1=P1A1 (2)

[0064] Additionally, as the piston 200 extends within the cylinder 108, hydraulic fluid is drawn or pumped from the reservoir 214 into the chamber 210B through the bypass check valve 218. As the piston 200 begins to extend, the pressure in the second chamber 210B decreases below the pressure of the fluid in the fluid reservoir 214, so the fluid in the fluid reservoir 214 flows through the bypass check valve 218 into the chamber 210B and fills the second chamber 210B. Preferably, the controller 50 monitors the pressure hydraulic fluid via the pressure sensor 122, and also monitors the movement of the piston 200 based on the input it receives from the linear distance sensor 150.

[0065] As the piston 200 and the punch 208 extend, the movable crimping die 116 and the fixed crimping die 115 move toward each other in preparation for crimping a connector placed within the crimping area 160. When the movable die 116 reaches the connector, the connector resists this action. The increased resistance from the connector causes the pressure of the hydraulic fluid provided by the pump 104 to increase.

[0066] The tool 100 includes a sequence valve 120 that includes a poppet 220 and a ball 222 connected to one end of the poppet 220. A spring 224 pushes the poppet 220 to cause the ball 222 to prevent flow through the sequence valve 120 until the fluid reaches a predetermined pressure set point that exerts a force on the ball that exceeds the force exerted by the spring 224 on the poppet 220. For example, the predetermined pressure set point that causes the sequence valve 120 to open may be between 350 psi and 600 psi; however, other pressure values ​​are possible. This configuration of the sequence valve 120 is an exemplary configuration for illustration, and other sequence valve designs may be implemented.

[0067] Once the pressure of the fluid exceeds the predetermined pressure set point, the fluid pressure overcomes the spring 224 and the sequence valve 120 opens, allowing the fluid to enter the second chamber 210B. Thus, the fluid now acts on the annular area A2 of the piston 200 in addition to the area A1. Thus, the fluid acts on the entire cross-sectional area (A1+A2) of the piston 200. For the same flow rate Q used in equation (1), the piston 200 and the ram 208 now move at a speed equal to V2, where V2 can be calculated using the following equation:

[0068]

[0069] As shown in equation (3), V2 is less than V1 due to the increase in area from A1 to (A1+A2). In this way, the piston 200 and the punch 208 are decelerated to a controlled speed, which enables a controlled, more precise working operation. However, the pressure of the fluid has increased to a higher value (e.g., P2), so the force applied to the piston 200 has also increased and can be calculated using the following equation:

[0070] F2=P2(A1+A2) (4)

[0071] F2 is greater than F1 due to the increase in area from A1 to (A1+A2) and the increase in pressure from P1 to P2. Therefore, when the sequence valve 120 is open, high pressure hydraulic fluid can enter the extension cylinder 206 and chamber 210B to allow the ram 208 to apply sufficient force to crimp the connector at a controlled speed.

[0072] Due to the opening of the sequence valve 120, high pressure fluid now fills the chamber 210B. The high pressure fluid pushes the ball of the bypass check valve 218, closing the bypass check valve 218, thereby preventing fluid from flowing back from the chamber 210B to the fluid reservoir 214. In other words, the bypass check valve 218 has fluid at the reservoir pressure on one side and high pressure fluid in the chamber 210B on the other side. The high pressure fluid closes the bypass check valve 218, thus not allowing fluid to be drawn from the reservoir 214 into the chamber 210B.

[0073] The tool 100 includes a pressure sensor 122 configured to provide sensor information indicative of fluid pressure. The pressure sensor 122 may be configured to provide the sensor information to the controller 50.

[0074] If you will refer to Figure 5 and Figure 6 As described in more detail in the flowchart of , once the piston 200 begins to experience increased pressure when applying the initial crimping force on the outer surface of the connector, the controller 50 will be directed to the lookup table to obtain certain expected values. In one arrangement, based on user input information, the controller 50 will extract the desired crimping distance and the desired crimping pressure. The controller 50 then operates the motor 102 and the hydraulic circuit 124 to drive the piston 200 to the target crimping distance and the target crimping pressure. When the linear distance sensor 150 senses that the piston 200 has moved to the target crimping distance, the controller 50 can determine that the initiated crimping of the identified connector is completed.

[0075] Once the connector is crimped and the piston 200 reaches the end of its stroke within the cylinder 108, the hydraulic pressure of the fluid increases because the motor 102 can continue to drive the pump 104. The hydraulic pressure can continue to increase until a threshold pressure value is reached. In one example, the threshold pressure value can be 8500 psi; however, other values ​​are possible. Once the controller 50 receives information from the pressure sensor 122 that the pressure has reached the threshold pressure value, the controller 50 can close the motor 102 to retract the piston and the ram 208 to a desired position, such as an original or fully retracted position.

[0076] In one example, the tool 100 includes a return spring 228 disposed in the first chamber 210A. The spring 228 is fixed at the end 109A of the cylinder 108 and acts on the surface of the piston head 203A toward the piston rod 203B and the punch 208. When the piston retraction has been actuated, the spring 228 pushes the piston head 203A back. Moreover, the fluid pressure in the extension cylinder 206 and the second chamber 210B is higher than the pressure in the reservoir 214. Therefore, the hydraulic fluid is discharged from the extension cylinder 206 back to the reservoir 214 through the release valve 216. At the same time, the hydraulic fluid is discharged from the second chamber 210B back to the reservoir 214 through the high-pressure check valve 212 and the release valve 216, while being blocked by the check valve 218 and the check valve 204. In particular, the check valve 204 prevents backflow into the pump 104.

[0077] Figure 5 A flow chart of an exemplary method 300 for crimping a connector using a dieless hydraulic crimper is shown according to an exemplary embodiment. Figure 5 The method 300 shown in FIG. 1 shows that a method may be used, for example, Figures 1 to 4 and Figure 7 Embodiments of the method for using a hydraulic tool as shown in FIG. In addition, an apparatus or system may be used or configured to perform Figure 5 . In some instances, components of a device and / or system may be configured to perform a function such that the components are actually configured and constructed (with hardware and / or software) to achieve the performance. In other examples, components of a device and / or system may be arranged to be adapted to, capable of, or suitable for performing a function, such as when operated in a particular manner. Method 300 may include one or more operations, functions, or actions as shown in one or more of blocks 310 to 410. Moreover, various blocks may be combined into fewer blocks, divided into additional blocks, and / or various blocks may be removed based on the desired implementation.

[0078] It should be understood that for this and other processes and methods disclosed herein, the flowchart illustrates the functionality and operation of one possible implementation of the present embodiment. Alternative implementations are included within the scope of the exemplary embodiments of the present disclosure, where, depending on the functionality involved, the functionality may be performed in a sequence different from that shown or discussed, including substantially simultaneously or in reverse order, as understood by those skilled in the art.

[0079] At box 310, method 300 includes a step where the user inputs certain information required for the desired crimping into the hydraulic tool. As previously described, this information can be input into the tool through the user interface assembly 20. For example, at box 310, the user can input the type of connector to be crimped. That is, the user can input that an aluminum connector is being crimped or a copper connector is being crimped. In addition, once the type of connector is selected and entered into the tool, the user can be asked to enter the size of the connector into the hydraulic tool. Based on this input data, the controller 50 of the hydraulic tool 100, 130 will be able to determine the target crimping pressure to ensure proper crimping. In addition, based on this input data, the controller 50 of the hydraulic tool 100, 130 will also be able to determine the target crimping distance that the piston 200 will move to perform the desired crimping.

[0080] For example, once this data is entered into the tool, at block 320, the method 300 includes a step where the controller 50 looks up the crimp target distance and crimp pressure that will be used for the specific information input at block 310. The method 300 uses, at least in part, the information input by the user at block 310 to look up these crimp target distances and crimp pressures. This crimp information may be contained in a lookup table stored in the memory 80, which is accessible by the controller 50 (see, e.g., Figure 2 ).

[0081] At block 330, the method 300 queries the controller 50 whether the tool trigger has been pulled to initiate or start crimping. For example, the tool trigger may include, for example, Figure 7 The tool trigger 138 is shown. If at box 330, the controller 50 determines that the tool trigger has not been pulled, the method 300 returns to the beginning of box 330 and waits for a period of time to query again whether the tool trigger has been pulled.

[0082] If at box 330, the controller 50 determines that the tool trigger has been pulled, the crimping action begins. That is, the method 300 will proceed to box 340, where the controller 50 starts the actuation of the hydraulic tool motor 102. After the motor 102 has been actuated, as described herein, the internal pressure within the hydraulic tool will begin to increase. Once the punch or piston 200 begins to move in the distal direction or crimping direction, the controller 50 will detect and monitor the movement of the piston 200 as it moves in that direction. Specifically, the movement of the piston 200 will be detected and monitored by the linear distance sensor 150 to determine whether the piston 200 moves at the target crimping distance as previously determined by the controller 50 at box 320. After the piston 200 begins its movement toward the crimping target as described herein, at box 350, the controller 50 monitors whether the piston 200 reaches its target crimping distance. In a preferred arrangement, the target crimping distance can be determined by the controller 50 by analyzing the position information received from the linear distance sensor 150, as described herein. If the controller 50 determines at frame 350 that the piston 200 has not reached the target crimping distance, the method 300 proceeds to frame 360. At frame 360 ​​of the method 300, the controller 50 preferably determines, through a pressure sensor (e.g., pressure sensor 122), whether the hydraulic circuit 124 of the hydraulic tool 100 is at the maximum hydraulic pressure. If the method 300 determines at frame 360 ​​that the maximum hydraulic pressure has not been reached, the method 300 returns to frame 340 and the controller 50 continues to operate the motor 102 to increase the fluid pressure within the hydraulic circuit 124 to continue to drive the piston 200 toward the crimping working area 160.

[0083] Alternatively, if at block 360 , the controller 50 determines that the tool maximum pressure has been reached, the method 300 proceeds to block 370 where the motor 102 is stopped.

[0084] After stopping the motor at frame 370, the method 300 proceeds to frame 380, where the controller 50 can record certain operating parameters. For example, at frame 370, the controller 50 can record the final crimping pressure and the crimping distance that the piston 200 travels to complete the desired crimping. Thereafter, the method 300 proceeds to frame 390, where the controller 50 can determine whether the resulting crimping meets the desired lookup crimping pressure and the desired crimping distance. For example, in one arrangement, the controller 50 compares the completed pressure and distance recorded at frame 380 with the target crimping distance and target crimping pressure extracted from the lookup table by the controller 50 at frame 320. If these pressure and / or distance values ​​are not comparable, the method 300 proceeds to frame 400, where a crimping failure indicating a failed result is indicated, and then a crimping failure indicating a failed result may be recorded. Alternatively, if these values ​​are comparable, the method 300 proceeds to frame 410, where a successful crimping can be indicated to the user, as described herein. In one arrangement, the controller 50 may also store the successful crimp in the memory 80 , and may also be recorded in a tracking log and may be stored in the memory 80 .

[0085] In addition, the user of the power tool 100 may be visually and / or audibly informed of a successful crimp by some type of human interface device: for example, by one of the user interface components 20 illuminating a green LED that indicates some other similar indication. Alternatively or additionally, an operator interface may be provided along a surface of the tool housing that provides visual and / or graphical confirmation that a previous crimp, including a successful crimp, was made. This may be the same or a different operator interface that the user uses at block 310, where the user enters crimp size and connector type information before crimping begins.

[0086] Figure 6 A flow chart is shown of an alternative method 500 for crimping using a dieless hydraulic crimper according to an exemplary embodiment that does not require initial user input prior to commencing crimping. Figure 6 The method 500 shown in FIG. 5 shows that a method may be used, for example, Figures 1 to 4 and Figure 7 100, 130. The method 500 may include one or more operations, functions, or actions as shown in one or more of blocks 510 to 630. In addition, various blocks may be combined into fewer blocks, divided into additional blocks, and / or various blocks may be removed based on the desired implementation.

[0087] At box 510, method 500 includes an optional step of a user inputting certain information before starting the desired crimping. For example, at box 510, the user may input the type of connector to be crimped. For example, the user may input that an aluminum connector is being crimped or that a copper connector is being crimped.

[0088] At box 520, the hydraulic tool controller 50 queries whether the tool trigger has been pulled to initiate the crimping operation. If at box 520, the hydraulic tool controller 50 determines that the tool trigger has not been pulled, the method 500 loops back to box 510 and waits for a period of time before making the query again.

[0089] If the controller 50 determines at box 520 that the tool trigger has been pulled, the crimping action is initiated. That is, the method 500 advances to box 530, where the controller 50 activates the motor 102 so that the hydraulic tool pressure will increase within the hydraulic circuit 124, as described herein. After the hydraulic pressure within the hydraulic circuit 124 increases, the piston 200 begins to move in the distal direction toward the crimping head 114. After the piston 200 moves, the hydraulic tool 100 will detect and monitor the internal pressure of the tool 100, as determined by box 540. For example, when the controller 50 receives feedback information from the pressure sensor 122, the pressure can be monitored by the controller 50. Specifically, the controller 50 will monitor the pressure to determine whether a threshold pressure is detected. The threshold pressure will determine whether the piston 200 first engages the outer surface of the connector to be crimped. After the piston 200 begins its distal movement toward the crimping target, at box 540, the controller 50 determines whether and when the tool reaches a threshold pressure, also known as a connector measurement pressure.

[0090] If the controller 50 determines that the connector measurement pressure has been met, and therefore the piston 200 begins to exert force on the outer diameter of the crimped connector, the method proceeds to box 550. The connector outer diameter is measured at box 550. In a preferred arrangement, the connector outer diameter can be measured by utilizing a linear distance sensor 150. For example, the linear distance sensor 150 can provide distance information about how far the piston 200 has traveled from a reference position (i.e., the piston's original or retracted position). And because the controller 50 can determine the relative position of the piston 200 at this point in time, the controller 50 will be able to determine the connector outer diameter. The controller 50 can therefore record the outer diameter in the memory 80.

[0091] After determining the connector outer diameter at box 550, the controller 50 looks up the target crimping distance and the target crimping pressure through a lookup table, which is preferably stored in the memory 80. The pressure in the hydraulic circuit 124 continues to increase, so the piston 200 continues to move toward the crimping head 114 to complete the crimping. Next, at box 570 of the method 500, the controller 50 queries whether the piston 200 has reached the target crimping distance. As previously described, in one arrangement, the controller 50 will receive this distance information about the target crimping distance from the linear distance sensor 150.

[0092] If the controller 50 determines that the target crimp distance has not been reached based on the distance information provided by the linear distance sensor 150, the method proceeds to box 580. At box 580, the controller 50 determines whether the hydraulic tool 100 is at the maximum hydraulic tool pressure. Preferably, the controller 50 receives pressure information from the pressure sensor 122 to make this determination. If at box 580, the controller 50 determines that the maximum hydraulic tool pressure has been reached, the method 500 proceeds to box 590, where the controller 50 initiates stopping the tool motor 102.

[0093] Alternatively, if at frame 570, the controller 50 determines that the target crimping distance has been reached (i.e., the piston has indeed traveled the desired crimping target distance), the method 500 proceeds to frame 590, where the controller 50 takes action to stop the motor 102. As a result, the hydraulic circuit 124 will function as described herein to return hydraulic fluid to the fluid reservoir 214.

[0094] After stopping the motor 120 at box 590, the method 500 proceeds to box 600, where certain operating parameters and / or recorded information may be recorded. For example, at box 600, the controller 50 may record the final crimping pressure within the hydraulic circuit 124, and the final crimping distance that the piston 120 traveled to complete the crimping. Thereafter, the method 500 proceeds to box 610, where the controller 50 determines whether the completed crimping meets the lookup pressure and distance determined at box 560. For example, the controller 50 may compare the completed pressure and distance recorded at box 600, and the target distance and pressure determined at box 560.

[0095] If the pressure and / or distance values ​​are not comparable, the method 500 proceeds to block 620 where a crimp failure is indicated and then recorded as a failed crimp. Alternatively, if the values ​​are comparable, the method 500 proceeds to block 630 where a successful crimp is indicated to the user. In one arrangement, the controller 50 may store the successful crimp in the memory 80 and may also record it in a tracking log.

[0096] In addition, a user of the power tool 100 may be visually and / or audibly notified of a successful crimp by some type of human interface device: illumination of a green LED of some other user interface component 20. Alternatively or additionally, an operator interface may be provided along a surface of the tool housing that provides visual and / or graphical confirmation that a previous crimp, including a successful crimp, was made. This may be the same or a different operator interface used by the user at block 510, where the user inputs crimp size and connector type information to the power tool before crimping begins.

[0097] Figures 8 to 10A crimping tool head 700 is depicted according to an exemplary embodiment of the present disclosure. As just one example, the crimping tool head or work head 700 may be used with a hydraulic tool as disclosed herein, such as with a Figure 1 The hydraulic tool 10 shown in Figure 7 In particular, Figure 8 depicts a side view of the crimping tool head 700 in a closed position, Fig. 9 A side view of the crimping tool head 700 is shown in an open position, and Fig.10 An exploded view of the crimping tool head 700 is shown.

[0098] like Figures 8 to 10 As shown, the cutting tool head 700 includes a first frame 712 and a second frame 714. The second frame 714 is movable relative to the first frame 712, so that the crimping tool head 700 can be (i) open to insert one or more objects into the crimping area 716 of the crimping tool head 700, and (ii) closed to facilitate crimping the objects in the crimping area 716. In particular, in order to crimp the objects and / or workpieces positioned in the crimping area 716, the crimping tool head 700 includes a punch 718 slidably disposed in the first frame 712 and a crimping anvil 720 on the second frame 714. The punch 718 is movable from a proximal end 722 of the crimping area 716 to the crimping anvil 720 at a distal end 724 of the crimping area 716. Thus, the punch 718 and the crimping anvil 720 can provide a compressive force to an object (eg, metal, wires, cables, and / or other electrical connectors) positioned between the punch 718 and the crimping anvil 720 in the crimping area 716 .

[0099] like Figures 8 to 10 As shown, the punch 718 may have a shape that generally narrows in a direction from the proximal end 722 toward the distal end 724. Therefore, the cross-section of the farthest end of the punch 718 may be smaller than the cross-section of the most proximal end of the punch 718. As an example, the punch 718 may have a generally pyramidal shape. As another example, the punch 718 may have multiple portions, including one or more inwardly tapered portions 718A and one or more cylindrical portions 718B (see Fig.10 ).

[0100] Also like Figures 8 to 10As shown, the crimping anvil 720 may have a shape that generally narrows in a direction from the proximal end 722 toward the distal end 724. For example, the crimping anvil 720 may have a generally V-shaped surface profile or a generally U-shaped surface profile. In some embodiments, the shape and / or size of the punch 718 may generally correspond to the shape and / or size of the crimping anvil 720, or vice versa. At least in part due to the narrowed shape of the punch 718 and the crimping anvil 720, the crimping tool head 700 can advantageously crimp objects with greater force over a smaller surface area than other tool heads (e.g., crimping tools having a generally flat punch and a generally flat crimping anvil). This, in turn, helps to improve the electrical properties of the objects coupled by the crimping operation.

[0101] As described above, the crimping head tool 700 can be coupled to an actuator assembly that is configured to distally move the punch 718 to crimp an object in the crimping area 716. For example, the actuator assembly can include a hydraulic pump, and / or an electric motor that distally moves the punch 718. In addition, for example, the actuator assembly can include a switch that is operable to move the punch 718 between the proximal end 722 and the distal end 724. For example, the switch can be moved between a first switch position and a second switch position. When the switch is in the first switch position, the actuator assembly causes the punch 718 to be in a retracted position (e.g., at the proximal end 722). However, when the switch is in the second switch position, the actuator causes the punch 718 to move toward the crimping anvil 724 to crimp an object in the crimping area 716.

[0102] In addition, if Figures 8 to 10 As shown, the first frame 712 has a first arm 726 and a second arm 728 extending from the base 730. The first arm 726 is generally parallel to the second arm 728. The first arm 726 and the second arm 728 also have substantially the same length. In this structure, the first frame 712 is in the form of a U-shaped clip (i.e., U-shaped); however, in other examples, the first frame 712 may have a different form. In addition, although the first frame 712 is formed as a whole by a single piece in the example shown, in other examples, the first frame 712 may be formed by multiple parts.

[0103] As described herein, the second frame 714 includes a crimping anvil 720. Figures 8 to 10 In the embodiment of the present invention, the crimping anvil 720 is integrally formed as a one-piece unit with the second frame 714. In an alternative example, the crimping anvil 720 can be connected to the second frame 714. For example, the crimping anvil 720 can be releasably connected to the second frame 714 by one or more first connecting members that extend through one or more holes in the crimping anvil 720 and the second frame 714. By releasably connecting the crimping anvil 720 to the second frame 714, the crimping anvil 720 can be easily replaced and / or repaired.

[0104] The second frame 714 is hingedly connected to the first arm 726 at the first end 732 of the second frame 714. Specifically, the second frame 714 can be Figure 8 The closed frame position shown and Fig. 9 In the closed frame position, the second frame 714 extends from the first arm 726 to the second arm 728 such that the crimping area 716 is generally defined by the punch 718, the crimping anvil 720, the first arm 726, and the second arm 728. In the open frame position, the second frame 714 extends away from the second arm 728 to provide access to the crimping area 716 at the distal end 724.

[0105] exist Figures 8 to 10 In the embodiment of the present invention, the second frame 714 is hingedly connected to the first arm 726 by a first pin 734 extending through the first end 732 of the second frame 714 and the distal portion of the first arm 726. The distal portion of the first arm 726 includes a plurality of prongs 736 separated by gaps, and the first end 732 of the second frame 714 is disposed in the gaps between the prongs 736. This arrangement helps to improve the stability and alignment of the second frame 714 relative to the first frame 712. This in turn helps to improve the alignment of the punch 718 and the crimping anvil 720 during the crimping operation. Despite these benefits, in other examples, the second frame 714 can be hingedly connected to the first arm 726 in a different manner.

[0106] When the second frame 714 is in the closed frame position, the second end 738 of the second frame 714 is releasably coupled to the second arm 728 via the latch 740. Generally speaking, the latch 740 is configured to rotate relative to the second arm 728 between the following positions: (i) a closed latch position, in which the latch 740 can couple the second arm 728 to the second frame 714, such as Figure 8 As shown, and (ii) an unlatched position, wherein the latch 740 releases the second arm 728 from the second frame 714, as shown Fig. 9 For example, the latch 740 may be hingedly coupled to the second arm 728 via the second pin 742, and the latch 740 may thus be rotatable relative to the second arm 728 about the second pin 742. Fig. 9 The latch 740 is shown in the open latch position while the second frame 714 is in the open frame position, but the latch 740 may be in the open latch position when the second frame 714 is in other positions. Similarly, the latch 740 may be in the closed latch position when the second frame 714 is in the open frame.

[0107] In order to releasably couple the latch 740 to the second frame 714, the latch 740 and the second frame 714 include corresponding retaining structures 744A, 744B. Figure 8, the latch 740 includes a proximally inclined bottom surface 744A that engages a distally inclined top surface 744B of the second frame 714 when the latch 740 is in the closed latch position and the second frame 714 is in the closed frame position. The spacing of the inclined surfaces 744A, 744B is configured such that when the latch 740 is moved to the unlatched position, the surface 744A of the latch 740 can be released from the surface 744B of the second frame 714. Similarly, the spacing of the inclined surfaces 744A, 744B is configured such that when the second frame 714 is in the closed frame position and the latch 740 is in the closed latch position, the engagement between the surface 744A and the surface 744B prevents rotation of the second frame 714.

[0108] The release lever 746 is coupled to the latch 740 and is operable to move the latch 740 from the closed latch position to the open latch position. For example, the proximal portion 747 of the release lever 746 can be coupled to the proximal portion 743 of the latch 740 (e.g., via a coupling member, such as a screw or a releasable pin). In this way, the release lever 746 can be rotationally fixed relative to the latch 740.

[0109] The release lever 746 also includes a protrusion 748 extending from the release lever 746 toward the second arm 728 of the first frame 712. Figures 8 to 9 As shown, when the release lever 746 is coupled to the latch 740, the protrusion 748 can engage against the second arm 728 of the first frame 712. In this manner, the protrusion 748 can act as a fulcrum about which the release lever 746 can rotate.

[0110] In this arrangement, rotation of the release lever 746 about the protrusion 748 and toward the second arm 728 causes a corresponding rotation of the latch 740 about the second pin 742 and away from the second frame 714. The release lever 746 can thus be operated by a user to release the second frame 714 from the latch 740 and the second arm 728 so that the second frame 714 can be moved away from the latch 740. Figure 7 The closed frame position shown in the figure is moved to Fig. 9 The open frame position shown in .

[0111] The latch 740 can be biased toward the closed latch position by a biasing member. For example, the biasing member can be a spring 750 extending between the second arm 728 and the latch 740 to bias the latch 740 toward the closed latch position. Figure 8 The spring 750 is shown when the latch 740 is in the closed latch position, and Fig. 9 The spring 750 is shown when the latch 740 is in the unlatched position. Figures 8 to 9As shown, the spring 750 extends between a first surface 752 on the proximal portion of the latch 740 and a second surface 754 on the second arm 728. In one example, the second surface 754 can be a lateral projection on the second arm 728. Because the second arm 728 is fixed and the latch 740 is rotatable, the spring 750 applies a biasing force directed from the second arm 728 to the proximal portion of the latch 740. Thus, in this arrangement, the spring 750 biases the latch 740 to rotate. Figures 8 to 9 Rotate in a clockwise direction toward the closed latch position.

[0112] like Fig.10 As shown, the first frame 712 also includes a channel 756 extending through the base 730. When the crimping tool head 700 is coupled to the actuator assembly, a portion of the actuator assembly can extend through the channel 756 and be coupled to the punch 718 within the first frame 712. In this way, the actuator assembly can be moved distally through the channel 756, thereby moving the punch 718 toward the crimping anvil 720. As an example, the punch 718 can be releasably coupled to the actuator assembly by one or more second coupling members 758 (e.g., releasable pins or screws). This can allow replacement and / or repair of the punch 718, and / or facilitate removable connection of the crimping tool head 700 to the actuator assembly.

[0113] The crimping tool head 700 may also include a return spring (such as Figure 3 ), which is configured to move the punch 718 in the proximal direction toward Figures 8 to 9 Therefore, when the far end stroke of the punch 718 is completed (during the crimping operation), the return spring can return the punch 718 to its retracted position.

[0114] Fig.11A , Fig. 11B and Fig. 11C A hydraulic circuit 1100 is shown according to an exemplary embodiment. Such a hydraulic circuit 1100 may also be used with a hydraulic tool, such as Figure 1 The hydraulic crimping tool 100 shown in FIG. Figure 7 The hydraulic tool 130 shown in FIG.

[0115] The hydraulic tool 1100 includes an electric motor 1102 ( Fig. 11B), which is configured to drive a hydraulic pump 1104 via a gear reducer 1106. The hydraulic tool 1100 also includes a reservoir or tank 1108, which operates as a reservoir for storing hydraulic oil at a low pressure level (e.g., atmospheric pressure or slightly above atmospheric pressure, such as 30-70psi). When the motor 1102 rotates in a first rotational direction, the pump piston 1110 reciprocates up and down. When the pump piston 1110 moves upward, fluid is drawn from the tank 1108. When the pump piston 1110 moves downward, the drawn fluid is pressurized and delivered to the pilot pressure rail 1112. When the motor 1102 rotates in the first rotational direction, the shear seal valve 1114 remains closed, so that the channel 1116 is disconnected from the tank 1108.

[0116] The pressurized fluid in the pilot pressure rail 1112 passes through the check valve 1117 and the nose 1118 of the sequence valve 1119 and communicates to the chamber 1121 through the passage 1120. Fig. 11C As shown, chamber 1121 is partially formed in inner cylinder 1122 and partially formed in punch 1124 slidably received in cylinder 1126. Punch 1124 is configured to slide around the outer surface of inner cylinder 1122 and the inner surface of cylinder 126. Inner cylinder 1122 is screwed into cylinder 1126 and is therefore immovable. Fig. 11C As shown, the pressurized fluid entering the chamber 1121 exerts pressure on the inner diameter "d1" of the punch 1124, thereby causing the punch 1124 to expand (e.g., Fig. 11C 11). The die head 1127 is coupled to the punch 1124 so that extension of the punch 1124 within the cylinder 1126 (i.e., movement of the punch 1124 to the left in FIG. 11) causes the working head of the tool to move toward the working head (such as Figure 1 The crimping head 114 shown in FIG. 1 is moved.

[0117] Return to reference Fig.11A , the sequence valve 1119 includes a poppet valve 1128, which is biased toward a valve seat 1130 by a spring 1132. When the pressure level of the fluid in the pilot pressure rail 1112 exceeds a threshold value set by the spring rate of the spring 1132, the fluid pushes the poppet valve 1128 against the spring 1132, thereby opening a fluid path through the passage 1134 to the chamber 1136. The chamber 1136 is defined within the cylinder 1126, between the outer surface of the inner cylinder 1122 and the inner surface of the cylinder 1126. Therefore, referring to Fig. 11C , the pressurized fluid now acts on the inner diameter "d1" of the punch 1124 and the annular area of ​​the punch 1124 surrounding the inner cylinder 1122. Thus, the pressurized fluid now exerts pressure on the entire diameter "d2" of the punch 1124. This causes the punch 1124 to exert a greater force on the object being crimped.

[0118] like Fig.11A As shown, hydraulic tool 1100 also includes a pilot / shuttle valve 1138. Pressurized fluid in pilot pressure rail 1112 communicates through nose 1140 of pilot / shuttle valve 1138 and acts on poppet 1142 to seat poppet 1142 on valve seat 1144 within pilot / shuttle valve 1138. As long as poppet 1142 is seated on valve seat 1144, fluid flowing through check valve 1117 cannot flow through nose 118 of sequence valve 1119 and passage 1146 around poppet 1144 to tank passage 1148, which is fluidically connected to tank 1108. As such, fluid is forced through passage 1120 into chamber 1121, as described herein.

[0119] Additionally, fluid in pilot pressure rail 1112 is allowed to flow around pilot / shuttle valve 1138 through annular area 1149 to passage 1116. However, as described above, when shear seal valve 1114 is closed, passage 1116 is blocked and fluid in communication with passage 1116 is prevented from flowing to tank 1108.

[0120] The crimper 1100 includes a pressure sensor (e.g., pressure sensor 122, Figure 3 ). The pressure sensor is configured to measure a pressure level within the cylinder 1126 and provide information indicative of the measurement to the controller. As long as the measured pressure is below a threshold pressure value, the controller commands the motor 1102 to rotate in a first rotational direction. However, once the threshold pressure value is exceeded, the controller commands the motor 1102 to stop and reverse its rotational direction to a second rotational direction opposite the first rotational direction. Rotating the motor 1102 in the second rotational direction causes the shear seal valve 1114 to open, thereby causing a fluid path to be formed between the pilot pressure rail 1112 and the passage 1116 through the annular area 1149 to reach the tank 1108. Because the fluid in the pilot pressure rail 1112 is allowed to flow to the tank 1108 when the shear seal valve 1114 is opened, the pressure level in the pilot pressure rail 1112 is reduced.

[0121] Fig.12 A close up view of the hydraulic tool 1100 is shown, showing the pilot / shuttle valve 1138. Once the pilot pressure rail 1112 is depressurized due to the opening of the shear seal valve 1114, the pressure level acting at the first end 1200 of the poppet valve 1142 is reduced. At the same time, the pressurized fluid in the chamber 1121 is communicated to the passage 1146 through the nose 1118 of the sequence valve 1119 and acts on the surface area of ​​the flange 1202 of the poppet valve 1142. In this way, the poppet valve 1142 is unloaded (e.g., by being pushed downward).

[0122] The return spring 1150 surrounds the punch 1124, and the return spring 1150 pushes the punch 1124 (e.g., Fig.11A , Fig. 11C Thus, fluid in chamber 1121 is forced out of chamber 1121 through nose 1118 of sequence valve 1119 to passage 1146, then around nose or second end 1204 of poppet valve 1142, now unloaded, to tank passage 1148, and ultimately to tank 1108. Similarly, fluid in chamber 1136 is forced out of chamber 1136 through check valve 1152, through nose 1118 of sequence valve 1119 to passage 1146, then around nose or second end 1204 of poppet valve 1142 to tank passage 1148, and ultimately to tank 1108. Check valve 1117 prevents flow back to pilot pressure rail 1112. The flow of fluid from chamber 1121 and chamber 1136 to canister 1108 releases chamber 1121 and chamber 1136 so that punch 1124 returns to the starting position and crimper 1100 is again ready for another cycle.

[0123] In some cases, the shear seal valve 1114 may not operate properly. In these cases, when the motor 1102 is commanded to rotate in the second rotational position, the shear seal valve 1114 may not open the path from the passage 1116 to the tank 1108, and the pressure level in the pilot pressure rail 1112 is not released and remains high. In this case, the poppet valve 1142 may not be unloaded, and the fluid in the chamber 1121 and the chamber 1136 is not released. Therefore, the punch 1124 may not return to the starting position. In order to release the chamber 1121 and the chamber 1136 in the event of a failure of the shear seal valve 1114, the hydraulic tool 1100 may be equipped with an emergency release mechanism as described herein.

[0124] like Fig.12 As shown, a mechanical switch or button 1206 is connected to a poppet valve 1208 disposed within the pilot / shuttle valve 1138. In an emergency or fault condition, the button 1206 may be pressed (downward), which causes the poppet valve 1208 to be pushed further within the pilot / shuttle valve 1138 (e.g., Fig.12 As poppet 1208 moves, it contacts pin 1210, which is partially disposed within poppet 1142.

[0125] The pin 1210 contacts a check ball 1212 disposed within the poppet valve 1142. The check ball 1212 is seated at the valve seat 1214 within the poppet valve 1142 as long as the pilot pressure rail 1112 is pressurized and the poppet valve 1142 is seated at the valve seat 1144. However, when the button 1206 is pressed and the poppet valve 1208 moves downward to contact and push the pin 1210 downward, the check ball 1212 is unloaded from the valve seat 1214. Thus, pressurized fluid in the pilot pressure rail 1112 is allowed to flow through the poppet valve 1142, around the check ball 1212, around the pin 1210 and the poppet valve 1208 to the tank passage 1148, and ultimately to the tank 1108. In this way, in the event of a failure of the shear seal valve 1114, the pressure in the pilot pressure rail 1112 is released by pressing the button 1206. Releasing the pressure in pilot pressure rail 1112 allows poppet valve 1142 to unload under the fluid pressure in passage 1146 , thereby relieving chamber 1121 and chamber 1136 , as described above.

[0126] Advantageously, FIG. 11 and Fig.12 The configuration shown in combines the operation of the emergency pressure relief mechanism with the pilot / shuttle valve 1138, rather than including a separate lever mechanism and associated separate valve, to allow pressure to be released in the event of a hydraulic circuit failure.

[0127] The description of the different advantageous embodiments has been given for the purpose of illustration and description, and the description of the different advantageous embodiments is not intended to be exhaustive or limited to the embodiments in the form disclosed. Modifications and variations will be apparent to those of ordinary skill in the art. In addition, different advantageous embodiments may provide different advantages over other advantageous embodiments. The selected one or more embodiments are selected and described in order to best explain the principles of the embodiments, the practical application, and to enable others of ordinary skill in the art to understand the various embodiments of the present disclosure with various modifications suitable for the intended specific use.

Claims

1. A method of operating a hydraulic crimping tool to crimp a connector, the method comprising: Start the crimping action; activating the electric motor to increase the hydraulic tool pressure in the hydraulic circuit; moving the piston from a proximal position to a distal position toward the crimping head; The piston is fully retracted at the proximal-most position; monitoring the hydraulic tool pressure; detecting a threshold pressure when the piston contacts an outer surface of the connector to be crimped; Measure the outer diameter of the connector; Determining target crimping information according to the outer diameter of the connector; Increasing the pressure of the hydraulic tool to move the piston toward the crimping head to complete the crimping action on the connector; as well as After work is completed on the connector, the piston is moved to a partially retracted position so that the piston stroke begins from the partially retracted position to work on the next workpiece; the partially retracted position is between the distal-most position and the proximal-most position. 2 . The method according to claim 1 , wherein the target crimping information comprises a target crimping distance. The method according to claim 1 , wherein the target crimping information comprises a target crimping pressure.

4. The method of claim 1 further comprising querying whether a hydraulic tool trigger has been pulled before initiating the crimping action; and waiting for a period of time before making another query if the hydraulic tool determines that the tool trigger has not been pulled.

5. The method of claim 1, further comprising measuring the connector outer diameter with a linear distance sensor.

6. The method according to claim 5 also includes providing distance information using the linear distance sensor, which indicates how far the piston is from a first reference position to a second position where the piston contacts the outer surface of the connector; the first reference position is one of the proximal position and the partially retracted position. 7 . The method of claim 1 , further comprising monitoring the hydraulic tool pressure using feedback information from a pressure sensor.

8. The method of claim 1, further comprising determining the target crimp information from a lookup table based on the connector outer diameter.

9. The method of claim 1 , further comprising sensing movement of the piston using a linear distance sensor that can provide sensor information indicative of movement of the piston; and The sensor information is used to move the piston to the partially retracted position to begin working on the next workpiece.

10. The method of claim 1, further comprising detecting a profile provided along an outer surface of the piston.

11. The method according to claim 1, further comprising: using linear distance sensor information to control the piston to extend to a predetermined position to hold the connector at a given position prior to a crimping sequence; as well as Movement of the piston is continuously sensed.

12. The method of claim 1, further comprising operating the motor to crimp the connector according to at least one of a target distance or a target pressure.

13. The method of claim 1, further comprising generating an output signal during the crimping action and transmitting the output signal to a controller connected to the motor.

14. The method of claim 13, further comprising generating the output signal to represent a distance the piston has moved from a reference position, the reference position being one of the proximal-most position and the partially retracted position.

15. The method of claim 14, further comprising generating the output signal to include a piston home position.

16. The method of claim 14, further comprising generating the output signal to include a fully retracted position of the piston.

17. The method of claim 14, further comprising generating the output signal to represent a direction of movement of the piston.

18. The method of claim 17, further comprising generating the output signal to indicate a direction of movement of the piston toward the crimping head.

19. The method of claim 1 further comprising detecting a linear displacement of the piston.

20. The method of claim 19, further comprising detecting linear displacement of the piston as the tool performs the crimping action.

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