Power tool

Abstract

The purpose of the present disclosure is to provide a power tool having a structure capable of reaching the thrust required for press machining a workpiece while also providing the power tool with a compact and light-weight configuration. As a means for solving this problem, this power tool (1) comprises: a main body (2) having an electric motor (3), a feed screw (4), and a slider (5); and a tool head (6) connected to the main body (2). The tool head (6) has a receiving part (7) connected to the main body (2), a toggle link (9) connected to the slider (5), and a pressing part (8) connected to the toggle link (9). The toggle link (9) is disposed as a pair at symmetrical positions with respect to the axis (P1) of the feed screw (4).

Description

power tools

[0001] The present invention relates to a power tool for pressing a workpiece such as a crimp terminal.

[0002] Conventionally, a power tool has been proposed that combines a tool head having a fixed jaw and a movable jaw with a main body having a cam and an electric motor (Patent Document 1: DE 19709017 A1). Also, a power tool is known that combines a tool head having a pair of jaws rotatably connected to each other with a main body having a feed screw and an electric motor (Patent Document 2: JP 2022-187472 A1).

[0003] German Patent Application Publication No. 19709017 Japanese Patent Application Laid-Open No. 2022-187472

[0004] Generally, direct-acting power tools and clamping power tools are used depending on the type of workpiece. For example, direct-acting power tools are used when crimping low-current electric wires to crimp terminals or low-current electric wires to sleeves in electronic devices, communication devices, and electrical equipment.

[0005] In recent years, terminal shapes, sizes, and other types have become more diverse, and a thrust of 500 kgf may be required to crimp a low-current electric wire to a crimp terminal or sleeve. While hydraulic pump-based configurations can achieve the thrust required for press processing, such as compressing, crimping, and cutting the workpiece, they are large and heavy, making them difficult to use. The cam-based configuration described in Patent Document 1 is not practical because it requires a large and robust cam to achieve the required thrust. Furthermore, Patent Document 2 is a clamp-type tool, making it difficult to apply to linear-acting tools.

[0006] The present invention has been made in view of the above circumstances, and has an object to provide a power tool that is small and lightweight, yet has a structure that can achieve the thrust required for press working a workpiece.

[0007] The present invention solves the above problem by the solution disclosed below in one embodiment.

[0008] The electric tool of the present invention is an electric tool for press-processing a workpiece, comprising a main body having an electric motor, a feed screw connected to the electric motor, and a slider connected to the feed screw, and a tool head connected to the main body, wherein the tool head has a receiving portion connected to the main body, a toggle link connected to the slider, and a pushing portion connected to the toggle link, and the toggle links are arranged in pairs at symmetrical positions relative to the axis of the feed screw.

[0009] According to this configuration, the use of toggle links increases thrust and allows for a smaller, lighter structure than a configuration using cams. Furthermore, by arranging a pair of toggle links at symmetrical positions about the axis of the feed screw, the pair of toggle links can share half of the reaction force received during press working, allowing for even press working of the workpiece on the axis. Therefore, while maintaining a small, lightweight configuration, it is possible to achieve the thrust of 500 kgf required for press working of the workpiece.

[0010] For example, the toggle link includes a first member having a first arm with a guide portion formed thereon and a second arm extending from the first arm, the first arm being connected to the slider by a first pin; a second member connected to the second arm by a second pin and to the pressing portion by a third pin; and a third member connected to the second member by a fourth pin and engaging with the guide portion by a fifth pin, the fifth pin sliding inside the guide portion. This configuration allows the feed screw to more than double its traction force while uniformly press-forming the workpiece along its axis. For example, the guide portion is shaped like an elongated hole or a groove.

[0011] As an example, the toggle link is arranged such that the second pin is disposed farther from the axis than the third member, the second pin is closer to the fifth pin than the fourth pin to press the workpiece, and the second pin is farther from the fifth pin than the fourth pin to remove the workpiece from the receiving portion. With this configuration, the toggle link can be expanded and contracted in the width direction of the power tool, so that the travel length of the pushing portion can be reduced to one-third of the travel length of the feed screw, thereby tripling the thrust.

[0012] As an example, the workpiece is arranged in a direction perpendicular to the axis, the second pin is arranged in a direction perpendicular to the axis, the workpiece is pressed by moving the second pin away from a center line passing through the workpiece in the longitudinal direction, and the workpiece can be removed from the receiving part by moving the second pin toward the center line. With this configuration, the toggle link can be made thin, while the travel length of the pushing part can be reduced to one-third of the travel length of the feed screw, thereby tripling the thrust.

[0013] As an example, the tool head has a pair of covers that cover the toggle link, and the thickness of the covers is smaller than the thickness of the main body in the same direction as the center line. With this configuration, the thickness from the main body to the tool head is small, so that the tool head can easily approach the workpiece even in a complex work area, thereby improving workability.

[0014] As an example, the main body has a control unit that drives and controls the electric motor, a lower limit switch that is activated when the slider moves to the lower limit position, and a current sensor that detects the current value of the electric motor, and the control unit determines that processing of the workpiece is incomplete if the current value has not reached a set value when the slider moves to the lower limit position and the lower limit switch is activated, and controls the electric motor to continue operating until the current value reaches the set value. With this configuration, press processing can be reliably performed even if there is dimensional variation in the workpiece due to manufacturing, or if there is positional variation between the male shape of the pressing portion and the female shape of the receiving portion due to wear, etc.

[0015] As an example, the main body has an upper limit switch that is activated when the slider moves to the upper limit position and a trigger switch that is activated in conjunction with a trigger lever gripped by the operator. When the trigger switch is activated, the electric motor rotates forward, and when the control unit determines that processing of the workpiece is complete, the electric motor rotates reversely. When the slider moves to the upper limit position and the upper limit switch is activated, the electric motor stops. With this configuration, processing of the workpiece begins when the operator grips the trigger lever, thereby improving safety at the start of work. Furthermore, when the pushing portion and receiving portion separate and the upper limit switch is activated, the electric motor stops, thereby improving safety at the end of work.

[0016] As an example, the main body includes a reducer that connects the feed screw and the electric motor, a handle portion in which the reducer is mounted, a battery pack that supplies power to the electric motor, and a mounting portion to which the battery pack is detachably mounted, and the electric motor is driven by power from the battery pack to compress, crimp, or cut the workpiece. This configuration can further increase thrust according to the reduction ratio of the reducer. Furthermore, the tool is highly portable and easy to use when held by a worker on-site.

[0017] According to the present invention, it is possible to realize a power tool that is small and lightweight, yet has a structure that can achieve the thrust required for press working of a workpiece.

[0018] FIG. 1 is a schematic perspective view showing an example of a power tool of the present embodiment. FIG. 2A is a front view of the power tool shown in FIG. 1. FIG. 2B is a left side view of the power tool shown in FIG. 1. FIG. 2C is a rear view of the power tool shown in FIG. 1. FIG. 2D is a right side view of the power tool shown in FIG. 1. FIG. 3A is a schematic internal structural view of the power tool shown in FIG. 1. FIG. 3B is a schematic internal structural view showing the relationship between a trigger lever and a switch board in the power tool shown in FIG. 1. FIG. 4 is a schematic internal structural view showing a toggle link in the power tool shown in FIG. 1. FIG. 5 is a schematic circuit structural view showing an example of the circuit configuration of the power tool shown in FIG. 1. FIG. 6A is a schematic internal structural view showing a state in which the pressing portion of the power tool shown in FIG. 1 has moved away from the receiving portion. FIG. 6B is a schematic internal structural view showing a state in which the pressing portion of the power tool shown in FIG. 1 has approached the receiving portion.

[0019] An embodiment of the present invention will be described in detail below with reference to the drawings. A power tool 1 includes a main body 2 and a tool head 6 attached thereto. To facilitate explanation of the positional relationship of each part of the power tool 1, arrows X, Y, and Z are used to indicate the directions in the drawings. Note that the power tool 1 operates normally in any orientation.

[0020] The power tool 1 converts the rotational motion of the electric motor 3 into the linear motion of the pressing portion 8 to press the workpiece 90. As an example, the workpiece 90 is a crimp terminal 91 and a low-current electric wire 92. The power tool 1 compresses and crimps the crimp terminal 91 at a location where the low-current electric wire 92 is attached. In all the drawings used to explain the embodiment, members having the same functions are denoted by the same reference numerals, and repeated explanations of such members may be omitted.

[0021] 1 and 2A to 2D are schematic external views showing an example of a power tool 1 according to this embodiment. The power tool 1 includes a main body 2 having an electric motor 3, a feed screw 4, a slider 5, a control unit 27, a control switch 31, and a trigger lever 33, a tool head 6 that is connected to the main body 2 for operation, and a battery pack 2c. The main body 2 has a handle portion 2a that is shaped like a handle and can be gripped by an operator in a direction away from the tool head 6. The main body 2 has an attachment portion 2b at the lower end of the handle portion 2a, and the battery pack 2c is connected to the attachment portion 2b. This embodiment is a portable, cordless power tool 1 that can be held by an operator.

[0022] 3A is a schematic diagram of the internal structure of the power tool 1. The tool head 6 has a receiving portion 7 connected to the main body 2, a toggle link 9 connected to the slider 5, and a pushing portion 8 connected to the toggle link 9. When the electric motor 3 rotates forward, the slider 5 moves backward along the axis P1 of the feed screw 4. When the electric motor 3 rotates backward, the slider 5 moves forward along the axis P1 of the feed screw 4. The slider 5 moves forward to an upper limit position in the direction of the Z-direction arrow in the figure, and moves backward to a lower limit position in the opposite direction to the Z-direction arrow in the figure.

[0023] The receiving portion 7 has a base portion 7b attached to the main body 2 and a die 7a attached to the base portion 7b. The pressing portion 8 has a support portion 8b connected to a toggle link 9 and a punch 8a attached to the support portion 8b. In the power tool 1, when the slider 5 retracts and the pressing portion 8 advances, the punch 8a approaches the die 7a and presses the workpiece 90. When the slider 5 retracts and the pressing portion 8 retracts, the punch 8a moves away from the die 7a, allowing the workpiece 90 to be removed.

[0024] The toggle links 9 are arranged in pairs at symmetrical positions with respect to an axis P1 that passes through the feed screw 4 in the longitudinal direction. A center line P2 that passes through the workpiece 90 in the longitudinal direction is perpendicular to the axis P1. The tool head 6 has a pair of covers 26 that cover the toggle links 9. The thickness of the covers 26 is smaller than the thickness of the main body 2 in the same direction as the direction of the center line P2 that is perpendicular to the axis P1.

[0025] 3B is a schematic diagram of the internal structure of the power tool 1, showing the relationship between the control switch 31, the trigger lever 33, and the switch board 28a. The control switch 31 and the trigger lever 33 are arranged in opposite directions on the main body 2. As an example, the control switch 31 is a push switch, and the trigger switch 32 is a microswitch, and each switch is mounted on the switch board 28a.

[0026] The trigger lever 33 is rotatably supported on a shaft member 33a provided on the main body 2, and the trigger switch 32 is actuated in conjunction with the trigger lever 33. As will be described later, when the worker grips the trigger lever 33, the trigger switch 32 is pressed by the trigger lever 33 and actuates, and the actuation of the trigger switch 32 causes the control unit 27 to control the operation of the electric motor 3, thereby pressing the workpiece 90. When the worker releases his grip on the trigger lever 33, the trigger switch 32 is released and stops, and the stopping of the trigger switch 32 causes the control unit 27 to stop the electric motor 3, making it possible to remove the pressed workpiece 90.

[0027] The tool head 6 presses the workpiece 90 by applying the principle of leverage. The toggle link 9 has a first member 11, a second member 12, and a third member 13. The first member 11, the second member 12, and the third member 13 are formed by processing hard metal sheets or by laminating hard metal plates in the thickness direction. The toggle link 9 has a first pin 21, a second pin 22, a third pin 23, a fourth pin 24, and a fifth pin 25. The first pin 21, the second pin 22, the third pin 23, the fourth pin 24, and the fifth pin 25 are formed by hard metal shafts or hard metal pins.

[0028] The first member 11 has a first arm 14 having a guide portion 14a formed in the longitudinal direction in the shape of a long hole or a groove, and a second arm 15 extending outward from the first arm 14, and the first arm 14 is rotatably connected to the slider 5 by a first pin 21.

[0029] The second member 12 is rotatably connected to the second arm 15 by the second pin 22, rotatably connected to the support portion 8b of the pressing portion 8 by the third pin 23, and rotatably connected to the third member 13 by the fourth pin 24. The fourth pin 24 is disposed at a position farther away from the axis P1 than the third pin 23. The second pin 22 is disposed at a position farther away from the axis P1 than the fourth pin 24.

[0030] The third member 13 is pivotally connected to the second member 12 by a fourth pin 24, and slidably engaged with the guide portion 14a by a fifth pin 25. When the toggle link 9 is in operation, the fifth pin 25 slides inside the guide portion 14a.

[0031] The toggle link 9 is disposed such that the second pin 22 is located farther from the axis P1 than the third member 13. The workpiece 90 is press-formed by the movement of the second pin 22 approaching the fifth pin 25 more closely than the fourth pin 24. The workpiece 90 can be removed from the receiving portion 7 by the movement of the second pin 22 moving farther away from the fifth pin 25 than the fourth pin 24.

[0032] The toggle link 9 moves in a direction in which the second pin 22 moves away from the center line P2 that passes through the workpiece 90 in the longitudinal direction, thereby pressing the workpiece 90. The position at which the workpiece 90 is pressed may correspond to the bottom dead center of the toggle link 9. The toggle link 9 moves in a direction in which the second pin 22 moves closer to the center line P2, thereby enabling the workpiece 90 to be removed from the receiving portion 7. The position at which the workpiece 90 can be removed may correspond to the top dead center of the toggle link 9.

[0033] The feed screw 4 is journaled on a bearing 4a and is connected to the drive shaft 3a of the electric motor 3 via a reducer 3b. A pair of toggle links 9 are arranged symmetrically with respect to an axis P1 that passes through the length of the feed screw 4. With this configuration, the orientation of the openings of the receiving portion 7 and the pushing portion 8 can be easily changed between the direction of the X arrow and the opposite direction of the X arrow to suit the dominant hand of the worker and the layout of the work site.

[0034] 5 is a schematic circuit diagram showing an example of the circuit configuration of the power tool 1. The control unit 27 has, as an example, a CPU 27a formed by a one-chip microcomputer. The control unit 27 has a current sensor 38 that detects the current of the electric motor 3 and a timer 37 that measures the operating time of the electric motor 3. The CPU 27a is provided with a sensor circuit that functions as the current sensor 38 and a timer circuit that functions as the timer 37. As an example, the CPU 27a sends a PWM signal to a driver 27b, supplies power to the electric motor 3 via a driving element such as a power MOSFET, and controls the driving of the electric motor 3.

[0035] The battery pack 2c has a secondary battery made of a lithium-ion battery. For example, the power supply voltage is 7 to 42 V and the battery capacity is 1 to 10 Ah. The voltage of the battery pack 2c is stepped down via a regulator 27c and supplied to the CPU 27a. The CPU 27a is configured to be able to check the remaining charge of the battery pack 2c and monitor the state of the battery pack 2c.

[0036] The control unit 27 and the switch board 28a are connected via signals. A trigger switch 32, an upper limit switch 34, and a lower limit switch 35 are mounted on the switch board 28a. The trigger switch 32 is activated by operating a trigger lever 33. The upper limit switch 34 is activated when the slider 5 moves to the upper limit position. The lower limit switch 35 is activated when the slider 5 moves to the lower limit position.

[0037] The CPU 27a controls the driving of the electric motor 3 based on the actuation signals of each switch received from the switch board 28a. As an example, the upper limit position of the slider 5 is detected when a first pin arranged on the slider 5 presses an upper limit switch 34. Furthermore, the lower limit position of the slider 5 is detected when a second pin arranged on the slider 5 presses a lower limit switch 35.

[0038] The main body 2 has a display board 28b. The control unit 27 and the display board 28b are connected via signals. The display board 28b is equipped with LEDs 36a, 36b, and 36c. The LED 36a lights up or flashes when the power tool 1 is in automatic mode. The LED 36b lights up or flashes when there is an abnormality in the power tool 1. The LED 36c lights up or flashes when the power tool 1 is in manual mode.

[0039] When the control switch 31 is activated and a predetermined signal is input to the CPU 27a, the CPU 27a determines that the signal generated by the activation of the trigger switch 32 is valid and controls the drive of the electric motor 3. Each time the operator presses the control switch 31 for a predetermined period of time, for example, three seconds or more, the operation mode is switched. The automatic mode is used when performing continuous work, and the CPU 27a controls the display to light the LED 36a, for example, to display green. The manual mode is used when performing a single work, and the CPU 27a controls the display to light the LED 36c, for example, to display green.

[0040] When an abnormality signal is input to the CPU 27a from an external sensor, the CPU 27a determines that the power tool 1 is abnormal, and the LED 36b lights up or blinks, for example, in red, under the display control of the CPU 27a. As an example, when the current value of the battery pack 2c exceeds 20 A, the LED 36b blinks 10 times at a cycle of 5 Hz. As an example, when the substrate temperature of the control unit 27 reaches 80°C, the LED 36b lights up for 3 seconds. As an example, when the temperature of the battery pack 2c is 90°C or higher, the LED 36b blinks 3 times at a cycle of 1 Hz. As an example, when the voltage of the battery pack 2c is 7.8 V or lower, the LED 36b blinks 10 times at a cycle of 5 Hz. Note that the above setting conditions are merely examples and are not limited to these setting conditions.

[0041] The relationship between the operator's operation and the operation of the power tool 1 and the control switch 31, trigger switch 32, upper limit switch 34, and lower limit switch 35 is shown in Table 1 below.

[0042]

[0043] As shown in Table 1, the power is turned on when the control switch 31 is operated, and when the operator grips the trigger lever 33 while the power is on, the workpiece 90 is pressed. The power is then turned off after a predetermined waiting time has elapsed since the operator released the trigger lever 33. As an example, the power is turned off 60 seconds after the trigger lever 33 was released.

[0044] Fig. 6A is a schematic diagram of the internal structure of the power tool 1 when the punch 8a is separated from the die 7a. Fig. 6B is a schematic diagram of the internal structure of the power tool 1 when the punch 8a is approaching the die 7a. The operation of the power tool 1 will be described below.

[0045] In step S1 of Table 1, when the operator presses and releases the control switch 31, the control switch 31 changes from OFF to ON and then returns to OFF, the power is turned ON by the control of the control unit 27, and the operation of the trigger switch 32 is enabled. When the operation of the trigger switch 32 is enabled, the process transitions from step S1 to step S2.

[0046] In step S2 of Table 1, the worker attaches the workpiece 90 to the die 7a in a state where the punch 8a is separated from the die 7a as shown in FIG. 5A.

[0047] In step S3 of Table 1, the operator grips the trigger lever 33. When the operator grips the trigger lever 33, the electric motor 3 rotates forward and the slider 5 moves backward. As shown in Fig. 6B, the slider 5 moves backward, causing the toggle link 9 to push the punch 8a. The punch 8a is pushed forward by the toggle link 9, thereby pressing the workpiece 90 placed on the die 7a.

[0048] As the press working of the workpiece 90 progresses, the lower limit switch 35 is activated. As an example, the working time is 1 to 3 seconds. If the detected value of the current sensor 38 exceeds the first current value but does not exceed a second current value set to a value higher than the first current value at the time the lower limit switch 35 is activated, the control unit 27 determines that the press working of the workpiece 90 is complete and continues the next process. If the detected current value exceeds the second current value at the time the lower limit switch 35 is activated, the control unit 27 determines that an abnormality has occurred and performs abnormality processing. As an example, the first current value is set to 8.5 to 9.5 A, and the second current value is set to 19.5 to 20.5 A.

[0049] In step S4 of Table 1, the operator releases the trigger lever 33. When the operator releases the trigger lever 33, the electric motor 3 rotates in the reverse direction, and the slider 5 moves forward. As shown in Fig. 6A, as the slider 5 moves forward, the toggle link 9 pulls the punch 8a. As the punch 8a moves backward due to being pulled by the toggle link 9, the workpiece 90 that has been placed in the die 7a and pressed can be removed.

[0050] In step S5 of Table 1, the operator removes the workpiece 90. After a predetermined time has elapsed since the operator released the trigger lever 33, the power is turned off with the punch 8a separated from the die 7a.

[0051] In addition to the above explanation, the operation of each part will be explained below. If the current value of the electric motor 3 has not reached the set value when the electric motor 3 rotates forward and the slider 5 moves to the lower limit position, activating the lower limit switch 35, the control unit 27 determines that machining of the workpiece 90 is incomplete and controls the electric motor 3 to continue operating until the current value reaches the set value. Furthermore, if the current value of the electric motor 3 is within a set range including the set value when the electric motor 3 rotates forward and the slider 5 moves to a predetermined lower limit position, activating the lower limit switch 35, the control unit 27 determines that machining of the workpiece 90 has been completed and controls the electric motor 3 to rotate in the reverse direction. Then, when the electric motor 3 rotates in the reverse direction, the slider 5 moves to the upper limit position, activating the upper limit switch 34, the electric motor 3 stops.

[0052] If the detection value of the current sensor 38 does not exceed the first current value at the time the lower limit switch 35 is activated, the control unit 27 controls the feed screw 4 to continue operation. If the detection value of the current sensor 38 is below the second current value when a set time has elapsed since the current exceeded the first current value, the control unit 27 determines that machining of the workpiece 90 is normal and continues processing. On the other hand, if the detection value of the current sensor 38 exceeds the second current value when the set time has elapsed, the control unit 27 determines that an abnormality has occurred and performs abnormality processing. As an example, the set time is set to 5 to 15 ms.

[0053] When the control unit 27 determines that the press working of the workpiece 90 is normal, it controls the slider 5 to move to the upper limit position. On the other hand, when the control unit 27 determines that the press working of the workpiece 90 is abnormal, it moves the slider 5 to the upper limit position, stops the electric motor 3, and displays an error by flashing the LED 36b in red.

[0054] According to this embodiment, the power tool 1 has a structure that enhances the reliability of machining operations and is excellent in safety. The present invention is not limited to the above-described embodiment, and various modifications can be made without departing from the scope of the present invention.

Claims

1. A power tool for press-forming a workpiece, comprising: a main body having an electric motor, a feed screw connected to the electric motor, and a slider connected to the feed screw; and a tool head connected to the main body, wherein the tool head has a receiving part connected to the main body, a toggle link connected to the slider, and a pushing part connected to the toggle link, and the toggle links are arranged in pairs at symmetrical positions relative to the axis of the feed screw.

2. The power tool according to claim 1, wherein the toggle link comprises a first member having a first arm on which a guide portion is formed and a second arm extending from the first arm, the first arm being connected to the slider by a first pin, a second member connected to the second arm by a second pin and connected to the pressing portion by a third pin, and a third member connected to the second member by a fourth pin and engaged with the guide portion by a fifth pin, the fifth pin sliding inside the guide portion.

3. The power tool according to claim 2, wherein the toggle link is arranged such that the second pin is positioned farther from the axis than the third member, the second pin is closer to the fifth pin than the fourth pin to press the workpiece, and the second pin is farther from the fifth pin than the fourth pin to enable the workpiece to be removed from the receiving part.

4. The power tool according to claim 2, wherein the workpiece is arranged in a direction perpendicular to the axis, the second pin is arranged in a direction perpendicular to the axis, the workpiece is pressed by moving the second pin away from a center line passing through the workpiece in the longitudinal direction, and the workpiece can be removed from the receiving part by moving the second pin toward the center line.

5. The power tool according to claim 4, wherein the tool head has a pair of covers that cover the toggle link, and the thickness of the covers is smaller than the thickness of the main body in the same direction as the center line.

6. The power tool according to claim 2, wherein the main body has a control unit that drives and controls the electric motor, a lower limit switch that is activated when the slider moves to the lower limit position, and a current sensor that detects the current value of the electric motor, and the control unit determines that processing of the workpiece is incomplete if the current value at the time when the slider moves to the lower limit position and the lower limit switch is activated has not reached a set value, and controls the electric motor to continue operating until the current value reaches the set value.

7. The power tool according to claim 6, wherein the main body has an upper limit switch that is activated when the slider moves to the upper limit position, and a trigger switch that is activated in conjunction with a trigger lever gripped by an operator, and when the trigger switch is activated, the electric motor rotates forward, and when the control unit determines that processing of the workpiece is complete, the electric motor rotates reverse, and when the slider moves to the upper limit position and the upper limit switch is activated, the electric motor stops.

8. The power tool according to any one of claims 1 to 7, wherein the main body has a reducer that connects the feed screw and the electric motor, a handle portion in which the reducer is disposed, a battery pack that supplies power to the electric motor, and a mounting portion to which the battery pack is detachably attached, and the electric motor is driven by power from the battery pack to compress, crimp or cut the workpiece.

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