Lead Screw Compression Tool for Cartridge-Free Connector Crimping
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Solution Overview
Problem
Current tools for applying compression to electrical connectors and splices in power distribution networks are not universally applicable, leading to high maintenance costs, complex operations, and safety risks, particularly due to the use of explosive cartridges.
Innovation Solution
A compression tool designed to be coupled with a battery-powered impact wrench, featuring a simple and robust structure with a lead screw and support tip, eliminating the need for explosive cartridges and providing universal adaptability to various connectors and splices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If explosive cartridges are used to apply wedge-type connectors, then the connector application force is sufficient, but the safety of technicians deteriorates and operational complexity increases
Solution Approach 1:
The patent removes the explosive cartridge component from the system entirely. Instead of using explosive force to apply connectors, the invention employs a mechanical impact wrench that delivers controlled impact forces through a lead screw mechanism, eliminating the safety hazards associated with explosive materials while maintaining sufficient application force.
Solution Approach 2:
The patent replaces the chemical-explosive mechanical system with a purely mechanical impact-driven system. The impact wrench uses kinetic energy from battery-powered motor to deliver controlled impacts through a lead screw, substituting the chemical energy conversion of explosives with mechanical energy conversion, thereby improving safety while maintaining force application capability.
2Manufacturing precision
If brand-specific tools are used for each connector model, then the precision of connector application is maintained, but the device complexity and maintenance costs increase
Solution Approach 1:
The patent designs a universal impact-driven compression tool that can accommodate multiple connector types and sizes through a standardized interface system. The tool features interchangeable adapters or adjustable compression chambers that allow a single base tool to perform multiple functions, eliminating the need for separate brand-specific tools for different connector models while maintaining application precision through controlled impact mechanisms.
3Force
If hydraulic tools and screwdrivers are used for connector application, then the compression force is controlled, but the productivity and operational speed deteriorate
Solution Approach 1:
The patent employs periodic impact action through the impact wrench mechanism, delivering a series of controlled blows to rapidly advance the connector into the compression position. This periodic impact action combines the speed of impact driving with the controlled compression force, achieving both high productivity and precise force control that neither hydraulic tools nor manual screwdrivers can match.
4Adaptability or versatility
If color-coded polymeric or metal cartridges are used for different connector models, then the adaptability to various connectors is improved, but the loss of substance and maintenance costs increase
Solution Approach 1:
The patent employs durable, reusable compression tool components that maintain their functional properties over extended use. The impact-driven mechanism and compression chambers are designed to withstand repeated use without degradation, eliminating the need for disposable cartridges. The tool serves itself by maintaining consistent compression capability through robust mechanical design, reducing consumable waste while preserving adaptability to various connector types.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The tool achieves efficient, safe, and precise compression applications with reduced costs and enhanced safety, offering high durability and versatility, while eliminating the need for cartridges and reducing ergonomic strain.
Implementation Method 1
containing a lead screw (2) with an external thread, symmetrically arranged along the entire length of the compression tool (1)
Implementation Method 2
compression tool couplable to a battery-powered impact wrench
Data Source
AI summary
The present patent relates to a compression tool (1) comprising a lead screw (2); a support tip (4); a rear engagement (5), such as an engagement tip in a battery-powered impact wrench (B); and an applicator body (A) comprising a rear block (6A) arranged perpendicularly to and symmetrically centered on the rear end of said applicator body (A) and having a threaded hole (7) for passage/fastening of the lead screw (2), and a front block (6B) arranged perpendicularly to and symmetrically centered on the front end of said applicator body (A); wherein the lead screw (2) is fitted into the applicator body (A) by screwing through the threaded hole (7) of the rear block (6A) of said applicator body (A).