Modular Hydraulic Power Unit for Versatile Hand-Held Tools
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Solution Overview
Problem
Existing hand-held hydraulic tools have different drive systems for various handle assemblies, leading to increased manufacturing costs and complexity.
Innovation Solution
A portable, hand-held hydraulic power tool with a modular power unit that includes a motor, transmission assembly, and pump assembly, allowing the tool to be used with different types of tool handle assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different drive systems are used for different handle assemblies, then the tool can be adapted to various handle types, but manufacturing costs and complexity increase
Solution Approach 1:
The patent implements a universal drive system that can interface with multiple types of handle assemblies through a standardized mounting interface. The drive system includes a motor, transmission assembly, and pump assembly that remain consistent across different tool configurations, while only the handle assembly varies. This allows the same core mechanism to serve multiple functions and compatible with different handle types, reducing manufacturing complexity and costs while maintaining versatility.
Solution Approach 2:
The tool is divided into distinct modular components: a standardized drive system module and interchangeable handle assembly modules. The drive system is segmented into motor, transmission, and pump components that can be independently manufactured and assembled. This segmentation allows the handle assemblies to be varied without affecting the core drive system, enabling adaptability while controlling manufacturing complexity.
2Device complexity
If a modular power unit is used with different handle assemblies, then manufacturing costs are reduced, but the tool must maintain portability and force generation capability
Solution Approach 1:
The patent employs a hydraulic system where a motor-driven pump generates high-pressure hydraulic fluid that acts on a piston to produce substantial crimping or cutting force. The hydraulic multiplication of force allows a relatively small motor to generate the large forces required for electrical connector crimping and conductor cutting, maintaining force capability while using a compact modular power unit that reduces manufacturing costs.
Solution Approach 2:
The transmission assembly includes a gear mechanism that provides high torque multiplication in a compact form factor, enabling the motor to rapidly generate the necessary force through mechanical advantage without requiring a large, expensive motor. This allows the modular power unit to maintain force generation capability while keeping the overall system compact and cost-effective.
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 modular design reduces manufacturing costs and complexity while maintaining the tool's portability and ability to generate significant forces for crimping or cutting applications.
Implementation Method 1
The transmission assembly is in series with and is operatively coupled to the motor. The pump assembly is in series with and is operatively coupled to the transmission assembly.
Implementation Method 2
The piston assembly is rotatably coupled to the pump assembly such that the piston assembly is in fluid communication with an output conduit of the pump assembly
Data Source
AI summary
Portable, hand-held hydraulic tools having a modular power unit within a handle assembly and a working head assembly mated to the handle assembly. The working head assembly can have a pair of movable jaws or a movable jaw and a fixed jaw. The jaws can be configured to perform different operating operations, such as crimping operations and cutting operations.