Multi-Pump Crimping Tool With Cam Clutch Jaw Motion
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Solution Overview
Problem
Existing crimping tools require long handles to achieve mechanical advantage, leading to inefficiencies and potential work hardening due to discrete incremental steps and backlash, especially when multiple actuations are needed.
Innovation Solution
A crimping tool with a cam assembly and sprag clutch mechanism that allows continuous, smooth movement of jaws from open to closed positions, using a movable handle to rotate cam members and prevent reverse rotation, coupled with a biasing member for efficient crimping and easy reset.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single actuation mechanism is used for crimping, then the tool structure is simple, but the handle length becomes excessively long to achieve sufficient mechanical advantage
Solution Approach 1:
The single actuation mechanism is segmented into multiple pump cycles, where each cycle delivers a portion of the total crimping force. The cam assembly divides the crimping action into discrete stages that can be accumulated over multiple handle actuations, eliminating the need for an excessively long handle while maintaining sufficient mechanical advantage.
Solution Approach 2:
The sprag clutch mechanism enables continuous accumulation of crimping force across multiple actuation cycles. Each pump cycle adds to the total force applied to the jaws, creating a continuous useful action that builds up the required crimping pressure without requiring all force to be generated in a single long-stroke motion.
2Length of moving object
If discrete incremental actuations are used for crimping, then the tool can be compact, but backlash and work hardening occur due to non-smooth jaw movement
Solution Approach 1:
The cam assembly is designed with continuous cam surfaces that guide the jaw movement through smooth, continuous arcs rather than discrete steps. This continuous action eliminates backlash between actuation cycles and prevents work hardening by maintaining consistent, vibration-free contact between the jaws and the workpiece throughout the crimping process.
Solution Approach 2:
The cam mechanism converts the periodic handle actuations into a controlled, progressive jaw closure sequence. Each cam lobe is shaped to provide optimized force distribution during its rotation, ensuring that the periodic input motions result in smooth, cumulative jaw movement without shocks or reversals that would cause backlash.
3Length of moving object
If multiple pump cycles are required for crimping, then sufficient force can be achieved with compact handles, but the number of actuations increases
Solution Approach 1:
The sprag clutch mechanism allows the crimping force to be continuously accumulated across multiple pump cycles without loss. Each actuation cycle builds upon the previous one, with the clutch preventing any reverse motion or energy loss, thereby maximizing the efficiency of each pump stroke and reducing the total number of cycles needed compared to traditional ratchet mechanisms.
Solution Approach 2:
The cam assembly varies the mechanical advantage parameter throughout the crimping cycle, providing higher force multiplication during the critical closing phases and optimized speed during the approach phases. This dynamic parameter adjustment allows sufficient force to be achieved in fewer cycles while maintaining compact handle dimensions.
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
Enables compact, efficient crimping with continuous motion, reducing handle pumping requirements and providing visual feedback on crimp completion, thus preventing work hardening and extending tool lifespan.
Implementation Method 1
A first cam member is rotatable about an axis, the first cam member being operably coupled to second jaw. A second cam member is rotatable about the axis, the second cam member being operable coupled to the first jaw.
Implementation Method 2
A clutch is operably coupled to the first cam member and the second cam member, the clutch being configured to allow free-rotation in first direction about the axis and prevent rotation in an opposite second direction.
Implementation Method 3
A biasing member is coupled between the first jaw and the second jaw, the biasing member biasing the first jaw and the second jaw towards the open position.
Data Source
AI summary
A tool and method of operating the tool is provided. The tool includes a first jaw, the first jaw arranged to rotate about a first pivot. A second jaw is arranged adjacent the first jaw, the second jaw arranged to rotate about a second pivot. A first cam member is rotatable about an axis, the first cam member being operably coupled to second jaw. A second cam member is rotatable about the axis, the second cam member being operable coupled to the first jaw. At least one movable handle is operably coupled to the first cam member and the second cam member. A clutch is operably coupled to the first cam member and the second cam member, the clutch being configured to allow free-rotation in first direction about the axis and prevent rotation in an opposite second direction.