Open-Head Dieless Crimping Tool for Large Conductor Access
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Solution Overview
Problem
Existing portable dieless crimping tools face challenges in accessing and crimping large conductors, such as #8 conductors and larger, especially in environments like overhead high tension power lines, where traditional locking nest structures are not suitable.
Innovation Solution
A dieless crimping tool design featuring a working head with a partially open I-beam structure, providing open access to a working area, and a nest positioned within this area for receiving crimping members. The tool includes a piston coupled to an indentor that moves along an indentor guide assembly between a home position and an impacting position adjacent the nest, allowing for effective crimping without dies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a locking nest structure is used to withstand crimping forces, then structural strength is improved, but accessibility to the working area deteriorates
Solution Approach 1:
The head frame is divided into multiple I-beam structures with open sections, segmenting the enclosure to provide access pathways while maintaining overall structural strength through the distributed I-beam framework
Solution Approach 2:
The head frame employs an asymmetric I-beam structure with strategically positioned open sections that provide optimal access to the working area while maintaining sufficient strength in critical load-bearing regions
2Adaptability or versatility
If a dieless crimping operation is used, then adaptability is improved, but crimping force deteriorates
Solution Approach 1:
A hydraulic system with a piston is integrated into the tool to generate and transmit high crimping forces through hydraulic pressure, enabling dieless crimping operations to achieve sufficient force levels for large conductors
Solution Approach 2:
The hydraulic system allows dynamic adjustment of crimping force parameters, enabling the tool to adapt force levels to different conductor sizes and crimping requirements while maintaining adaptability across various applications
3Device complexity
If an indentor is used to impact wire lugs, then device complexity is reduced, but manufacturing precision deteriorates
Solution Approach 1:
An indentor guide assembly acts as an intermediary mechanism between the piston and the indentor, ensuring precise positioning and alignment of the indentor with the wire lug while maintaining relatively simple device architecture
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 effectively crimps large conductors without the need for dies, offering flexibility and suitability for use in various environments, including those with overhead high tension power lines, while maintaining structural integrity and safety.
Implementation Method 1
a piston coupled to the indentor that moves the indentor along the indentor guide assembly between a home position adjacent the tool frame and an impacting position adjacent the nest
Data Source
Figure 1
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AI summary
Portable, hand held, battery operated, dieless, hydraulic crimping tools are provided with a working head and a tool frame. The working head has a head frame with an open access to a working area of the working head. The open access may be in the form of a C- shape. The working head has a nest to receive a crimping member. An indentor is attached to a piston within the tool frame. The piston moves the indentor between a home position adjacent the tool frame and an indenting position where the indentor impacts the crimping member.