PEX Crimping Tool With Power Screw Jaw Actuation
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Solution Overview
Problem
Manual crimping tools for PEX tubing are inefficient and lack the precision and power needed for consistent crimping operations, particularly in residential and commercial construction where polymer tubing is increasingly used due to the rising cost of copper pipes.
Innovation Solution
A power tool with a drive unit, power screw mechanism, and a working assembly featuring pivotally coupled jaws and a biasing member, along with an electronic control system that includes sensors and a controller to manage the crimping process, providing axial movement and torque for efficient crimping operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual crimping tools are used, then the tool complexity is low, but the crimping precision and consistency are insufficient
Solution Approach 1:
The patent replaces the purely mechanical manual operation with a power-driven system incorporating an electric motor, control circuitry, and automated actuation mechanisms. This substitution enables precise control of crimping force and duration through electronic means, significantly improving crimping precision while accepting increased device complexity.
Solution Approach 2:
The crimping tool incorporates a control system that automatically manages the crimping process parameters including force application, duration, and jaw positioning. The system self-regulates the crimping operation based on sensor feedback and pre-programmed sequences, eliminating the need for manual judgment and ensuring consistent precision across all operations.
2Productivity
If manual crimping tools are used, then the ease of operation is maintained, but the productivity and efficiency are low
Solution Approach 1:
The power-driven crimping tool enables continuous operation without the fatigue and speed limitations of manual tools. The automated system can perform crimping operations continuously at consistent speeds, significantly boosting productivity. The tool maintains operational simplicity through intuitive controls and automatic cycle management, requiring minimal user intervention.
Solution Approach 2:
The patent extracts the physically demanding aspects of crimping from the operator by incorporating a power drive system. The motor performs the force-intensive work of actuating the crimping jaws, while the operator's role is reduced to positioning the tubing and initiating the automated cycle, thereby improving both productivity and ease of operation.
3Force
If power-driven mechanisms are added, then the crimping power and force are improved, but the device complexity increases
Solution Approach 1:
The power transmission system is segmented into distinct functional modules including the motor unit, transmission mechanism, and jaw actuation system. This segmentation allows each component to be optimized independently and facilitates easier maintenance and troubleshooting. The modular approach manages complexity by organizing the power-driven elements into manageable, functionally-separated units.
Solution Approach 2:
The patent incorporates intermediate transmission elements such as gears, belts, or linkages that mediate between the motor and the crimping jaws. These intermediaries transform the motor's rotational output into the linear force required for crimping, while also providing mechanisms for force multiplication and controlled delivery, thereby achieving high crimping force without directly coupling the motor to the jaws.
4Volume of moving object
If a compact design is implemented, then the material costs and space are reduced, but the stability and precision may be compromised
Solution Approach 1:
The patent employs a nested design where the inner housing containing precision components is positioned within the outer housing. This nested arrangement maximizes space utilization, creating a compact overall form factor while providing protective enclosures for sensitive elements. The concentric housing structure inherently provides structural stability and rigidity despite the reduced overall size.
Solution Approach 2:
The housing structure utilizes composite construction combining rigid materials for structural support with lighter materials for non-critical components. This composite approach reduces overall weight and material costs while maintaining the necessary structural stability and precision alignment. The strategic selection of materials allows for a compact design without compromising the rigidity required for precise crimping operations.
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 power tool enables efficient, precise, and consistent crimping of PEX tubing fittings, reducing manual effort and improving the quality and repeatability of the crimping process while minimizing material costs through a compact and stable design.
Implementation Method 1
a ball screw mechanism including a ball screw and a nut, the nut being affixed to the inner housing and the ball screw being rotatable about an axis parallel to the rotational axis of the output shaft and in threaded engagement with the nut such that the ball screw is axially displaceable in response to rotation of the ball screw relative to the nut
Data Source
AI summary
A power tool includes an outer housing having a drive unit support portion and a handle portion, an inner housing positioned at least partially within the outer housing, and a drive unit positioned in the drive unit support portion, the drive unit including an output member. The power tool also includes a power screw mechanism with a nut fixed relative to the outer housing and a screw coupled for co-rotation with the output member and axially movable relative to the output member. The screw is in threaded engagement with the nut such that the screw moves axially in response to rotation of the screw relative to the nut. The power tool also includes a working assembly coupled to the inner housing for movement in response to axial movement of the screw.