Piston-Actuated Crimping Tool Holder for Reduced Hand Strain
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Solution Overview
Problem
Manual crimping tools for electrical wires and terminals are taxing on mechanics' hands, especially when high output rates are required, and existing solutions that reduce hand strain are not universally applicable due to safety protocols and regulatory limitations.
Innovation Solution
A device with a piston subassembly and holding subassembly that securely holds the tool's legs, allowing actuation without manual compressive force through a pneumatic system, where a piston head moves between positions to bring the legs together, actuating the tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual crimping is used to operate the tool, then the mechanic can directly control the crimping action, but it causes strain on the mechanic's hand and wrist especially at high output rates
Solution Approach 1:
The patent replaces the manual mechanical squeezing action with an electrical actuator system. The actuator receives an electrical signal and automatically actuates the tool legs to close the crimping head, eliminating the need for manual hand squeezing and thereby reducing hand and wrist strain while maintaining high output rates.
Solution Approach 2:
The patent employs a pneumatic actuator that uses compressed air to drive the tool legs together. The pneumatic system provides automated actuation force, replacing manual mechanical effort and enabling high-speed crimping operations without causing hand strain to the mechanic.
2Ease of operation
If a foot portion is added to provide leverage, then less force is required from the mechanic's hand, but it still puts strain on the hand and wrist and is not usable with short wires
Solution Approach 1:
The patent replaces the foot-portion leverage system with an electrical actuator that directly controls the tool legs. This substitution eliminates the need for manual leverage mechanisms entirely, reducing hand force requirements to minimal levels for triggering the actuator, and enabling use with short wires since no manual squeezing or foot pressure is needed.
3Ease of operation
If electrical crimping devices are used to reduce hand strain, then less strain is placed on the mechanic's hand, but they are not useable in many applications due to safety protocols and regulations
Solution Approach 1:
The patent introduces a controller as an intermediary between the user and the actuator. The controller receives a trigger signal from the user and then actuates the tool through the actuator mechanism. This intermediary approach allows the system to maintain electrical automation benefits while providing manual control oversight, potentially meeting safety protocol requirements that mandate human involvement in the crimping process.
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
Reduces mechanical strain on the hand and wrist by automating the crimping process, enabling efficient actuation of tools for various applications without manual force application, thus improving user safety and productivity.
Implementation Method 1
A device with a piston subassembly and holding subassembly that securely holds the tool's legs, allowing actuation without manual compressive force through a pneumatic system
Data Source
AI summary
Devices and methods for actuating a tool and methods for making such devices are provided. In one example, the device includes a piston subassembly. The piston subassembly includes a cylinder having a cavity, a head disposed in the cavity to move between first and second positions, and a rod coupled to the head and extending away from the second position. A holding subassembly is coupled to the piston subassembly. The holding subassembly includes a first holding member coupled to the rod and configured to hold a first leg of the tool and a second holding member spaced apart from the first holding member. The second holding member is configured to hold the second leg of the tool. When the head moves from the first position towards the second position, the rod moves the first holding member towards the second holding member.