Ram Retraction Selection for Battery-Powered Crimping Tools
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Solution Overview
Problem
Battery-powered crimping tools lack efficient control over ram retraction, leading to inconsistent and wasteful battery usage, particularly when repeatedly crimping the same size of connector, as existing systems rely on manual trigger control or mechanical stoppers not applicable to battery hydraulic tools.
Innovation Solution
A user-selectable retraction control system with a rotatable selector member and hydraulic fluid release system allows users to set specific retraction locations for the ram, minimizing unnecessary battery consumption by optimizing the amount of ram retraction based on the connector size and material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If manual trigger control is used for ram retraction, then the tool can be operated, but battery consumption is excessive and retraction is inconsistent
Solution Approach 1:
The patent applies parameter changes by providing multiple predetermined retraction positions (first, second, and third positions) corresponding to different connector sizes. The user can select from these predefined parameters rather than manually controlling continuous retraction, which reduces battery consumption by avoiding unnecessary retraction while maintaining operational ease through standardized position selection.
Solution Approach 2:
The patent implements dynamics by making the retraction control system adaptive to different working conditions. The system dynamically adjusts the retraction stopping position based on the selected connector size, transitioning from static manual trigger control to a dynamic system that automatically positions the ram at optimal retraction points for different applications.
2Duration of action of moving object
If full retraction is used for all crimps, then the ram returns to starting position, but battery life is reduced and crimp cycle time increases
Solution Approach 1:
The patent applies partial action by providing predetermined retraction positions that correspond to partial retraction rather than full retraction to the starting position. The first retraction position provides partial retraction for small connectors, the second position provides intermediate retraction for medium connectors, and the third position provides full retraction for large connectors. This eliminates unnecessary retraction distance while ensuring adequate ram withdrawal for each connector size, thereby extending battery life without compromising productivity.
3Ease of operation
If mechanical stoppers are used, then retraction is limited, but the device complexity increases and it is not applicable to battery hydraulic tools
Solution Approach 1:
The patent applies mechanics substitution by replacing complex mechanical stopper systems with a simplified control system. Instead of using physical mechanical stoppers at different retraction positions, the invention uses a control system that receives user input and automatically positions the ram at the appropriate retraction position, thereby reducing mechanical complexity while maintaining ease of operation.
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 solution enables precise control over ram retraction, reducing battery consumption and shortening crimp cycle times by allowing users to set the exact amount of retraction needed for each crimp, thereby extending battery life and improving operational efficiency.
Implementation Method 1
a hydraulic drive system on the frame, wherein the hydraulic drive system comprises a hydraulic pump connected to the battery; a ram connected to the hydraulic drive system, wherein the ram is adapted to be extended on the frame by hydraulic fluid from the hydraulic drive system
Implementation Method 2
the ram retracts to its original rear position with the aid of a spring pressing against the ram
Data Source
AI summary
A compression tool including a ram; a drive system, a battery and a user selectable retraction control. The drive system is connected to the ram to extend the ram and allow retraction of the ram. The battery is connected to the drive system to at least partially power the drive system. The user selectable retraction control is connected to the drive system. The user selectable retraction control includes a plurality of ram retraction settings which are adapted to be selected by a user to at least partially control respective different retraction stopping locations of the ram.