Toggle Lever Crimping Pliers with Adjustable Knee Angle
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing crimping pliers face challenges in generating consistent pressing forces across various workpiece geometries and materials, leading to inadequate force distribution when handling workpieces with different cross-sectional areas, which can result in either insufficient or excessive force application.
Innovation Solution
The design incorporates a toggle lever drive with a roller-curve principle and a ratchet mechanism, along with a force-displacement compensation element, such as a spring element, to manage the movement of the actuating elements and dies, allowing for adjustable knee angles and flexible deformation to accommodate workpieces of varying sizes, ensuring controlled force application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a toggle lever drive is used to generate pressing forces, then the required maximum pressing forces can be generated by manual actuation, but the pressing force distribution becomes inconsistent when handling workpieces with different cross-sectional areas
Solution Approach 1:
The patent applies the dynamics principle by making the knee angle of the toggle lever drive adjustable during operation. The drive mechanism transitions from a fixed geometric configuration to a dynamically adjustable one, allowing the knee angle to be changed based on the workpiece cross-sectional area. This enables the pressing force characteristics to be adapted to different workpiece geometries while maintaining the ability to generate required maximum pressing forces through manual actuation.
2Manufacturing precision
If the knee angle of the toggle lever drive is fixed, then the pressing force characteristics are determined, but the device cannot accommodate workpieces with cross-sectional areas differing by large factors
Solution Approach 1:
The patent implements dynamics by enabling the knee angle to be dynamically adjusted during operation. The drive mechanism includes components that allow changing the geometric relationship between toggle levers based on the specific workpiece being pressed. This dynamic adjustment capability expands the range of applicable workpiece sizes from a fixed set to a continuous range, while maintaining precise pressing force control through the toggle lever mechanical advantage.
Solution Approach 2:
The patent applies parameter changes by modifying the knee angle parameter of the toggle lever drive to match the workpiece cross-sectional area. The system includes adjustment mechanisms that change the geometric parameters of the drive mechanism, specifically the knee angle, to optimize pressing force distribution for each workpiece size. This parameter adjustment enables the device to handle workpieces with cross-sectional areas differing by factors of up to 200.
3Reliability
If a ratchet mechanism is added to secure the hand lever position, then operational safety is improved, but the device complexity increases
Solution Approach 1:
The patent applies the merging principle by integrating the ratchet mechanism with the existing toggle lever drive and hand lever assembly. The ratchet components are combined with the mechanical structure already present, sharing common elements such as the hand lever, pivot points, and mounting structures. This integration approach adds the security function without proportionally increasing overall device complexity, as the ratchet mechanism utilizes the existing structural framework.
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
This configuration enables crimping pliers to effectively handle workpieces with cross-sectional areas differing by a factor of up to 200, providing precise control over pressing forces and preventing excessive deformation, while maintaining operational ease and safety.
Implementation Method 1
force-displacement compensation element, such as a spring element
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a crimping tool with two hand levers (3, 5) and two actuating elements (9, 10) arranged in the area of a crimping head (4), which actuate dies (12) between which a workpiece can be crimped. A toggle lever drive (33) with two toggle levers (34, 35) forming a toggle angle (36) acts between the hand levers (3, 5) and the actuating elements (9, 10). One toggle lever (34) is formed by a roller (23) which is rotatably mounted relative to the hand lever (5). The roller (23) rolls on a cam track (24) fixed to the other hand lever (3). A positive locking mechanism (48) is formed by a locking toothed lever (28) which is rotatably mounted relative to the roller (23). One lever part (30) of the locking tooth lever (28) is coupled to the hand lever (3) via a sliding guide, while the other lever part (29) of the locking tooth lever (28) forms a locking tooth (31) of the positive locking mechanism (48).