Wire Forming Plier with Symmetric Round Barrels
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Solution Overview
Problem
Conventional tools for forming electrical wire loops, such as long-nose pliers and multi-tools, often damage the wire due to asymmetrical serrated jaws, leading to inconsistent loop geometries and weakened conductors, which can cause connection failures and safety issues.
Innovation Solution
A multi-purpose plier with symmetrically shaped round barrels at the anterior ends, allowing for controlled wire forming without damaging the wire, and featuring a lap joint for secure alignment, insulated grips for safety, and integrated stations for stripping, crimping, and cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional long-nose pliers with asymmetrical serrated jaws are used to form wire loops, then the wire can be bent into a loop shape, but the wire surface is damaged with nicks and scratches
Solution Approach 1:
The patent replaces the conventional asymmetrical serrated jaws with rounded, smooth-formed jaws that have curved surfaces. This spheroidality principle eliminates sharp edges that cause nicks and scratches on the wire, allowing the wire to be formed into loops without surface damage while maintaining consistent loop geometry.
Solution Approach 2:
The patent employs asymmetrical jaw designs where each jaw has a different profile - one jaw features a rounded forming surface while the other has a complementary shaping surface. This controlled asymmetry enables precise loop geometry formation without the damage caused by conventional symmetrical serrated jaws.
2Ease of operation
If conventional pliers are used to form wire loops, then the wire can be bent, but the loop geometry is inconsistent
Solution Approach 1:
The patent incorporates locally optimized jaw surfaces with specific radii and curvature profiles designed for different wire gauges. Each section of the jaw has tailored geometric properties that ensure consistent loop formation for specific wire sizes, improving manufacturing precision while maintaining ease of operation.
Solution Approach 2:
The patent provides multiple jaw configurations with different forming radii and geometries to match various wire gauges and terminal requirements. By changing the geometric parameters of the jaws according to the specific application, consistent loop geometry is achieved across different wire sizes and terminal types.
3Ease of operation
If sharp serrated jaws are used to grip and form wire, then the wire can be manipulated, but the conductor strength is weakened
Solution Approach 1:
The rounded, curved jaw surfaces provide gentle contact with the wire during manipulation and forming operations. This eliminates stress concentration points that would occur with sharp edges, maintaining conductor strength while still enabling effective wire manipulation and loop formation.
Solution Approach 2:
The smooth, rounded jaw surfaces act as an intermediary between the tool and the wire, distributing contact forces evenly across the wire surface. This mediates the gripping and forming actions to avoid localized stress that would weaken the conductor, while still providing sufficient control for wire manipulation.
Data Source
AI summary
A wire forming plier and electrical multi-tool for the purpose of forming, stripping, crimping and cutting electrical wire is disclosed. The plier features two arms overlapped and pivoted together; the posterior ends of the arms serve as handles. Two symmetrically shaped round barrels, different in size, identified with indicia, extend from the anterior ends of the plier arms for the purpose of forming a controlled bend in electrical wires/conductors of varying thicknesses/gauges to fit around specific terminal screw/stud sizes. As the handles are squeezed together, the cylindrical tips will grasp the electrical conductor by applying pressure to the wire between the round and smooth barrel surfaces. While the wire is securely held between the cylindrical tips the wire loop is quickly and easily formed around either barrel by manually rotating the entire tool about a longitudinal axis in either direction.