Abstract:
A die set for bending work pieces using a power crimping tool, the die set including a first die including a first inside surface and a second inside surface angled a predetermined number of degrees relative to the first surface and a second die including an inside surface corresponding to the first inside surface of the first die and an inside surface corresponding to the second inside surface of the first die.

Description:
BACKGROUND 
       [0001]    Field 
         [0002]    The present disclosure relates to crimping dies and, more particularly, to crimping dies for making bends. 
         [0003]    Description of the Related Art 
         [0004]    Many portable power tools are hand held tools that use electric motors to drive a working head used to perform various tasks, such as crimping, drilling, shaping, fastening, grinding, polishing, heating, etc. There is a segment of the portable tool product market that incorporate a hydraulic pump to enable the working head to apply a relatively large amount of force or pressure for a particular task. Such tools may operate with a hydraulic pump actuated by a battery powered electric motor. Battery powered hydraulic power tools are employed in numerous applications to provide an operator with a desired flexibility and mechanical advantage. For example, operators of crimping tools used for making crimping connections, such as crimping large power connectors onto large conductors, may need added force to crimp such large conductors, e.g., #8 conductors and larger, to suitable connectors. As another example, operators of cutting tools attempting to cut large conductors, e.g., #8 conductors and larger, benefit greatly when utilizing hydraulic power which enables the operator to apply greater force to quickly and cleanly cut such large conductors. 
         [0005]    Heretofore, technicians working in the field have been required to carry with them wire lugs of various shapes and sizes. The wire lugs are generally aluminum or copper, although other metals and/or alloys may be utilized as suitable. The wire lugs generally include a wire receiving part and a connection part. The wire lugs are currently manufactured in straight form or in preformed angles where the wire receiving part of the wire lugs are at an angle relative to the connection part of the lug. Thus, in the field, service personnel need to carry with them numerous different angled types of lugs in the event they are needed for a particular job. 
         [0006]    What is needed is a system that allows technicians in the field to carry just straight wire lugs. The wire lugs can then be bent by the technician at desired angles as suitable for a particular job. 
       SUMMARY 
       [0007]    A die set for bending work pieces using a power crimping tool, the die set including a first die including a first inside surface and a second inside surface angled a predetermined number of degrees relative to the first surface and a second die including an inside surface corresponding to the first inside surface of the first die and an inside surface corresponding to the second inside surface of the first die. 
         [0008]    A die set for bending work pieces using a power crimping tool, the die set including a pair of opposing dies having opposing surfaces between which forms a work area, wherein the opposing surfaces form a work area for bending a portion of the work piece at a predetermined angle with respect to another portion of the work piece. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    A more complete appreciation of the present disclosure and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein: 
           [0010]      FIG. 1  is a perspective view of a power crimping/bending tool utilized according to illustrative embodiments of the present disclosure; 
           [0011]      FIG. 2  is a block diagram for describing various parts of the power crimping/bending tool shown in  FIG. 1  according to illustrative embodiments of the present disclosure; 
           [0012]      FIGS. 3 and 4  are partial perspective views for describing a die set for bending a work piece at a 90 degree angle according to an embodiment of the present disclosure; 
           [0013]      FIGS. 5, 6 and 8  are partial perspective views showing the die set described with respect to  FIGS. 3 and 4  at various stages during bending of a work piece, according to an embodiment of the present disclosure; 
           [0014]      FIG. 7  is a close up view of a work piece being bent utilizing the die set shown in  FIGS. 3 and 4  according to embodiments of the present disclosure; 
           [0015]      FIGS. 9 and 10  are partial perspective views for describing a die set for bending a work piece at a 30 degree angle according to illustrative embodiments of the present disclosure; and 
           [0016]      FIGS. 11 and 12  are partial perspective views for describing a die set for bending a work piece at a 45 degree angle according to illustrative embodiments of the present disclosure. 
       
    
    
     DETAILED DESCRIPTION 
       [0017]    Illustrative embodiments of the present disclosure may be provided as improvements to power crimpers. For example, a power crimper may be provided with dies capable of bending the wire receiving part of a wire lug at an angle relative to the connection part of the wire lug. 
         [0018]    Illustrative embodiments of the present disclosure allow technicians in the field to carry straight wire lugs only. The technician in the field can then make appropriate bends in the wire lugs to suit a particular job requirement. 
         [0019]    According to various illustrative embodiments of the present disclosure, die sets are provided for bending wire lugs to particular angles. With the die sets of the present disclosure, service personnel can carry one lug type—straight lugs—and make any required bends to the wire lugs as needed in the field. 
         [0020]    In certain illustrative embodiments described herein, a die set may be constructed from a material that is generally harder and/or less malleable than the material being bent. For example, according to various embodiments of the present disclosure, die sets are provided for bending wire lugs which are generally made from relatively soft and/or malleable materials such as copper or aluminum. The die sets may be made from steel or an alloy that is relatively harder and/or less malleable than copper and/or aluminum. 
         [0021]    Referring to  FIG. 1 , there is shown a portable hand tool  10  according to an embodiment of the present disclosure. The portable hand tool shown in the figures and described herein is a portable, hand held, battery operated, hydraulic crimping tool. Although the present disclosure describes the hand tool as a portable, hand held, battery operated, hydraulic crimping tool, it should be understood that the tool of the present disclosure is not limited to such crimping tools. Features of the portable hand tool of the present disclosure could also be used in other types of tools, such as a battery operated, hydraulic bending tools or any other suitable type of battery operated tool. In addition, any suitable size, shape or type of elements or materials can be used to form the shape of the tool frame. For ease of description, the portable, hand held, battery operated, hydraulic crimping tool shown and described herein will be referred to as the “tool.” 
         [0022]    Referring to  FIGS. 1 and 2 , the tool  10  according to an exemplary embodiment of the present disclosure generally includes a frame  12 , a working head  14 , a pump  16 , a motor  18 , a battery  20 , a fluid reservoir  22 , a controller  24  and a hydraulic drive conduit system  28 . The frame  12  includes a main body  13  and a handle  40  that form a pistol-like shape. However, the frame  12  could be in any suitable type of shape, such as, for example, an in-line shape. 
         [0023]    The pump  16 , motor  18 , fluid reservoir  22 , controller  24 , and hydraulic drive conduit system  28  are located within the main body  13  of the frame  12 . The tool  10  may also include a camera  26  mounted to the frame  12  and oriented to provide a video of a working area of the working head  14 . The working head  14  includes a frame section  30  and a ram  32 . The frame section  30  may be connected to the front end of the frame  12  and fixed or locked in position, or the frame section  30  may be rotatably connected to the frame  12 . The ram  32  is movably connected to the frame section  30  of the working head  14 . In the exemplary embodiment shown, the frame section  30  and the ram  32  are adapted to removably receive conductor crimping dies (not shown) at a receiving area  34 . According to embodiments of the present disclosure, the frame section  30  and ram  32  are also adapted to removably receive wire lug bending dies (not shown) at receiving area  34 . 
         [0024]    The ram  32  is adapted to move forward and backward as indicated by arrow  36 . The hydraulic drive conduit system  28  is connected between the pump  16  and the rear end of the ram  32 . Hydraulic fluid pumped by the pump  16  through the hydraulic drive conduit system  28  and against the rear end of the ram  32  causes the ram to move forward the distance “D” toward a distal end of the working head  14 . The tool  10  preferably includes a spring (not shown) which is adapted, as is known in the art, to return the ram  32  to its rearward (or home) position when hydraulic fluid pressure is removed from the rear end of the ram  32 . In the exemplary embodiment shown, the ram  32  has a rear end diameter of about 2 inches. However, the diameter of the rear end of the ram could have any suitable size or shape for functioning as a hydraulic fluid contact surface. In the exemplary embodiment shown, the ram  32  is adapted to move a distance “D” between its home position and its forward position which is towards the distal end of the working head  14 . The distance “D” can be any distance suitable to perform the desired action of the working head  14 , here the desired crimping and/or bending action. For example, the distance “D” could be between about 1 inch and about 2 inches, and preferably about 1.7 inches. 
         [0025]    The handle  40  includes one or more operator controls, such as trigger switches  44  and  46 , which can be activated by an operator by, for example, pressing the trigger switches. The handle  40  of the frame  12  may include a hand guard  42  to protect an operators hand while operating the tool  10  and to prevent unintended operation of trigger switches  44  and  46 . According to an embodiment of the present disclosure, one of the trigger switches (e.g., trigger switch  44 ) is used to activate the ram  32  to move it toward the distal end of the working head  14  and perform the crimping or bending operation. The other trigger switch (e.g., trigger switch  46 ) is used to retract ram  32  to the base position shown in  FIG. 1 . The operator controls (e.g., trigger switches  44  and  46 ), are operably coupled to the controller  24 . As shown in  FIG. 1 , a battery  20  is removably connected to the bottom of the handle  40 . In another embodiment, the battery  20  could be removably mounted or connected to any suitable position on the frame  12 . In another embodiment, the battery  20  may be affixed to the tool  10  so that it is not removable. The battery  20  is preferably a rechargeable battery, such as a lithium ion battery, that can output a voltage of at least 16 volts, and preferably in the range of between about 16 VDC and about 24 VDC. In the exemplary embodiment shown in  FIG. 1 , the battery  20  can output a voltage of about 18 VDC. 
         [0026]    The motor  18  is coupled to the battery  20  and the controller  24 , and its operation is controlled by the controller  24 , which will be described in more detail below. Generally, the motor  18  is adapted to operate at a nominal voltage corresponding to the voltage of the battery  20 , i.e., between about 16 volts and about 24 volts. For example, if the battery  20  is adapted to output a voltage of about 18 volts, then the motor  18  would be adapted to operate at a voltage of about 18 volts. Under a no-load condition, such a motor  18  can operate at about 19,500 rpm with a current of about 2.7 amps. At maximum efficiency, the motor  18  can operate at about 17,040 rpm with a current of about 18.7 amps, a torque of about 153 mN-m (1560 g-cm), and an output of about 273 W. An example of such an 18 volt motor  18  may be a RS-775WC-8514 motor, manufactured by Mabuchi Motor Co., Ltd. of Chiba-ken, Japan. However, as noted above, any suitable type of motor adapted to operate above a 16 V nominal voltage could be used. For example, the motor may be a RS-775VC-8015 motor, also manufactured by Mabuchi Motor Co., Ltd., which has a nominal operating voltage of about 16.8 volts. As another example, the motor may be a motor adapted to operate at a 24 V nominal voltage. The output shaft of the motor  18  is connected to the pump  16  by a gear reduction or gearbox  48 . Any suitable type of gear reduction assembly  48  could be provided. 
         [0027]    Referring again to  FIG. 2 , the tool  10  may include a poppet valve  50  connected to the hydraulic drive conduit system  28 . The poppet valve  50  is adapted to open when the conduit system  28  reaches a predetermined pressure, such as between about 8000 and about 11,000 psi. When the poppet valve opens, hydraulic fluid being pumped by the pump  16  can exit the conduit system  28  and return to the fluid reservoir  22 . The poppet valve  50  can be adapted to generate an audible sound when it opens. This audible sound can signal to the operator that the tool  10  has reached its maximum predetermined hydraulic pressure and, thus, the action of the working head  14 , e.g., crimping and/or bending action, is completed. 
         [0028]    In the exemplary embodiment shown in  FIG. 2 , the controller  24  is adapted to sense a current drop of electricity to the motor  18 . When the poppet valve  50  opens, resistance to rotation of the motor  18  is reduced such that the motor draws less current. The controller  24  senses this current drop via a current sensor  120  (not shown), and automatically deactivates the motor  18  for a predetermined period of time. In a preferred embodiment, the predetermined period of time is between about 2 seconds and about 3 seconds. However, any suitable predetermined period of time could be set. In an alternate embodiment, the controller  24  could be adapted to deactivate the motor  18  until a reset button or reset like procedure is performed by the operator. With this type of system, an operator can sense via a tactile feedback that the motor  18  and pump  16  have stopped and would not need to rely on an audible signal being heard or a visual signal from an LED positioned on the tool  10 . Crimping die sets are available that can be inserted in working area  34  for crimping wire cables to wire lugs. In addition, according to embodiments of the present disclosure described below, wire lug bending die sets are provided for bending wire lugs as desired. 
         [0029]    According to an embodiment of the present disclosure as shown in  FIGS. 3 and 4 , a die set  100  includes die  100 A and corresponding die  100 B which are inserted in receiving area  34  of tool  10 . According to this embodiment of the present disclosure, the die set  100  is utilized for making a 90 degree bend in a workpiece such as a wire lug. The distal ends of ram  32  include protruding edges  102  and  104 . Die  100 A includes slots  106  and  108  that slidably engage protruding edges  102 ,  104 , respectively as shown. Fixed end  110  of tool  10  includes protruding edges  112 ,  114 . Die  100 B includes slots  116  and  118  that slidably engage protruding edges  112 ,  114 , respectively as shown. The slots and protruding edges allow the dies to be removably attached to the working end of tool  10  as shown. According to an embodiment of the present disclosure, dies  100 A and  100 B are interchangeable. Die  100 A includes vertical surface  153  and a substantially horizontal member surface  150  extending from a top edge thereof. Horizontal member surface  150  includes an arched rollover surface  151 , the purpose of which will be described later below. Die  100 B includes a vertical surface  155  which corresponds to vertical surface  153  of die  100 A and a substantially flat surface  152  which is perpendicular to surface  155 . 
         [0030]    A workpiece to be bent in this example is a two holed straight wire lug  2  as shown in  FIG. 3 . The wire lug  2  includes an end  4  having a tubular opening  3  which is dimensioned for receiving a cable of a specified diameter or a cable within a specified range of diameters. The cable is permanently attached to end  4  of wire lug  2  by a crimping process utilizing tool  10  and crimping dies (not shown). The wire lug  2  also includes a substantially straight flat end  6  having one or more holes  8  therein. Holes  8  are dimensioned for attachment to an attachment point such as, for example, a threaded post. 
         [0031]    As shown in  FIG. 5 , with the ram  32  in the retracted position, the flat end  6  of wire lug  2  is inserted into a work area between dies  100 A,  100 B and held in position by the operator. The operator then presses trigger  44  of tool  10  causing the ram  32  to move in direction X as shown in  FIG. 6  until the operator receives an audible and/or tactile feedback from tool  10  as described above indicating that the motor  18  and/or pump  16  have stopped. As shown in close-up in  FIG. 7 , horizontal surface  150  of die  100 A and horizontal surface  152  of die  100 B bend the wire lug  2  at point  5  to a 90 degree angle. In addition, arched rollover surface  151  of die  100 A smoothly rolls the end  4  of wire lug  2  such that the tubular opening  3  of wire lug  2  is at a 90 degree angle relative to flat end  6 . The operator then presses trigger  46  retracting ram  32  to the position as shown in  FIG. 8  so that now bent wire lug  2  can be easily removed. 
         [0032]    According to an embodiment of the present disclosure as shown in  FIGS. 9 and 10 , a die set  300  is provided for making a 30 degree bend in a workpiece such as wire lug  2 . Die  300 A includes a vertical surface  302  and a surface  304  that is 30 degrees from vertical as shown. Die  300 B includes corresponding surfaces  306  and  308  as shown. The flat end  6  of wire lug  2  is inserted into the work area between dies  300 A and  300 B and held in place by the operator. The operator presses trigger  44  causing ram  32  to move in direction X, bending flat end  6  of wire lug  2  such that end  4  of wire lug  2  is bent at a 30 degree angle with respect to flat end  6  of wire lug  2 . Ram  32  can then be retracted so that wire lug  2  can be removed. 
         [0033]    According to an embodiment of the present disclosure as shown in  FIGS. 11 and 12 , a die set  400  is provided for making a 45 degree bend in a workpiece such as wire lug  2 . Die  400 A includes a vertical surface  402  and a surface  404  that is 45 degrees from vertical as shown. Die  400 B includes corresponding surface  406  and  408  as shown. The flat end  6  of wire lug  2  is inserted into the work area between dies  400 A and  400 B and held in place by the operator. The operator presses trigger  44  causing ram  32  to move in direction X, bending flat end  6  of wire lug  2  such that end  4  of wire lug  2  is bent at a 45 degree angle with respect to flat end  6  of wire lug  2 . Ram  32  can then be retracted so that wire lug  2  can be removed. 
         [0034]    The die sets contemplated by the present disclosure are not limited to those described above. For example, die sets may be provided for bending straight wire lugs to any suitable angle, generally from 0 to 135 degrees. Of course, die sets may be provided for bending straight wire lugs to angles greater than 135 degrees as desired for a particular job. That is, die sets can be provided such that virtually any angled bend can be made in the wire lug  2 . In addition, although the above described embodiments describe bending straight wire lugs, the die sets disclosed herein are capable of bending even wire lugs that are pre-bent to a particular angle to any other angle as desired. In addition, the above-described dies are capable of bending various sizes and types of wire lugs and are not limited to the particular wire lugs shown. For example, any suitable wire lug capable of fitting within the die sets may be used. The above described die sets may also be utilized for bending items other than wire lugs including, for example, ground bars, connectors, etc. 
         [0035]    In the above-described embodiments, the wire lug is shown prior to a wire or cable being crimped onto the wire lug. Of course, if desired, the wire or cable may be crimped onto the wire lug prior to bending. 
         [0036]    It is noted that the outside surfaces of the die sets described above are semicircular in cross section to match the portions of the tool on which they are to be attached. It will be appreciated that the present disclosure is not limited to the crimping/bending tool described herein and the outside surfaces of the dies sets may be provided in any suitable size and shape designed to fit the particular crimping/bending tool being used. 
         [0037]    As shown throughout the drawings, like reference numerals designate like or corresponding parts. While illustrative embodiments of the present disclosure have been described and illustrated above, it should be understood that these are exemplary of the disclosure and are not to be considered as limiting. Additions, deletions, substitutions, and other modifications can be made without departing from the spirit or scope of the present disclosure. Accordingly, the present disclosure is not to be considered as limited by the foregoing description.