Abstract:
A crimping tool for crimping an electrical contact toward engagement with an electrical conductor, including a housing, a pair of crimping dies, a die support arrangement supporting a first one of the crimping dies in a stationary position on said housing, and a displacing mechanism for displacing the other crimping die between open and closed positions relative to the stationary crimping die. The displacing mechanism includes a rotary drive shaft, a crimping arm having a first end portion connected with the movable crimping die member, and a rotary-to-reciprocatory motion converting mechanism adjacent the other end of the crimping arm for transforming the rotary motion of the drive shaft to a reciprocatory motion of the crimping arm, thereby to displace the movable crimping die between the open and closed positions.

Description:
REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of PCT Application No. PCT/EP2009/061992 filed Sep. 16, 2009, which is based on the German priority application No. 20 2008 013 411.0 filed Oct. 10, 2008. It is also related to the companion Broeker et al U.S. application Ser. No. 13/061,152 filed Feb. 27, 2011 [Attorneys Docket No. 50069]. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    A crimping tool for crimping an electrical contact toward engagement with an electrical conductor, including a housing, a pair of crimping dies, a die support arrangement supporting a first one of the crimping dies in a stationary position on said housing, and a displacing mechanism for displacing the other crimping die between open and closed positions relative to the stationary crimping die. The displacing mechanism includes a rotary drive shaft, a crimping arm, and a rotary-to-reciprocatory motion converting mechanism for transforming the rotary motion of the drive shaft to a reciprocatory motion of the crimping arm. 
         [0004]    2. Description of Related Art 
         [0005]    The state of the art reveals manually controlled crimping tools in the form of crimping pliers-type tools, where in order to press terminals, connectors or contacts onto electrical conductors, the two handles of the tool must be pressed together manually. Repeated use of such a crimping tool is very tiring for the hand of a user, so that in case of continuous use, the user, after several crimping functions, is no longer able to work the crimping pincers. 
         [0006]    The object of the present invention therefore is to provide a crimping tool that will make it possible to press cable lugs or cable connectors without getting tired. 
       SUMMARY OF THE INVENTION 
       [0007]    Accordingly, a primary object of the present invention is to provide a crimping tool for crimping an electrical contact toward engagement with an electrical conductor, including a housing, a pair of crimping dies, a die support arrangement supporting a first one of the crimping dies in a stationary position on said housing, and a displacing mechanism for displacing the other crimping die between open and closed positions relative to the stationary crimping die, said displacing mechanism including a rotary drive shaft, a crimping arm, and a rotary-to-reciprocatory motion converting mechanism for transforming the rotary motion of the drive shaft to a reciprocatory motion of the crimping arm. The drive shaft is adapted to be driven by an electric drill that is connected with the crimping tool by a support sleeve. 
         [0008]    According to a more specific object of the invention, the crimping arm is longitudinally displaced in the crimping direction by a ratchet wheel that is driven in given direction in a step-by-step manner by the drive shaft via rotary-to-reciprocating motion converting means. In one embodiment, the motion concerting means includes a crank arm for reciprocating a transport pawl. The rotary motion of the ratchet wheel is transmitted to the crimping arm by an eyelet and eccentric cylinder arrangement. In a second embodiment, the motion converting means includes a reciprocating linear follower member that is engaged at one end by the circumferential surface of a cam that is driven by the drive shaft, the other end of the follower member being connected with the transport pawl. Here, the rotary motion of the ratchet wheel is transmitted to the crimping arm via a pressure follower member that engages the surface of a cam that is connected with the ratchet wheel. 
         [0009]    According to another object of the invention, manually operable release means are provided for releasing the stationary crimping die from its stationary position relative to the housing, thereby to affording opening of the dies to clear a jam occurring during the crimping operation. 
         [0010]    Another object is to provide a crimping tool that can be held and guided by the hands of a user, such as this is the case, for example, in the case of a manual electric drilling machine. 
         [0011]    In the inventive crimping tool, a drive unit of the crimping tool has a drive shaft that is rotatably positioned around its longitudinal axis, which drive shaft can be driven by an electric motor. This electric motor supplies the force to be provided for the crimping procedure so that the hand of the user, as a result, is considerably relieved and only has to guide the crimping tool itself 
         [0012]    The drive shaft of the crimping tool can be clamped into a drill chuck of a drill connected with the electric motor in a final or a separable manner. In both cases, the user therefore has available an easily handled electric tool that in a simple manner and without any major effort can be operated or used by the user. In the latter case, it is furthermore advantageous that the user—for different working steps, for example, crimping of cable lugs and cutting cables—needs only one electrical tool, such as a manual drill or a storage battery-powered drill for employment at the corresponding yokes (crimping yoke, cutting yoke). 
         [0013]    According to a special embodiment, the crimping tool has a rotary support relative to the sleeve that is connected with the drill. The latter in a particularly preferred manner is stuck on the adaptor flange of a drill and is fixed by means of a clamping ring. Handling is definitely simplified as a result of this firm connection between drive part and drill. 
         [0014]    For the pressing motion required for a crimping use, the drive unit according to the invention has a transport catch that can be moved alternately in a reciprocatory manner, an eccentric wheel, and a crimping stamp. In particular, the crimping stamp is connected with the eccentric wheel by a connecting rod. In a simple manner, this facilitates a conversion of the translation movement of the transport catch into a rotary movement of the eccentric wheel, whereby the rotary motion of the eccentric wheel via the connecting rod is again converted into a translation movement of the crimping stamp. 
         [0015]    The conversion of the rotary movement of the drive shaft into a translation movement of the transport catch is brought about either via a crank drive or a cam drive. The cam drive offers the advantage that one can distribute the required movement for the crimping process most extensively freely upon the circumference of a cam disk. In this way, the working stroke can be adapted to the individual requirements. 
         [0016]    Preferably, the drive unit furthermore has a locking pawl that is pressed against the eccentric wheel by spring biasing means. This locking catch mechanism, in addition, prevents fast rotary movements of the eccentric wheel and makes it possible to guide the eccentric wheel in this fashion into the lower dead center of the drive mechanism in order then to be able to take out the cable lug with the crimp insert fully opened. 
         [0017]    Preferably, a manually controlled unit is arranged on the eccentric wheel for the purpose of manually turning the eccentric wheel. That facilitates the fast opening and closing of the crimp insert. 
         [0018]    In order to remove the terminals or connectors in a simple manner, or if the tool is not properly handled, the stationary crimping die can also be unlocked and opened when under load. For this purpose, the head unit is made with first and second support arms, whereby on the first support arm, there is rotatably positioned an eccentric bolt, which eccentrically is positioned on a tool housing part so that it can be rotated around a second pivotal point in such a manner that the first support arm can be moved parallel to the longitudinal axis of the first support arm away from the drive unit and so that, as a result, a locking action with the second support arm can be released. After unlocking, the support arms can be pivoted away laterally outwardly, and a connector that has been falsely inserted can then be taken out. 
         [0019]    According to a preferred embodiment, the crimping insert is removably retained by the support arms. This makes it possible to exchange the crimping insert, and that, in turn, makes it possible to make crimping connections in differing forms and with differing cross-sections. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0020]    Other objects and advantages of the invention will become apparent from a study of the following specification, when viewed in the light of the accompanying drawing, in which: 
           [0021]      FIGS. 1 and 2  are front and rear perspective views, respectively, of the crimping tool of the present invention; 
           [0022]      FIG. 3  is a front perspective view, with certain parts removed, of the crimping tool of  FIG. 1 ; 
           [0023]      FIG. 4  is a detailed front elevation view of a first crank-arm-driven embodiment of the operating mechanism of  FIG. 3 ; 
           [0024]      FIG. 5  is a detailed perspective view of a second cam-driven embodiment of the operating mechanism; 
           [0025]      FIGS. 6   a -  6   c  are detailed elevation views illustrating the manner of releasing the stationary crimping die from its normal crimping position; 
           [0026]      FIGS. 7 and 8  are front perspective views illustrating the operation of the crimping dies; 
           [0027]      FIGS. 9 and 10  illustrate the manner of connection of the crimping tool to an electric drill; and 
           [0028]      FIG. 11  illustrates the manner of rotation between the crimping tool and its support sleeve. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0029]    In the following description of figures, terms such as top, bottom, left, right, front, rear, etc., refer exclusively to the exemplary illustration and position of the crimping tool as chosen for the particular figures. These concepts are not to be construed in any restrictive manner, in other words, these relationships can change in different working positions or as a result of the mirror symmetry design or the like. 
         [0030]    Referring first more particularly to  FIGS. 1 and 2 , the crimping tool of the present invention includes a housing H that is rotatably connected with a support sleeve  21  that is adapted for connection with an electric drill, as will be described in great detail below, a head unit A, and a drive unit B. Handle  14  connected with the housing permits controlled rotation of the housing relative to the sleeve. Crimping means  19  including a pair of crimping dies  19   a  and  19   b  are provided for crimping a terminal or connector T with a conductor C, as will be described below. A first one of the crimping dies  19   a  is supported at a stationary position on the housing by a pair of vertical spaced support arms  17  and  50 , and a horizontal support arm that is connected between the upper ends of the vertical support arms. Manual activating means including a knob  11  are provided for manually operating the movable die member  19   b  toward its open position, and a release knob  20  provides means for opening the stationary crimping die  19   b  in the event of jamming of the crimping tool. 
         [0031]    Referring now to  FIG. 3 , the lower crimping die  19   b  is connected with the upper end of a crimping arm  16  that is connected for longitudinal movement relative to the housing H. The upper die  19   a  is supported in a stationary position relative to the housing by the vertical and horizontal support arms  17 ,  18  and  50 , as described above. The lower end of the crimping arm is connected with a pressure member  15  that is connected with the upper end of an eyelet connecting rod  13  having at its lower end an integral eyelet portion  22 . Alternatively, the crimping arm could be spring biased toward the open position. As shown in  FIG. 4 , the connecting rod eyelet portion  22  of connecting rod  13  is mounted on a tubular ball bearing race  12  which is rotatably supported on a circular disk  112  that is eccentrically arranged relative to a ratchet wheel  8  that is rotatably connected with the housing. The upper end of the connecting rod  13  contains a recess  23  that receives the protuberance portions  24  of the pressure member  15 , which pressure member has a front surface  25  for engagement with the crimping arm  16 . The ratchet wheel  8  is provided on its outer circumference with a set of ratchet teeth  28 . The ratchet wheel  8  is rotated in a given direction in a step-by-step manner by a transport pawl  6  that is reciprocated (as shown by the arrow F) by the drive shaft  1  supported in ball bearings  3  via crank means  4   a , crank arm  4 , and slide member  5 . The transport pawl  6  is pivotally connected with the slide member  5  by a tongue and groove connection  26 ,  27 , and is biased by compression spring  7  (as shown by the arrow G) toward engagement with the ratchet teeth on ratchet wheel  8 . Locking pawl  9  is pivotally connected with the housing by pivot pin  42 , and is biased by spring  10  (as shown by the arrow H) toward engagement with the ratchet teeth  28 , thereby to prevent rotation of the ratchet wheel in the opposite direction. Thus, rotation of the drive shaft  1  in the direction shown by the arrow R causes connecting rod  13  (and pressure member  15  and crimping arm  16 ) to be incrementally displaced in the crimping direction as a result of the reciprocatory movement of the transport pawl  6 . 
         [0032]    This locking catch mechanism is advantageous, especially with crimping large line cross-sections. During the crimping process due to the high pressing forces, tensions are built up in the drive mechanism. These tensions are suddenly “discharged” after connecting rods have gone beyond the upper dead center into the downward movement of the drive mechanism. As a result, eccentric wheel  8  is turned so far that the cable lug can no longer be taken out of the crimping insert  19 . The locking catch mechanism of this crimping tool therefore, as described above, is so designed that fast rotary movements of eccentric wheel  8  are prevented and that the cable lug in the lower dead center of the drive mechanism can be taken out while the crimping insert  19  is fully opened. 
         [0033]    The two crimping parts  19   a  and  19   b  are made with a semicircular shape, whereby in the crimping part edge forming the diameter of the semicircle, there is provided a recess that is used to receive the connector, terminal or lug T that is to be pressed onto the conductor C. In head part A, the two crimping parts  19   a  and  19   b  are assembled to form a circle with a central opening for the pickup of the cable lug or the cable connector. The first crimping part  19   a , here with its circular circumference edge, lies in the horizontal die support member  18 . The second crimping part  19   b , with its circular edge, lies in a semicircular seat of an upper front of the crimping stamp  16 . 
         [0034]    To crimp the cable lugs/cable connectors, the crimp insert is closed or opened via the mechanics of the crimping tool. The cable lug/cable connector, inserted between the two crimping parts  19   a  and  19   b , as one can easily seen in  FIGS. 7 and 8 , is pressed upon a precisely defined path of by the upper movement of the lower crimping part  19   b . The double arrow L here indicates the direction of motion of the crimping parts and of the crimping stamp  16  that brings this motion about. 
         [0035]    According to an important feature of the invention shown in  FIGS. 6   a -  6   c , manually operable release means  20  are provided for releasing the stationary upper crimping die for displacement toward an open position, thereby to permit removal of a faulty or jammed connector from the crimping apparatus. In a preferred manner, the two support arms  17  and  18  are releasably connected together. As shown in  FIG. 6 , support arm  17  has for this purpose a bolt  30  that points normal to the longitudinal axes of the support arms, grasping behind this bolt is a recess  32  contained in a projection  31  on the front of the first support arm  17  facing toward the second support arm  18 . To unlock the support arms  17 ,  18 , there is rotatably positioned on the first support arm  17  an eccentric bolt  20  that eccentrically upon a tool housing part  29  is rotatably positioned around a second pivotal point in such a manner that the first support arm  17  can be moved parallel to its longitudinal axis away from drive unit B. As a result, bolt  30  is lifted out of recess  32 , and the first support arm  17  can be pivoted outwardly away from the second support member  18 . Subsequently, the second support member  18  can be pivoted upwardly. In order simply to insert or take out a connector or terminal, for example, in case the tool has been handled falsely, such as when a cable lug that is too big is put into the crimping insert  19 . 
         [0036]    Accordingly, a head unit A, according to this design, can also be unlocked and opened when under load. For this purpose, eccentric bolt  20  must be turned, preferably by 180° counterclockwise, as a result of which, support arm  17  is moved upwardly and thus unlocked. Subsequently, one can pivot the support arms  17  and  18  away to the side and the erroneously inserted connector can be removed. 
         [0037]    In a particular embodiment of the crimping tool, there is arranged on eccentric wheel  8  a manual actuation unit  11  for the manual turning of eccentric wheel  8 . This manual actuation unit  11  is firmly connected with eccentric wheel  8  and in the embodiment shown by way of example in  FIG. 3  has a head in the form of a hexagonal screw head upon which—on opposite sides of the circumference of the screw head—there are arranged noses which facilitate a turning action with the fingers of a user. An arrow on the front of the manual actuation unit  11  indicates the position of eccentric wheel  8  and thus also the advancement of a crimping process. 
         [0038]    Preferably, there is shown on the front surface of eccentric bolt  20  an arrow that indicates whether support arm  17  is in the lowered closed or in the raised opened position. Arrow E in  FIG. 6  here points to a preferred distribution direction of eccentric bolt  20 . Double arrow T clearly shows the movement direction of pick-up strap  17  that is brought about by the turning of eccentric bolt  20 . 
         [0039]    The manually controlled crimping tool is particularly distinguished here by the fact that drive unit B has a drive shaft  1  that can be driven by an electric motor and that is rotatably positioned around its longitudinal axis. A first embodiment of drive unit B is shown in  FIG. 3 . Along with drive shaft  1 , drive unit B has a transport catch  6  that can be moved alternately in a translational manner and which is in a working connection with an eccentric wheel  18 , which drives the crimping arm  16 . Eccentric wheel  18  in a preferred manner is made with ratchet teeth  28  located on the outside. On its side facing toward eccentric wheel  8 , transport catch  6  is likewise provided with gearing so that the transport catch  6  with eccentric wheel  8  during a transport procedure will engage each other in a form-locking manner. 
         [0040]    As shown in  FIGS. 9 and 10 , the crimping tool is preferably fashioned as a yoke for an electrically-driven or a battery-powered hand drill, whereby drive shaft  1  can be clamped separately into the drill chuck of the drill, or with the appropriate auxiliary adapter. In this case, to support the weight of the crimping tool against the drill axially with respect to drive shaft  1 , there is arranged a support sleeve  21  around the drive shaft upon drive unit B. On its end facing away from the crimping tool, support sleeve  21  is made as a resilient clamping portion  33  for the purpose of firmly clamping the support sleeve  21  upon a drill/battery-powered drill  38 . Upon the attachment of the crimping tool on the drill, support sleeve  21 , together with the crimping tool, is pushed over the drill chuck of drill  38  and is clamped and secured on the drill, preferably by means of clamping clip (not shown) that presses the clamping parts  38  together. In a preferred embodiment, there is inserted into the drill chuck of the drill first of all an auxiliary drive sleeve adapter (not shown). While the support  21  and the crimp tool are pushed upon, we insert into this drive sleeve the drive shaft  1  so that, in this way, we can transport torque from the drill to the drive shaft  1 . 
         [0041]    Two mechanisms are proposed for the translation of the drive moment from the drive shaft  1 , which is clamped into the electric motor or into the drill chuck upon the transport catch  6 . First of all, a crank drive arrangement has been described above with regard to the embodiment of  FIGS. 3 and 4 . A cam disk drive which will now be described in greater detail below with reference to  FIG. 5 . 
         [0042]    In this alternate drive embodiment, drive unit B has a cam disc drive. Here again, an electric motor, for example, the electric motor of a drill, transmits the drive moment via the drill chuck upon drive shaft  1 . Drive shaft  1  is here preferably made as a hexagonal unit so that a triple-cheek chuck of a drill can be clamped to the drive shaft, or an associated adapter. Drive shaft  1  is supported in drive unit B by means of a ball bearing, preferably a double ball bearing, and passes the rotary torque onto a cam roller  34 . Arranged on this cam roller  34  is a cam disc  35 , which rotates along with cam roller  34 . Slide member  36  specifically here works along the functional principle of a centric slide, moves in a sliding manner as a cam follower over the outer edge of cam disc  35 . In this way, the rotary movement of drive shaft  1  and cam disc  35  is converted into an alternating translation movement. Because cam disc  35 —as drive shaft  1  rotates to the left or the right—displays differing gradients, the correct rotational direction is assured via a freewheel connection (not shown) in the interior of cam disc  35 . Slide  36  converts the rotation movement into a translation movement and passes the latter on to transport pawl  6 . In place of eccentric wheel  8 , drive unit B here has a cam surface  37  that by means of the previously described ratchet mechanism is driven by the transport pawl analogous to the ratchet mechanism that works during the crank drive. The rotary movement of the cam surface  37  again is converted via a pressure member follower  39  into a translation movement, which is passed on to the crimp stamp  16 . In this cam disc drive, it is advantageous that one can distribute the movement required for the crimping process most extensively to the circumference of the cam disc. In this way, the working stroke can be adjusted to the individual requirements. 
         [0043]    As shown in  FIG. 11 , head unit A in a particularly preferred embodiment is positioned with respect to drive unit B so that it can be rotated around the longitudinal axis of the crimping stamp  16 , particularly by 360°, in order to simplify working in differing directions or when space is tight. As for the rotatable positioning of head unit A, particular preference is given to several latching positions in a particularly preferred manner at equal intervals. 
         [0044]    While in accordance with the provisions of the Patent Statutes the preferred forms and embodiments of the invention have been illustrated and described, it will be apparent to those skilled in the art that changes may be made without deviating from the invention described above.