Abstract:
The present invention relates to a powered crimping tool. In the parent application, referenced above, the tool, having a plurality of crimping jaws, is used to secure a cap onto a bottle or vial. In this application, the tool, having a pair of opposed crimping heads, is used to crimp a solderless terminal, splice, butt connector, or the like, having a wire inserted into a shaft and to be retained therein. The powered tool has a housing portion which the user holds and includes switches for the user to control the plunger and the crimping action. Selected mating crimper heads in the plunger and the crimper housing effectuate the crimping of the selected terminal to retain the wire therein. These mating crimper heads can be changed to accommodate a variety of different size and shape terminals, splices, butt connectors, wires, and the like. Terminals may be insulated or not. Wires may be stranded or solid.

Description:
This application is a continuation-in-part of application U.S. Ser. No. 09/243,301, filed Feb. 2, 1999, for a powered crimping tool to secure a cap onto a bottle or vial, incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     (a) Field of the Invention 
     The present invention relates to a powered crimping tool. In the parent application, referenced above, the tool, having a plurality of crimping jaws, is used to secure a cap onto a bottle or vial. In this application, the tool, having a pair of opposed crimping heads, is used to crimp a solderless terminal, splice, butt connector, or the like, having a wire inserted into a shaft and to be retained therein. The powered tool has a housing portion which the user holds and includes switches for the user to control the plunger and the crimping action. Selected mating crimper heads in the plunger and the crimper housing effectuate the crimping of the selected terminal to retain the wire therein. These mating crimper heads can be changed to accommodate a variety of different size and shape terminals, splices, butt connectors, wires, and the like. Terminals may be insulated or not. Wires may be stranded or solid. 
     (b) Description of the Prior Art 
     In the parent application, various crimping tools are taught related to crimping a cap onto a bottle or vial. U.S. Pat. No. 5,579,626, to Applicant Thomas, which teaches a manually operated crimping tool for securing a cap onto a bottle or vial. U.S. Pat. No. 4,987,722, to Koebbeman, teaches a hand-held bottle cap crimper having a pair of horizontal crimping handles, one upper fixed handle and one lower lever handle which moves about a single pivot point to move a crimper, the pivot point being between jaws and the handles so that the tool functions in a see saw fashion. U.S. Pat. No. 4,745,729 to Bethge et al., teaches a container closing apparatus used to put on a screw cap. U.S. Pat. No. 3,998,032, to Koebbeman, teaches a hand-held bottle cap crimper having a pair of horizontal crimping handles, one lower fixed handle and one upper lever handle which moves about a single pivot point to move a crimper, the jaws being between the pivot-point and the handles. U.S. Pat. No. 3,332,211, to Koll et al., teaches a cap applying apparatus. U.S. Pat. No. 3,217,519, to Demler, teaches a coaxial crimping tool. U.S. Pat. No. 2,415,896, to Marsh et al., a cap applying implement. U.S. Pat. No. 5,327,697, to Kent, teaches a chuck for a bottle capper. U.S. Pat. No. 3,771,284, to Boeckmann et al., teaches a capping apparatus. Finally, U.S. Pat. No. 3,747,441, to Amtsberg et al., teaches a pneumatic tool having combined nut running and crimping mechanism. 
     Solderless terminals have a shaft where a wire is to be received. The terminals may have any type head thereon, for example, loops or rings, hooks, prongs, or spades. The terminals may be insulated or not. The terminal heads have differing sizes, for example, to fit a variety of screw sizes. The shaft normally has a wire receiving opening which is surrounded by the shaft. The shatf typically has a lengthwise split therein which permits the shaft to be crimped down onto the wire inserted therein. Butt connectors, splices, and quick disconnect terminals are similarly configured. Historically, a manually operated ratchet crimping tool is used to crimp the terminal shaft to secure the wire therein. 
     SUMMARY OF THE INVENTION 
     The present invention relates to a powered crimping tool. In the parent application, the tool is used to secure a cap onto a bottle or vial. In the instant application, the tool is used to crimp the shaft of a terminal, splice, disconnect, or the like to retain a wire therein. The types of terminals, splices, and the like to be crimped were described above. In crimping wires within these items, this wire crimping tool has several advantages. First, hand fatigue is reduced with the powered crimper. Second, the powered tool can hold the terminal securely prior to crimping without compressing the terminal and making the wire more difficult to insert into the item shaft, a problem frequently encountered when operating a manual crimper. Third, the actual crimp can be the same every time, in contrast to manual crimping tools where the operator&#39;s hand pressure determines the crimp. With manual tools, an undercrimp resulting in a loose wire and bad electrical connection or an overcrimp resulting in terminal or wire damage can occur. This precise crimp permits use with exotic terminals, such as insulation piercing terminals, which are applied without stripping the insulation or covering from the wire, and require precise crimping to work properly. 
     The powered wire crimping tool has a vertical housing portion which the user holds while activating the crimping action. The crimping action results from a motor causing a plunger having a crimper head contained therein to move downward toward an opposed crimper head. When the crimper heads engage the shaft of the terminal, splice, disconnect, or the like, which is to have a wire crimped therein, the wire can be inserted into the shaft. Then the crimper can be further engaged to crimp the shaft onto the wire. While the crimper can simply be operated by turning on and off the motor, preferably means can be provided to adjust the finishing point of the crimping cycle or the plunger lower limit, as well as a pause point where the crimper heads engage the shaft prior to crimping, to permit insertion of the wire into the shaft. While means can also be provided to vary the starting point of the crimping cycle or the plunger upper limit, it is envisioned that by carefully sizing the geometry of the first and second crimper heads, a uniform starting point will suffice. If desired, as the terminal, splice, disconnect, or the like, are of various sizes, a variety of upper limits, pause points, and/or lower limits can be programmed with the user being able to select those desired for the terminal, splice, disconnect, or the like, the wire, and the crimping heads selected. 
     More particularly, the present invention comprises a housing containing a battery-operated motor. A speed reduction system having a ratio of about 64 to 1 causes a plunger lead screw to rotate at a speed of about {fraction (1/64)}th the motor speed. The plunger lead screw has a threaded drive shaft which is threadably received within the plunger threaded drive channel. Rotation of the plunger lead screw threaded drive shaft results in vertical movement of the plunger, as limited by the hex shaped plunger&#39;s vertical travel within the hex shaped plunger receiving opening in the crimper housing. Other forms of keying can be used. For example, in cross-section, a triangular, square, or other shaped plunger/plunger receiving opening could be used, so long as the plunger can not rotate within the plunger receiving opening. In fact, the plunger and opening do not have to have the same cross-section shape. For example, a plunger with triangular cross-section would fit inside a plunger receiving opening with hex cross-section. 
     The total movement of plunger from the upper to lower limit and back to the upper limit is controlled. Further, if desired, the crimping tool can include a control so that once the plunger has moved through a pre-set vertical distance, the plunger will complete one crimping cycle without the user having to continue to engage a control. This frees the user to concentrate on the crimping operation. For example, the control can require the activating button to be held down until the pause position has been reached. Then, simply pressing the activating button again will cause the plunger to complete the crimping cycle to the lower limit and return to the upper limit. For this period, the activating button does not have to be further engaged by the user. 
     Finally, the present invention comprises a powered crimping tool, having a housing containing a motor therein, the housing receiving a crimper housing having an opening therein, the crimper housing having a lower crimper head receiving member having a lower crimper head opening therein; a plunger received by the crimper housing opening, the plunger having an upper crimper head opening therein; an upper crimper head received by the upper crimper head opening and a lower crimper head received by the lower crimper head opening; the plunger being movable by the motor so as to move the upper crimper head toward the lower crimper head to crimp an item and to move the upper crimper head away from the lower crimper head to remove the item crimped. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     A better understanding of the present invention will be had upon reference to the following description in conjunction with the accompanying drawings, wherein: 
     FIG. 1 shows a first perspective view of the tool of the present invention; 
     FIG. 2 shows a second perspective view of the tool of FIG. 1, the tool being rotated about 90° clockwise from the view of FIG. 1; 
     FIG. 3 shows an exploded view of the tool of FIGS. 1 and 2 with a portion of the housing and insert removed to show how the housing receives the various components; 
     FIG. 4 shows a cross-sectional view of the tool of FIGS. 1 and 2 along the lines  4 — 4  of FIG. 2; 
     FIG. 5 shows an enlarged lower portion of the cross sectional view of FIG. 4 along the lines  5 — 5  of FIG. 4; 
     FIG. 6 shows an exploded perspective view of the jaws, circular spring, and steel bushing of the tool of the present invention; 
     FIG. 7 shows a top view of the jaw of FIG. 8 along the lines  7 — 7 ; 
     FIG. 8 shows a side view of one of the four jaws of the tool of the present invention; 
     FIG. 9 shows a bottom view of the jaw of FIG. 8 along the lines  9 — 9 ; 
     FIG. 10 is a block diagram of the electronic controls of the present invention; 
     FIG. 11 schematically shows the electronic controls of the present invention; 
     FIG. 12 is a computer flowchart for the powered crimper setup or adjustment and operation; 
     FIG. 13 shows an exploded view of the wire crimping tool with a portion of the housing and insert removed to show how the housing receives the various components; 
     FIG. 14 is a perspective view of the hex shaped plunger of the wire crimping tool of FIG. 13, the plunger having a crimper head inserted therein; 
     FIG. 15 is perspective view of the crimper housing of the wire crimping tool of FIG. 13, the crimper housing having a crimper head inserted therein; 
     FIG. 16 is a perspective view showing the crimper housing received by a portion of the tool housing of the wire crimping tool of FIG. 13, the hex shaped plunger with crimper head being received by the crimper housing; and, 
     FIG. 17 shows the assembled lower portion of the tool of FIGS. 13-16 in cross section. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     With reference to FIGS. 1-9, the tool  10  of the instant invention is shown having a housing  20 ; a motor  90  which drives a plunger lead screw  110 , through a speed or gear reduction system  95 , the plunger lead screw  110  interfacing a plunger  130 ; four jaws  70  circumscribing plunger  130  and retained by circular spring  86 . Tool  10  also contains electronics which permit the plunger  130  starting point to be adjusted and also permit the crimping cycle to be adjusted. 
     FIGS. 1 and 2 show the tool  10  having a split housing  20  having parts  20   a  and  20   b . Housing  20  comprises an upper housing portion  30  and a lower housing portion  40 . Lower housing portion  40  is the “grip” portion and will be held in a vertical orientation by a user when using the crimper. From portion  30  to jaws  70 , portion  40  contains a trigger portion  42  and a vertically elongated chamber portion  50  adjacent portion  30 . Adjacent chamber portion  50  is a middle plunger/gear receiving portion  56 . Finally, there is a lower jaw receiving portion  60 . 
     With reference to FIGS. 1-3, upper housing portion  30  includes a horizontal elongated chamber  32  which contains circuit board  38 . The operation of the electronics is explained later with reference to FIG.  10 . However, the circuit board  38  is operationally connected to the power source, shown as a pair of 3.6 volt batteries  36 , motor  90 , pulse sensor or encoder  91 , trigger  44 , rocker switch  47 , and LED  48 . One or more batteries can be used to power the tool  10  and are received in battery receiving channels  34 . If multiple batteries are used, they can be in parallel to provided more crimps per charge or in series to provide more power. Naturally, they will be matched to the motor requirements. As shown, a pair of batteries  36  provide 3.6 volts DC. Also, external power sources can be used to power the tool  10 . On the outside of chamber  32  are rocker switch  47  and LED 1548, the operation of which is explained with the description of the electronics with FIG.  10 . 
     Trigger portion  42  includes a trigger  44  and a trigger spring  46 . The trigger  44  is used to activate the crimping cycle and the spring  46  is used to deactivate the trigger  44 . Any comparable activation means can be employed in place of the trigger system. For example, a simple push button could be used which makes a simple contact when pressed to activate the crimp cycle. This push button could be anywhere on housing  20  and would replace the entire trigger portion  42 . So, instead of holding a trigger grip, the user would grip the cylindrical lower housing  40 . For ergonomic design, the external shape of lower housing portion  40  could altered from cylindrical without operational effect. 
     With particular reference to FIGS. 3-5, the internal connectivity of the components is described. Chamber  50  contains an internal upper motor receiving portion  52  with a motor seat  53  at its lower portion. FIGS. 4 and 5 show how motor  90  is received within portion  52  and seat  53 . Motor  90  is a typical DC  24  pole motor found in battery operated power tools, such as a Black &amp; Decker model VP720 powered screwdriver. Without load, the motor powered shaft  92  rotates at about 5760 rpm. Attached to shaft  92  are a pulse disk  94  and a shaft gear  96 . Pulse disk  94  provides for 8 pulses for every 3600 rotation of shaft  92 . Disk  94 &#39;s cooperation with pulse sensor  91  and the tool&#39;s electronics are explained later. 
     A wear plate  98  is received on the lower side of motor seat 2053 in middle portion  56 . Adjacent the wear plate  98  is a unitary injection molded insert  57 , a portion of which is shown in FIG.  3 . Insert  57  and chamber  50  contain a plurality of aligned bores  62  therein which receive screws or bolts  64  therein to attach insert  57  in its desired location within chamber  50 . Insert  57  contains a hex plunger channel  58  on its lower end and a gear channel  61  on its upper end, with a retaining member  59  with an opening therethrough in between  58 / 61 . Gear channel  61  receives the speed or gear reduction system  95  therein. 
     Speed or gear reduction system  95  contains a pair of 8 to 1 speed reduction assemblies which first reduce the motor revolutions from approximately 5760 rpm to approximately 720 rpm and then to approximately 90 rpm. Three first gears  100  are received on shafts  102  attached to the upper side of a rotor  104 . Motor shaft gear  96  is received within and engages the three first gears  100 . The interior circumference of gear channel  61  is channeled to match the gearing of gears  100 . With shaft gear  1596  rotating at 5760 rpm, gears  100  rotate around shafts  102  and translate within gear channel  61  thereby causing the rotor  104  and gear shaft  105  on the lower side of rotor  104  to rotate at 720 rpm. 
     Three second gears  106  are received on shafts  108  attached to the upper side of plunger lead screw  110 . Rotor shaft gear  105  is received within and engages the three second gears  106 . With gear shaft  105  rotating at 720 rpm, gears  106  rotate around shafts  108  and translate within gear channel  61  thereby causing the plunger lead screw and the plunger threaded drive shaft  112  extending downward therefrom to rotate at 90 rpm. This results in a 64 to 1 reduction of motor  90  rotational speed in two 8 to 1 reduction stages. Similar speed reduction systems in more or less stages can be employed to achieve the desired rotational speed of the plunger lead screw  110 . Also, under load, the rotational speeds will generally be less. 
     The plunger threaded drive shaft  112  receives an upper thrust bearing  116  thereover and then the shaft  112  is received through the opening in the insert  57  retaining member  59 , extending into the hex plunger channel  58 . On the under side of the member  59 , shaft  112  sequentially receives a lower thrust bearing  118 , a bearing housing  120 , a retaining washer  122  and a retaining clip  114 . The thrust bearings  116  and  118  help to minimize the torque requirements, the bottom thrust bearing  118  being leaded when the plunger  130  is moving downward and the upper thrust bearing  116  being loaded when the plunger  130  is moving upward. 
     Threaded drive shaft  112  is threadably received within plunger  130 &#39;s threaded drive channel  131 . Plunger hex guide member  132  and hex plunger channel  58  cooperate to prevent rotation of the plunger  130 , but permit movement toward or away from the member  59 . It is the rotation of plunger lead screw  110 &#39;s threaded drive shaft- 112  within plunger drive channel  131  and the cooperation of hex channel  58  and plunger hex guide member  132  which cause the circular rotation of motor  90 &#39;s shaft  92  to be translated into a vertical movement of the plunger  130 . 
     At the lower end of chamber  50  is a stop washer ridge  65  which has a stop washer  140  adjacent it&#39;s upper side. The lower side of stop washer  140  starts the lower jaw receiving portion  60  of the lower housing portion  40 . At the lower portion of portion  60  is a steel bushing ridge  66  which has a steel bushing  128  adjacent it&#39;s upper side. Between stop washer  140  and steel bushing  128  are a plurality of crimping jaws  70 . The upper part of jaws  70  abut stop washer  140 . The lower part of jaws  70  extend downward through an opening in steel bushing  128 . For the preferred embodiment, four jaws  70  are used, although other numbers can be employed within the scope of the invention. The lower portion of the plunger  130  is received within the central circular opening through the jaws  70 . 
     FIGS. 3-6 show that four jaws  70  are retained on plunger  130  by circular spring  86 . Other means, such as an elastic or rubber band can be employed. FIGS. 7-9 show one of the jaws  70 . Jaw  70  includes a lower crimping portion  72  and an upper opening portion  74 . Portion  72  includes a curved crimping lip  76 . The inside curved surface of jaw  70  has a plunger slide area  78  shaped such that when the four jaws  70  are placed together the areas  78  are generally cylindrical shaped with a diameter which approximates that of plunger  130 . An engagement point for opening  80  permits jaws  70  to open when received by plunger  130 &#39;s jaw opening portion  134 . A generally horizontal groove  82  is provided to receive circular spring  86 . 
     With particular reference to FIG. 5, the plunger  130  also includes a jaw crimping slide portion  133 , the jaw opening portion  134 , a cap engaging head  135 , a curved surface  136  for centering the cap, and a flat surface  137  to engage the cap top. It is seen that the jaw opening portion  134  has an hour glass shape. In FIG. 5, the jaws  70  are closed, as the plunger  130  has moved downward beyond the cap open position. It can be seen that, if the plunger  130  was moved upward, the jaw opening engagement point  80  will align with the start of the inward slope of jaw opening portion  134 . As the plunger  130  continues to move upward, the circular spring  86  in groove  82  causes point  80  to follow the inward slope, thereby causing the jaws  70  to spread apart at the bottom or open so that they can be placed over a bottle or vial for the crimping of a cap thereon. The jaws  70  would be the most open when point  80  is at the smallest diameter part of the hour glass of jaw opening portion  134 . As is explained hereinafter, this would generally be the starting point for the crimping cycle. However, if working in confined places, the tool user may not want the jaws to open to this widest opening. Therefore, the starting point can be adjusted by movement of the piston downward to slightly close the jaws  70 . For example, the hour glass portion of portion  134  toward portion  133  slopes inward at about 200 from vertical. The cooperation of the plunger  130  and the curved crimping lip  76  cause a cap to be crimped onto a vial or bottle. As explained hereinafter, this cooperation can be adjusted by controlling the stop point of the downward movement of the plunger  130 . 
     FIGS. 10 and 11 show, in block diagram and schematic, the electronic controls for the tool  10 , many of which are mounted on circuit board  38  or connected thereto. FIG. 12 shows a flowchart of how the computer program controls the setup and operation of the powered crimper. Battery or batteries  36  are shown providing power to motor  90  upon activation. When the battery or batteries have an insufficient charge remaining, the three-color LED  48  will be constantly illuminated in red. Pulse sensor  91  detects rotational movement of the motor  90  shaft. With motor  90  operating at 5760 rpm and the pulse disk identifying 8 pulses per motor shaft revolution, the starting and stopping points of the crimp cycle can be very accurately set, incrementally adjusted, and stored in memory. All of this is controlled by a Microchip Technologies PIC Micro Controller, model number PIC 16C58. 
     The tool  10  has a start-up mode and a crimp mode, which operate as shown by the flowchart of FIG.  12 . The start-up mode is initiated by engaging a reset switch  49  or upon insertion of a charged battery into battery receiving channel  34  if the 0.1 Farad memory backup capacitor has discharged because of an extensive period without a connected or charged battery. First, the motor  90  reverses, moving the plunger  130  upward, until a stall condition is detected. A stall condition is detected when the motor rpm decreases and the time between pulses from disk  94  is about 10 times the normal operating time. Then, the motor  90  reverses direction and moves the plunger downward to a pre-set START position. In general, the motor will rotate until the pulse sensor has detected a pre-set number of pulses. Typically, this will move the plunger downward so that the jaws  70  are at their most open position, that is, where  80  is at the narrowest diameter portion of hour glass  134 . The START or jaw open position can be adjusted by pressing the + or − on the rocker switch  47  to raise or lower the plunger. Each time the rocker switch  47  is pressed, the motor  90  rotates for a pre-set number of pulse counts and the LED will flash green one time. This can be any desired number, but is preferably  4  counts. Once the jaws  70  are set at the desired opening, the trigger  44  is pressed and released to disengage the start-up mode. Instead of using a rocker switch  47 , separate up and down adjustment switches can be provided. 
     The tool  10  is now configured for the preset crimp cycle. That is, upon activation of the crimp cycle by pressing the trigger  44 , the motor  90  will rotate until the pulse sensor has detected a pre-set number of pulses, thereby moving the piston from the START position to the STOP position. Then, the motor  90  will reverse and the piston will be returned to the START position. With the present embodiment, the piston moves through about 0.250 vertical inch between the START and STOP. The number of threads per inch of plunger drive shaft  112  and plunger threaded drive channel  131  affect how many pulses between START and STOP positions. 
     It is desirable that the operator not have to engage the trigger  44  for the entire crimp cycle. While it could be set so that a simple press and release of the trigger would cause the tool to go through a complete crimp cycle, a safety factor is desired. Therefore, the trigger  44  must be pressed and held until the motor  90  rotates for sensing of a pre-set number of pulses, for example, 640 pulses. If the pre-set number of pulses is not reached, the LED will flash yellow 10 times after the motor has reversed. Once this rotation has occurred, the “No RETURN” position has been reached and the crimp cycle will be completed even if the trigger is released, unless a stall condition is sensed. If a stall condition is sensed, by a time period between pulses which is about 10 times than the normal time period between pulses, before the plunger reaches the STOP position, the motor will automatically reverse and return the plunger to the START position and the LED  48  will flash red 10 times in 5 seconds or until the start of the next crimp cycle, if 2.5 less than 5 seconds, to notify the user that the crimp cycle was not completed. 
     In the crimp mode, the rocker switch  47  can be used to adjust the STOP position. By using the + or − on the rocker switch  47 , the plunger STOP limit can be adjusted downward or upward. Each time the rocker switch  47  is pressed, the motor  90  rotates for a pre-set number of pulse counts. This can be any desired number, but is preferably 8 counts and the LED will flash green one time. Therefore, if the tool  10  user sees that a bottle or vial has not had the cap adequately crimped thereon, the rocker switch  47  can be adjusted so that the plunger  130  will move further downward for the STOP position and that vial or bottle re-crimped. If the user sees that a vial or bottle is having the cap crimped on too tightly, the rocker switch  47  can be adjusted so that the plunger will stop further upward for the STOP position so that future vials or bottles will not have the cap crimped on as tightly. 
     While the above-described means for electronically adjusting the stop position is the inventors&#39; preferred embodiment, alternatives can be employed. For example, instead of using a controller which counts pulses to control the various positions, a limit switch could be employed. The motor would move the plunger one direction until a desired limit was reached and then the motor would be reversed and the plunger moved in the opposite direction. The limit switch limit could be altered to adjust the plunger downward limit. 
     With reference to FIGS. 13-17, the crimping tool is shown as a wire crimper, the tool  10  having its plunger  130  and jaw assemblies  70  replaced with a hex shaped plunger  230  and a crimper housing  250 , each containing a crimper head  240 ,  270 , respectively. The operation of the wire crimper is very similar to that of tool  10 , in that the motor  90 , powered shaft  92 , pulse sensor  91 , pulse disk  94 , speed reduction system  95 , and housing  20 , including insert  57  all function as previously described. 
     A crimper housing  250  includes a hex shaped area  252 , which is received by hex plunger channel  58  of insert  57 . As best seen in FIG. 17, a ring-shaped retainer  262  is received within lower portion  60  of housing  20  between ridge  65  and the lower end of channel  58  in insert  57  and a ring-shaped groove  264  into housing  250  receives ridge  66  of portion  60  of housing  20 , so that crimper housing  250  is secured with respect to housing  20 . 
     A plunger  230  has a hex shape and has an axial threaded bore  236  extending from the motor end. This bore  236  receives plunger threaded drive shaft  112  of plunger lead screw  110 . Plunger  230  has a first crimper head opening  232  at its opposite end. Opening  232  has an enlarged rear portion  234  and is sized to receive first crimper head  240 . First crimper head  240  includes an enlarged rear portion  242  and a crimping head face  244  and is sized to mate with opening  232  in plunger  230 . 
     Plunger  230  is received by a hex shaped plunger receiving opening  254  in crimper housing  250 . As the motor  90  is operated, plunger threaded drive shaft  112  rotates within crimper threaded bore  236  causing the plunger  230  to move to or from the motor  90  depending on the direction of rotation. 
     Crimper housing  250  contains a second crimper head receiving member  256  at its end opposite the hex shaped area  252  end. Member  256  includes a second crimper head opening  258  with an enlarged rear portion  260 , sized to receive second crimper head  270  having an enlarged rear portion  272  and a crimping head face  274 . Crimping head faces  244  and  274  of respective crimper heads  240  and  270  are cooperating faces to perform the desired crimping action. A plurality of pairs of crimper heads  240 ,  270  can be provided for the various types and sizes of terminals, splices, connectors, or the like to have a wire crimped therein. 
     While in the preferred embodiment of the wire crimper, second crimper head  270  is fixed with respect to the tool  10  and the first crimper head  240  is moved with respect thereto, either or both crimper heads could move. 
     In operation, to insert the desired crimper heads  240 ,  270 , crimper head  240  should be inserted into opening  232  in plunger  230  before crimper head  270  is inserted into opening  258  in housing  250 . This is accomplished by operating motor  90  to rotate screw  110  and move plunger  230  so that opening  232  is fully removed from opening  254 . This then permits the insertion of the desired first crimper head  240 . Then, motor  90  is reversed to draw plunger  230  and head  240  up into opening  254 . Then, second crimper head  270  can be inserted into opening  258 . The wire crimping tool is then ready for operation. 
     The desired operation is as follows. The motor  90  is operated to move the first crimper head  240  toward the second crimper head  270  until the terminal, or other item, to be crimped is “lightly” held by crimping head faces  244  and  274 . With the item to be crimped supported by the tool, the operator can insert the desired wire into the item shaft. Then the tool can be reactivated to crimp the shaft having the wire inserted therein to make a secure crimped connection. Withdrawing face  244  from  274  permits removal of the crimped item and wire. 
     This desired operation of the wire crimper is effectuated by the following start-up procedure. After activation of the reset switch  49  or after complete power loss, the wire crimper  10  is in set-up mode and the movable crimper head  240  is advanced to nearly the pause position by operation of motor  90  and corresponding movement of plunger  230 . In this set-up mode, the operator adjusts the pause position by using the rocker switch  47  (or separate up and down adjustment switches) to move the plunger  230  up or down. After this pause position has been set to “grab” the terminal lightly without crimping it, the operator puts the crimper in operating mode by pressing and releasing the activating button or trigger  44  one time. Alternatively, the set-up mode could be made slightly more complicated to allow adjustment both of the start position and the pause position. The final crimping position can be set in operating mode, as it is for the vial crimper of FIG.  1 . 
     The operation/adjustment of the wire crimper can be similar to that of the crimping tool of FIG.  1 . For example, the powered crimping tool can comprise a housing containing a motor therein, the housing having a trigger switch, at least one adjustment switch, and a reset switch. The housing can contain a circuit board having a controller operably connected thereto, with the trigger switch, the at least one adjustment switch, and the reset switch being operably connected to the controller. The motor includes a pulse disk on a motor powered shaft and where the tool includes a pulse sensor, the motor powered shaft being operably connected through a speed reduction system and a plunger lead screw to a plunger movable between a start position with a value of “x” counts and a stop position having a value of “y” counts, there being a pause position with a value of “z” counts, the pause position being intermediate of the start position and the stop position. By a first operation of the trigger switch and the motor thereby, the controller will cause the motor powered shaft to rotate until the pulse sensor has detected a first selected number of pulses with a value of “z−x” counts from the pulse disk to move the piston from the start to the pause position, unless a stall condition is detected. By a second operation of the trigger switch and the motor thereby, the controller will cause the motor powered shaft to rotate until the pulse sensor has detected a second selected number of pulses with a value of “y−z” counts from the pulse disk to move the piston from the pause to the stop position, unless the stall condition is detected. When the second selected number of pulses has been detected or the stall condition is detected, the motor powered shaft will rotate to return the piston to the start position. The tool also includes a first crimper and a second crimper, at least one of which is operably connected to the piston; the first and second crimpers being spaced a first distance when the plunger is at the start position, being spaced a second distance when the plunger is at the pause position, and spaced a third distance when the plunger is at the stop position, the first distance being greater than the second distance, the second distance being greater than the third distance. When the tool is in a reset mode, the at least one adjustment switch can be pressed to adjust the start position and the value of “x” counts. When the tool is in a crimp mode, the at least one adjustment switch can be pressed to adjust the stop position and the value of “y” counts. 
     The foregoing detailed description is given primarily for clearness of understanding and no unnecessary limitations are to be understood therefrom for modifications can be made by those skilled in the art upon reading this disclosure and may be made without departing from the spirit of the invention and scope of the appended claims.