Method and apparatus for assuring or determining appropriate closure of a crimp assembly

Methods and apparatus are disclosed for assuring or determining appropriate closure of a crimp ring assembly. In some embodiments, positive stopping apparatus on the crimp ring are used to assure appropriate closure of a crimp ring assembly. The positive stopping apparatus may be adjustable or non-adjustable and may be positioned on the free ends or adjoined ends of the segments of the crimp ring. In some embodiments, adjustable and/or cam operating pivot connections on the crimp ring are used to assure appropriate closure of a crimp ring assembly. In some embodiments, sensing apparatus or systems are disclosed for assuring or determining appropriate closure of a crimp ring assembly.

FIELD OF THE INVENTION

The present invention relates generally to crimping tools and crimp rings, chains, and jaws and, more particularly to methods and apparatus for assuring or determining appropriate closure of crimp assemblies about a fitting.

BACKGROUND OF THE INVENTION

A compression fitting is typically a tubular sleeve that is made of plastic or metal and may contain seals. To produce a joint between two ends of pipe, the fitting is slid over the ends of the pipes and then compressed radially. The fitting forms a leak resistant joint between the pipe ends. The joint has considerable mechanical strength and is self-supporting. Compression fittings for such joints are typically used when installing liquid or gas-carrying pipework in buildings. It is essential that the fitting be sufficiently compressed to guarantee absolute tightness for both mechanical strength and leak resistance.

A crimping tool, such as known in the art, may be used to compress the fitting on the pipe ends. A typical crimping tool includes at least two arms or jaws. A drive mechanism is used to move the jaws. The drive mechanism can include a hydraulic piston acted upon by hydraulic pressure via a manually driven or electric motor-driven pump within the tool. In some embodiments, at least a portion of the jaws may be moved radially inward during the crimping operation to directly crimp the fitting. In other embodiments, the arms of an actuator may actuate a crimp ring, sling, or chain that moves inwardly to crimp the fitting. The crimp ring may typically include two to seven ring segments connected together. The actuator arms of the crimping tool couple to pivot ports or indentations defined in the crimp ring. In general, crimp rings are used to crimp larger fittings having diameters greater than approximately 2.5 inches, but can be used on all sizes. Some existing crimp slings are used on diameters as small as 42-mm or 1½″, such as the multi-segment crimp slings made by Novopress for use on the Mapress fitting system.

The material deformation of the fitting by the jaws or crimp ring is preferably uninterrupted over the circumference of the fitting. Unfortunately, typical crimp jaws or crimp rings may not always give an ideal or near ideal crimp on the fitting, especially when the fitting has a large diameter. For example, typical jaws or crimp ring assemblies according to the prior art may not uniformly apply a crimping force to the fitting over the full displacement of the drive mechanism. In addition, typical jaws or crimp ring assemblies may not apply a uniform radial force to the outside circumference of the fitting during the crimping operation. Furthermore, the output force versus displacement of the drive mechanism achieved with prior art crimp ring assemblies may not be consistent when used with fittings of various sizes, materials, or tolerances.

Other situational problems may also exist that result in an incomplete crimp of the fitting. The rollers of the tool, tool force output, jaws, arms, fittings, crimp rings, and pipes are subject to differing tolerances which, if they add up unfavorably, may lead to insufficient compression of the fitting. Any inaccuracy in the manufacture of the crimping tool, jaws, ring, pipe, or fitting can affect the crimp produced. The crimping tool, jaws, ring, pipe, or fitting may also be influenced by ambient temperature or operating temperatures.

As one consequence of the problems discussed above, typical jaws or crimp rings may over-press a fitting. Over-pressing of the fitting may not necessarily occur for fittings up to 2-inches. For such smaller fittings, tips of the jaws may touch during the crimping operation, limiting the amount of crimp of the fitting. The detrimental effect of excessive tool force, however, can increase bending stress of the jaw arms for these sized fittings. The increased bending stress leads to premature fatigue of the jaws. There is a logarithmic relationship between alternating bending stress and fatigue life such that a small increase in alternating stress can yield a significant reduction in fatigue life. This only applies to designs where stress is high enough that fatigue life is considered finite (typically less than 106or 107cycles).

It is possible to over-press large fittings, such as 2½″ to 4″ ProPress XL fittings, when crimping the larger fitting with a crimp ring. The tips of the crimp ring segments do not touch, so that the amount of crimp of the fitting is not limited by a mechanical stop. If the tips do not touch, the stress of the ring is not increased, and the life of the ring is not reduced. However, the fitting can be over-pressed, which could result in detrimental effects of the crimped fitting, such as over-stress, breaking of the fitting, or kinking of the tube inserted in the fitting. In addition, over-crimping results in the rollers of the tool contacting the actuator cam at a different location. This may result in increased bending stress in the actuator arm, which will reduce the life of the actuator arm.

In another consequence, the crimp produced on the fitting may be incomplete and the tightness of the joint may not be guaranteed. Therefore, it is desirable that jaws or crimp rings use enough of the work available from the crimp tool to make a good crimp on the fitting, but not unduly shorten the life of the jaws through fatigue. It is also desirable that jaws or crimp rings be able to overcome some of the problems discussed above.

SUMMARY OF THE DISCLOSURE

Methods and apparatus for assuring or determining appropriate closure of crimp assemblies are disclosed. The crimp assemblies include, but are not limited to, crimp rings, crimp chains, actuator arms for actuating crimp rings or chains, or jaws for directly crimping a fitting. In some embodiments, the positive stopping apparatus on the crimp assembly assures appropriate closure of the assembly about a fitting. The positive stopping apparatus may be non-adjustable or adjustable. The positive stopping apparatus may be positioned on the free ends or adjoined ends of segments of a crimp ring. In other embodiments, adjustable pivot connections assure appropriate closure of a crimp ring assembly about a fitting. In still other embodiments, sensing apparatus or systems are disclosed for assuring or determining appropriate closure of a crimp assembly.

While the subject matter of the present disclosure is susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and are herein described in detail. The figures and written description are not intended to limit the scope of the inventive concepts in any manner. Rather, the figures and written description are provided to illustrate the inventive concepts to any person skilled in the art by reference to particular embodiments, as required by 35 U.S.C. § 112.

DETAILED DESCRIPTION

I. Apparatus for Assuring or Determining Appropriate Closure of a Crimp Ring Assembly A                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                              about a Fitting

A. Positive Stopping Apparatus on Free Ends of a Crimp Ring

Referring toFIGS. 1A–C, wherein the same reference numbers indicate like elements between Figures, non-adjustable and adjustable positive stopping apparatus20,30, and40for assuring or determining appropriate closure of a crimp ring are shown. A typical crimping tool has a force stop that limits travel of the actuator arms, which may provide a force control limited to ±6%. The force stop is activated when the output force reaches a predetermined level, for example, 32 kN. Stopping the crimp operation at the maximum output force is achieved with a release mechanism or switch mechanism. For example, a torque coupling may be used for a rotating drive; a pressure relief valve may be used for a hydraulic drive; or an over-current release may be used for electrically driven drives.

In contrast to the conventional force stops of crimping tools, a positive stopping apparatus having a mechanical stop provides a more reproducible and repeatable closure of the crimp ring about a fitting. For a given fitting used to join pipes, variations may exist in the crimping operation due to differences in materials, wall thickness, elasticity of the crimping tool, differences in manufacturing tolerances, heat expansion, etc. The closure of the crimp ring with a positive stopping apparatus can be designed or adjusted to meet specific tolerances when closed about a given fitting. The tolerance can be closer to the ideal dimension for crimping the fitting. The positive stopping apparatus may be fixed or adjustable and may be located on the crimp ring, which provides for ease in manufacture.

Referring toFIGS. 1A–C, a side view of a crimp ring10is illustrated. In general, crimp ring10includes a first ring segment11a, a second ring segment11b, and a pivot point or pin16. Although only two ring segments11aand11bare illustrated herein, it is understood that a crimp ring may have two or more segments. First and second segments11aand11bare pivotably connected together by pivot pin16.

First segment11aincludes a free end12aand includes a bifurcate end13awith a pivot bore defined therethrough. Second segment11bincludes a free end12band includes a second end13bwith a pivot bore defined therethrough. Second end13bof the second segment is positioned within bifurcate end13aof first segment11a. The pivot bores are aligned with one another, and the pivot pin16is inserted through the respective bores. External retainers (not shown) may be attached to ends of pivot pin16to hold the pin in the bores.

Ring segments11aand11bdefine an opening or crimp dimension18. A fitting (not shown) is disposed in opening18between segments11aand11b. First segment11ahas an actuator indentation14a, and second segment11bhas an actuator indentation14b. The actuator arms of a crimping tool (not shown) fit respectively within actuator indentations14aand14b. A crimping force is developed with a drive or hydraulic mechanism of the crimping tool, causing the arms of the tool to close segments11aand11bof the crimp ring about the fitting disposed therebetween.

InFIG. 1A, crimp ring10includes an embodiment of a positive stopping apparatus20in accordance with the present invention. Positive stopping apparatus20is positioned adjacent free ends12aand12bof ring segments11aand11b. Positive stopping apparatus20includes one or more positive stops, bosses or studs22and24to assure appropriate closure of crimp ring10when closed about a fitting. First segment11aincludes a boss or stud22disposed on free end12a, and second segment11bmay also include a second boss or stud24disposed on its free end12b. In general, the positive stop can include an adjustable shim, a screw, a machined surface, a shoulder, a tab, a head, a boss, a stud, or a nut.

Positive stop or boss22can be added by inserting an additional element to free end12aof segment11a, or it can be added by modifying the casting of a conventional ring segment. Positive stop22and24can also be integrally machined portions of ring segments11aand11b, respectively. Positive stop or boss22is machined or milled to appropriate faces and dimensions to assure that crimp ring10has accurate tolerances when closed about a fitting.

When the actuator arms actuate the crimp ring, segments11aand11bpivot about pin16. Free ends12aand12bof the segments are moved together, and the one or more positive stops, bosses or studs22and24on free ends12aand12bengage at a predetermined point during the crimping operation. The one or more positive stops, bosses or studs22and24restrict crimp dimension18from being reduced past a minimum dimension. The output force is quickly ramped to a maximum level where a conventional force stop of the crimping tool ceases the crimping operation. In this way, positive stopping apparatus20may reduce detrimental effects described above.

Referring toFIG. 1B, crimp ring10includes an embodiment of an adjustable positive stopping apparatus30in accordance with the present invention. Adjustable positive stopping apparatus30is positioned at free end12aof first segment11a. Adjustable stopping apparatus30includes an adjustable stop or boss32with an adjusting member34connected to free end12aof segment11a. Adjusting member34is a threaded pin or screw for adjustably positioning the boss32in relation to free end12aof first segment11a. A locking nut or shims (not shown) can be used in conjunction with adjusting member34to maintain the adjusted position of boss32on free end12aof segment11a.

Adjustable stopping apparatus30advantageously enables an operator to change the final closed position of the crimp ring and the final dimension of ring opening18. Using adjustable member34, adjustable stop or boss32is set to an accurate distance from free end12aof first segment11a. Thus, the operator can calibrate or fine-tune the crimp ring with adjustable stopping apparatus30. Adjustable stop or boss32assures accurate closure of crimp ring10about a fitting and reduces the above-mentioned, undesirable effects of over-pressing. Although one adjustable stop is illustrated, it is understood that second segment11bmay also include a stop or boss, either adjustable or fixed.

Referring toFIG. 1C, crimp ring10includes another embodiment of an adjustable positive stopping apparatus40in accordance with the present invention. Adjustable positive stopping apparatus40is positioned at free end12aof first segment11a. Adjustable positive stopping apparatus40includes a replaceable shim or spacer42. A fastener44is used to attach shim42to free end12a. One or more replaceable shims42, of varying thickness, can be attached to free end12aof segment11ato change the distance of engagement between free ends12aand12bof segments11aand11b. Replaceable shims42assure that segments11aand11bmeet at an appropriate tolerance when closed about a fitting.

B. Positive Stopping Apparatus on Adjoined Ends of a Crimp Ring

Referring toFIGS. 2A–C, embodiments of positive stopping apparatus50,60, and70are illustrated on crimp ring10adjacent adjoined ends13aand13bof segments11aand11b. InFIG. 2A, an embodiment of a positive stopping apparatus50is illustrated. Positive stopping apparatus50includes a first positive stopping surface52defined in bifurcate end13aand adjacent pivot point16on first segment11a. Positive stopping apparatus50also includes a second positive stopping surface54defined on adjoined end13bof second segment11band adjacent first positive stopping surface52.

As segments11aand11bof crimp ring10are brought together about a fitting, first and second positive stopping surfaces52and54engage, preventing further travel of segments11aand11btowards one another. The engagement between surfaces52and54can be pre-calibrated for a particular crimp ring and fitting size. Stopping surfaces52and54can be cast and/or machined in adjoined ends13aand13b. In other embodiments, crimp ring10can include laminated structures as disclosed below having positive stopping surfaces52and54. Positive stopping surfaces52and54restrict crimp dimension18from being reduced beyond a minimum dimension during the crimp operation, thereby reducing the undesirable effects described above, such as overpressing the fitting.

Referring toFIG. 2B, crimp ring10includes an embodiment of an adjustable positive stopping apparatus60in accordance with the present invention. Adjustable stopping apparatus60includes first and second positive stops62and64positioned at adjoined ends13aand13bof segments11aand11b. At least one of the positive stops62and64is adjustable allowing an operator to fine-tune closure of crimp ring10about a fitting to produce a near optimal crimp. In the present embodiment, adjustable stopping surface62is a threaded stop disposed on first segment11aadjacent pivot point16, and second positive stopping surface64is on second segment11badjacent pivot point16. Adjustable stop62can be set to engage fixed stop64to assure that crimp ring10closes about a fitting with appropriate tolerances.

Referring toFIG. 2C, crimp ring10includes another embodiment of an adjustable positive stopping apparatus70in accordance with the present invention. Adjustable stopping apparatus70is positioned outside pivot point16of segments11aand11b. Positive stopping apparatus70includes a first positive stop or extension72on first segment11aadjacent pivot point16. Positive stopping apparatus70also includes a second positive stop or extension74on second segment11badjacent pivot point16. As segments11aand11bare brought together about a fitting, first and second positive stops or extensions72and74engage one another to prevent over-pressing.

At least one of positive stops or extensions72or74is adjustable allowing an operator to fine-tune closure of the crimp ring about a fitting. For example, first positive stop72can be an adjustable stop, such as a nut or the like, that can be moved and locked in different positions along the length of a threaded extension. The second positive stop74can include an extension with a slot having the threaded extension disposed therethrough. As the first and second segments are moved in relation to one another about the pivot location, the nut of the adjustable stop72can engage the extension of the stop74. By adjusting the position of the adjustable stop72, the final closed dimension of the crimp ring can be determined.

C. Adjustable Pivot Connections for a Crimp Ring

In addition to the non-adjustable and adjustable positive stopping apparatus discussed above, adjustable pivot connections between the segments can also be used to assure appropriate closure of a crimp ring about a fitting. The adjustable pivot connections may be used independently from or in combination with embodiments of the positive stopping apparatus discussed above.

Providing adjustment at the pivot connections of segments allows the segments to better encompass or wrap around the fitting. In addition, adjustable pivot connections may allow the segments to apply radial force more uniformly about the outer circumference of the fitting. To provide adjustable pivot connections, one or more of the ring segments may share an adjustable pivot point. Alternatively, each ring segment may have its own pivot point, one or both of which may be adjustable. Embodiments of adjustable pivot connections of the ring segments according to the present invention are illustrated below with reference toFIGS. 3–10.

Referring toFIG. 3A, crimp ring10includes an adjustable apparatus80on adjoined ends13aand13bof segments11aand11b. A pivot pin86is disposed in elongated apertures82defined in end13aof first segment11aand is disposed in pivot apertures84in end13bof second segment11b. Elongated apertures82may have a uniform shape as illustrated or may have an irregular or curved shape in other embodiments. The position of pivot pin86is adjustable in elongated apertures82. Using a locking mechanism (not shown) such as disclosed below, pivot pin86is tightened or locked in the adjusted position in elongated apertures82.

By changing and locking the position of pin86in elongated apertures82, the overall diameter D of the crimp dimension18defined between segments11aand11bcan be adjusted. In addition, elongated apertures82may be oriented at an angle θ3in relation to a relative radial center Ca of first segment11a. For example, if θ3is approximately 90-degrees, then adjusting the pin in the elongated apertures will generally only alter the overall diameter D of the crimp dimension18. Depending on predefined angles of θ3other than 90-degrees, segments11aand11bmay have differing orientations or movements during the crimp operation.

Locking adjustable apparatus80can be used to fine-tune properties of the crimp on the fitting. In particular, adjustable apparatus80allows the pivot location of segments11aand11bto be adjusted, thereby adjusting properties of the crimp produced. For example, an operator can adjust locking adjustable apparatus80to change the final crimp dimension of opening18. Thus, adjustable apparatus80alters properties of the crimp of the fitting to assure a more accurate crimp on the fitting.

Referring toFIGS. 3B–C, an embodiment of a locking mechanism is illustrated for the adjustable pivot connection ofFIG. 3A. InFIG. 3B, an enlarged side view of the pivot connection of first and second segments11aand11bis illustrated. InFIG. 3C, a cross-section of the pivot connection for the segments is illustrated.

As best shown inFIG. 3C, first segment11adefines elongated apertures82in bifurcate end13a, and second segment11bdefines pivot apertures84in bifurcate end13b. Pivot pin86is disposed through elongated apertures82and pivot apertures84. Serrated areas83on the outside surfaces of bifurcate end13aare adjacent elongated apertures82. Serrated spacers85are disposed on the ends of pivot pin86. Serrated surfaces of spacers85engage serrated areas83. One end of pivot pin86includes a bolt head87b, and the other end has a nut87athreaded thereon to hold the serrated spacers85against the serrated areas83. Alternatively, both ends of pivot pin86can include nuts threaded thereon.

By loosening the nut, an operator can adjust the location of pivot pin86in elongated apertures82and the position of serrated spacers85on serrated areas83. By then tightening nut87a, the operator can lock serrated spaces85against serrated areas83to couple pivot pin86to end13aat the adjusted position in elongated apertures82. Pivot pin86and first end13arotate together, and pivot pin86freely rotates in pivot apertures84of second end13b.

Referring toFIG. 4A, crimp ring10includes an adjustable pivot connection or linking apparatus90having an intermediate linking element92a, a first pivot pin94, and a second pivot pin96. Intermediate linking element92aadjoins ends13aand13bof segments11aand11b. Linking element92ahas a first aperture with first pivot pin94disposed therethrough and pivotably connected to first segment11a. Linking element92ahas a second aperture with second pivot pin96disposed therethrough and pivotably connected to second segment11b. External retainers (not shown) may connect to the ends of the pins94and96to secure the pins in the apertures.

Pivot pins94and96in intermediate linking element92aare separated by a distance d1. The distance d1can be predetermined or selected to facilitate an appropriate crimp for a given fitting type or size. A set of intermediate linking elements can provide various distances between the pivot pins94and96. For example, intermediate linking element92acan be replaced by another linking element, such as a second intermediate linking element92bshown inFIG. 4B. Second intermediate linking element92bincludes apertures for the pins94and96separated by a second predetermined distance d2greater than the first distance d1.

By replacing one linking element having one distance with a second linking element having a second distance, an operator can adjust the relationship of pivot points for the segments11aand11b. For example, if it is found that over-pressing on a particular type, size, or manufacture of fitting has occurred during a crimp operation, an operator may add an intermediate linking element having a distance of approximately several hundredths of an inch greater between pivot points94and96. The crimp ring segments may include non-adjustable positive stopping apparatus, such as discussed above, which is calibrated for a specific fitting, for example. Thus, by adjusting the relationship of pivot points94and96, interchangeable linking elements92aand92bcan be used to fine-tune properties of the crimp made with crimp ring10.

Additional embodiments of linking apparatus90c–fare also illustrated inFIG. 4B. For one linking apparatus90c, an intermediate linking element92cdefines an elongated aperture93. First and second pivot pins94and96are disposed in elongated aperture93, and each pin94and96pivotably connects to an ends of a ring segment (not shown). Pivot pins94and96include adjustable locking mechanisms (not shown) for adjusting and locking their positions in the elongated aperture93. For example, pivot pins94and96can each include an adjustable locking mechanism, such as discussed above in the embodiment ofFIGS. 3B and 3C.

Another linking apparatus90d, illustrated inFIG. 4B, includes an intermediate linking element92d, which defines a first aperture95for pivotably attaching to first pivot pin94and first segment11a. First pin94is rotatable within first aperture95. Intermediate linking element92dalso defines an elongated aperture97for attaching to second pivot pin96and second segment11b. Second pivot pin96includes an adjustable locking mechanism (not shown) for adjusting and locking its position in the cam aperture97. For example, second pivot pin96can include an adjustable locking mechanism, such as discussed above in the embodiment ofFIGS. 3B and 3C.

Other linking apparatus90e-f, illustrated inFIG. 4B, demonstrate linking elements92eor92fdefining a plurality of adjustment positions98or99. For example, adjustment positions98include a plurality of slots defined in linking element92e. Alternatively, adjustment positions99include a plurality of apertures defined in linking element92e. Linking element92eor92fis pivotably attached to first pivot pin94disposed on first segment11a. Using the plurality of adjustment positions98or99, linking element92eor92fadjustably and pivotably attaches to second pivot pin94disposed on second segment11b. For linking element92e, second pivot pin96can include a lock or nut (not shown) to maintain the pin in one of the adjustment slots98. It should be noted that having the plurality of slots or apertures98or99of elements90e–fdepends on the required diameter for the pins. The construction of elements90e–fas shown may not be possible where larger diameter pins are required.

Referring toFIGS. 5A–B, crimp ring10includes embodiments of adjustable linking apparatus100aand100b. InFIG. 5A, adjustable linking apparatus100aincludes a linking element or threaded extension102passing through a trunnion104, which is pivotably attached to first ring segment11a. Threaded extension102is rotatably attached to a pivot pin106, which is pivotably attached to second segment11b. Rotation of threaded extension102causes trunnion pin104to move along threaded extension102in relation to pivot pin106. By altering the distance between pivots104and106, crimp dimension18defined by the segments can be changed.

Alternatively, each pivot pin pivotably attached to the segments may include trunnions, and ends of threaded extension may have oppositely pitched threads. Rotating the double-pitched extension102then moves the two trunnions in relation to one another to change crimp dimension18defined by the segments. Adjustable linking apparatus100aprovides a cost advantage, because the segments11a–bcan be symmetrical, allowing for double production from a single cast design.

InFIG. 5B, adjustable linking apparatus100bincludes a threaded extension103, a trunnion105, and a fixed notch or nut107. Trunnion105is pivotably attached on first segment11a. Threaded extension103is threadably disposed through trunnion105. A distal end of threaded extension130is received in fixed notch107attached on second segment11b.

Referring toFIG. 6, an embodiment of an adjustable pivot connection110for crimp ring10is schematically illustrated. Segments11aand11beach define a plurality of pivot apertures112. The plurality of pivot apertures112lies substantially in line with an approximate center C of crimp opening18. Pivot apertures112in the segments align together when the segments are in a closed position. A pivot pin114is adjustably positioned in one of the plurality of pivot apertures112. By interchanging pivot pin114between the apertures112, an operator alters the pivot connection between segments11aand11b, thereby adjusting properties of the crimp produced on a fitting.

Referring toFIG. 7, an embodiment of an adjustable pivot connection120is schematically illustrated. First and second segments11aand11beach define an elongated aperture122aand122b. A pivot pin124is disposed within elongated apertures122aand122b. Segments11aand11bpivot relative to one another about pin124. Pin124is locked in position in the apertures122aand122bto maintain a specific pivotable relationship between first and second segments11aand11b.

First segment11ahas a first crimp radius Radefined from a first center Ca. Elongated aperture122ais aligned with center Ca. Likewise, second segment11bhas a second crimp radius Radefined from a second center Ca. Elongated aperture122bis aligned with center Cb. However, elongated apertures122aand122bcan initially be provided with angles at any varying degrees θ1and θ2relative to centers Caand Cb. Furthermore, elongated apertures122aand122bcan have curved or irregular shapes other than the elongated shape illustrated inFIG. 7.

Orientations and shapes of elongated apertures122aand122bcan be used to determine the displacement of segments11aand11bin relation to one another and in relation to the fitting as the segments are pivoted about pin124. The orientations and shapes of elongated apertures122aand122bcan therefore alter properties of the crimp produced on a fitting and can be pre-configured to produce an appropriate crimp on the fitting.

Referring toFIG. 8, crimp ring10includes an eccentric pivot apparatus130. InFIG. 8, a partial perspective view of the pivot connection between segments11aand11bis illustrated. Segments11aand11bare illustrated in cross-section to reveal eccentric pivot apparatus130at the pivot connection. First segment11aincludes a bifurcate end13ahaving first and second sides, only one of which is illustrated. The sides define locking apertures15having splines. Second segment11bincludes an end13bdisposed in bifurcate end13aof first segment11a. End13bdefines a pivot aperture17. Eccentric pivot apparatus130is disposed in apertures15and17and forming the pivot connection between adjoined ends13aand13b.

Eccentric pivot apparatus130, which is shown in relevant detail inFIGS. 9A and 9B, includes a first base132and a second base138. An intermediate pin134is connected to first base132and extends from one side of first base132. Pin134has an axial center P offset from an axial center A of base132by a distance d. A key136is formed on a distal end of intermediate pin134. Key136disposes in a keyway137defined in second base138. Keyway137is also offset from axial center A of second base138by the distance d. The bases132and138can be connected in parallel and centrally aligned with one another on intermediate pin134. The bases132and138have a first diameter D1. The outer surfaces of the bases132and138include splines, which interlock with the splines of locking apertures15. Intermediate pin134has a second diameter D2that is less than the first diameter D1. The outer surface of the pin134is smooth, allowing the pin to rotate in pivot aperture17.

When assembled as shown inFIG. 8, first base132is disposed in one of the locking apertures15of first segment11a. The splines in locking aperture15allow the orientation of first base132to be locked in place when disposed in locking aperture15. A retainer (not shown) on the outside of bifurcate end13amay be used to hold first base132in locking aperture15. Intermediate pin134is disposed in pivot aperture17of second segment11b. Second base138is disposed in another locking aperture (not shown) with splines, and key136is disposed in keyway137. Another retainer (not shown) on the outside of bifurcate end13amay be used to hold second base138.

Second segment11bhas an axis of pivot about the axial center P of intermediate pin134. By removing, rotating, and repositioning bases132and138in locking apertures15, the eccentric pivot axis P of second segment11bcan be changed relative to first segment11a. Thus, eccentric pivot apparatus130provides an adjustable pivot axes P between segments11aand11b. Eccentric pivot apparatus130can be used to fine-tune the closure of segments11aand11babout a fitting as discussed below.

InFIGS. 10A and 10B, a side view and end cross-sectional view of eccentric pivot apparatus130in a first position are illustrated. InFIGS. 10C and 10D, a side view and end cross-sectional view of eccentric pivot apparatus130in a second position are illustrated. As best shown inFIGS. 10A and 10C, pivot axis P can be adjusted in relation to a relative center C of crimp ring10. For example, axes A of the bases132and138and pivot axis P of the intermediate pin134define a plane X. By removing, rotating, and repositioning bases132and138in locking apertures15, the plane X defined by axes A and P may be angled and oriented at varying degrees relative to the center C of segments11aand11b. The splines of bases132and138and locking apertures15allow the axes A and P defining the plane X to be adjusted in small increments.

By adjusting the orientation of plane X, a relative distance D between segments11aand11bcan be increased from zero to d. For example, if plane X is angled at 90-degrees relative to center C as shown inFIGS. 10A and 10B, the relative dimension D defined between segments11aand11bis increased by the distance d between the axes A and P. In addition, either segment11aor11bcan be positioned closer to the relative center C from 0 to d by adjusting the orientation of plane X. For example, if plane X is angled at 0-degrees relative to center C as shown inFIGS. 10C and 10D, the relative dimension D defined by segments11aand11bis not increased. However, first segment11ais positioned closer to center C than second segment11bby the distance d between axes A and P.

During a crimping operation, the segments11aand11bpivot about intermediate pin134. Eccentric pivot apparatus130allows the orientation of the pivot to be adjusted. Consequently, an operator can adjust eccentric pivot apparatus130to alter properties of the crimp produced on a fitting to produce an appropriate crimp on the fitting.

D. Alternative Crimp Ring Construction

Alternate embodiments of crimp ring construction will now be discussed with reference to the drawings. Some embodiments of the crimp rings and the segments disclosed herein may require intricate casting or precise machining to manufacture. Accordingly, in some embodiments of the present invention, the crimp ring may include a laminated structure. For example, embodiments of crimp rings having positive stopping apparatus or adjustable pivot connections may benefit from a laminated structure. In general, however, the laminated structures for crimp rings may be used independently from or in combination with the positive stopping apparatus or the adjustable pivot connections. The laminated structure may include exclusively or in combination stamped, cast, laser cut, water-jet cut, milled, or fine-blanked laminations. Furthermore, inserts may also be included as required to form the crimp ring.

Referring toFIG. 11A, a crimp ring150having a laminated structure in accordance with the present invention is illustrated. Crimp ring150, shown partially disassembled inFIG. 11A, includes a first segment152a, a second segment152b, and a pivot pin160. First and second segments152aand152beach include an end154aand154bdefining a pivot aperture156aand156b. Ends154aand154bare adjoined, and pivot pin160is positioned through apertures156aand156b. Although not shown inFIG. 11A, a torsion spring, which biases segments152a–bopen, is positioned within the bifurcate end154awith pivot pin160disposed through the torsion spring. External retaining rings162and164attach to ends of pin160to maintain the pin within the pivot apertures. A spacer (not shown), disposed on pin160, can be used between bifurcate ends154a–bto provide a stable hinged connection.

Each ring segment152aand152bcomprises a laminated structure. The laminated structure has, for example, five laminated layers, including a first side lamination172a, a first inner lamination174a, a center lamination176, a second inner lamination174b, and a second side lamination172b. First and second side laminations172aand172band center lamination176may each be comprised of a single lamination being stamped, cast, or otherwise formed. First and second inner laminations174aand174bmay each be fine-blanked and comprised of multiple layers of thin laminates, although inner laminations174aand174may each also be comprised of a single lamination. Center lamination176preferably includes an extension for alignment.

Relative heights and widths of individual laminations and the overall number of laminations may vary for different sized fittings or crimping patterns to be employed thereon. A plurality of rivets178are used to hold the laminations172a–b,174a–b, and175together to form the segments152aand152b. Alternatively, the laminations can be held together by other fasteners or by an adhesive. It is understood that the laminations can be held together by a number of other methods known in the art, including, but not limited to, welding and brazing.

Preferably, the laminated structure allows for parts, dimensions, or features of crimp ring150requiring key tolerances to be fine-blanked laminations. Less critical parts, dimensions, or features may be stamped or cast laminations. For example, crimp ring150with the laminated structure inFIG. 11Aincludes a positive stopping apparatus. First laminated segment152aincludes a first positive stopping surface158aadjacent pivot aperture156a. Second laminated segment152bincludes a second positive stopping surface158badjacent pivot aperture156b. First and second positive stopping surfaces158aand158bare preferably formed with fine-blanked laminations174aand174b. Use of fine-blanked laminations174aand174bfacilitates production of positive stopping surfaces158aand158bwith a high degree of precision.

In addition to providing a high degree of precision, constructing segments152aand152band assembling crimp ring150with laminations172a–b,174a–b, and176is simpler and less costly than casting and machining single piece segments to meet desired tolerances. With the laminated structure, reduced machining may be required to produce the positive stopping apparatus or adjustable pivot connections of the present invention.

Referring toFIGS. 11B–D, an alternative construction for a crimp ring is illustrated. The crimp ring, shown disassembled inFIG. 11B, is formed with symmetrical segments180a–bconnected together with a pivot pin160. InFIGS. 11C–D, a top view and cross-sectional view of one of the symmetrical segments180is illustrated.

First segment180aincludes a first bifurcate end182ahaving a first side183aand a second side184a. End182aalso defines a first space185aadjacent second side184aand defines a second space or gap186abetween sides183aand184a. The two sides183aand185adefine pivot apertures188afor pivot pin160. Being symmetrical to first segment180a, second segment180bincludes a second bifurcate end182bhaving the same arrangement of sides183b,184band spaces185b,186b.

To form the crimp ring from the two symmetrical segments180a–b, the bifurcate ends182a–bare adjoined. In particular, first side183aof upper segment180apositions in first space185bof lower segment180band positions adjacent second side184b. Second side184aof upper segment180apositions in gap186bof lower segment180band positions between first and second sides183band184b.

Pivot pin160is positioned through pivot apertures188a–b. To improve the hinged connection between ends182a–b, a spacer166can be used. For example, spacer166is positioned within the bifurcate ends182a–bwith pivot pin160disposed through an axial bore of the spacer. Although not shown inFIG. 11B, a torsion spring, which biases segments180a–bopen, is positioned within the bifurcate ends182a–bwith spacer166and pivot pin160disposed through the torsion spring. External retaining rings (not shown) attach to ends of pin160to maintain the pin within the pivot apertures. The second sides184a–beach include an extension189a–b, which engage inner surfaces of the gaps185a–bto limit how far the segments180a–bcan open once adjoined. It should be noted thatFIG. 11Bshows ring segment180bwith a positive stop24and thatFIG. 11Dshows ring segment180awith another positive stop22, such as described above with reference toFIG. 1A. In addition, segments180a–bdefine pivot ports181for articulating on hemispherical ends of actuator arms (not shown).

Referring toFIGS. 11E–F, another, alternative construction for a crimp ring190is illustrated. Crimp ring190, shown disassembled inFIG. 11B, is formed with symmetrical segments190a–bconnected together with a stepped pin196. InFIG. 11F, segments190a–bare shown in cross-section connected by stepped pin196.

In contrast to the embodiment ofFIGS. 11B–D, first segment192aincludes one ear193aat an end of the segment. A pivot aperture194ais defined in ear193a. Next to ear193a, first segment192adefines a ledge or space195a. Being symmetrical to first segment192a, second segment192bincludes an ear193bon one end. A pivot aperture194bis defined in ear193b. Next to ear193b, second segment192bdefines a ledge195b. Stepped pin196is used to hingedly connect segments192a–b. In contrast to the embodiment ofFIGS. 11B–D, stepped pin196has a spacer portion197integrally formed with first and second pin portions198a–b. Spacer portion197has a larger diameter than pin portions198a–bso that a shoulder is formed on both end of stepped pin196.

To form the crimp ring from the two symmetrical segments192a–b, ear193ais positioned on pin portion198aof stepped pin196, and ear193bis positioned on pin portion198b, as best shown inFIG. 11F. Ears193a–bare positioned against the shoulders formed by spacer portion197. Spacer portion197separates ears193a–bat an appropriate distance and provides a perpendicular surface that guides segments192a–bwhen pivoted. Although not shown inFIGS. 11E–F, a torsion spring, which biases segments192a–bclosed, is positioned between ears193a–band disposed on spacer portion197. Preferably, the width of the spacer portion197is no more than in necessary to fit the torsion spring thereon. External retaining rings199a–battach to ends of pin portions198a–b160to maintain ears193a–bthereon and to sustain the hinged connection.

Referring toFIGS. 12A–G, embodiments of crimp rings with interlocking ends according to the present invention will now be discussed. Referring first toFIG. 12A, a first embodiment of a crimp ring200is illustrated. Crimp ring200includes first and second segments202aand202b, although it is understood that the use of more segments is also possible. In contrast to previous embodiments, crimp ring200lacks a pivot pin structure to form the pivot connection between segments202aand202b.

First and second segments202aand202bare symmetrical and are positioned side to side to form the crimp ring200. Segments202aand202bdefine wells204aand204b. Ends of a C-clip206are disposed in the wells204aand204b. Segments202aand202bare pivotable on the ends of C-clip206. Structures (not shown) on C-clip206or segments202aand202bcan be used to keep the segments aligned.

In one embodiment, the ends of C-clip206define a radius, and the surfaces of the wells204aand204bengaging the ends of the C-clip also define the radius. The segments202aand202brotate about the centers of these radii. In this way, first segment202apivots about a pivot point P1, and second segment202bpivots about a pivot point P2. The pivot points P1and P2are separated by a distance d. C-clip206can be interchanged with another clip having a different distance between the ends to adjust the pivot points of the segments, thereby adjusting properties of the crimp produced with crimp ring200.

InFIG. 12B, a crimp ring210includes a first segments212aand a second segment212b, which are symmetrical and positioned side to side to form the crimp ring210. Segments212aand212beach include an extension214aand214bwith a bulbous or rounded end. Hooked surfaces218a–bof a C-clip216position on the ends of extension214aand214b. Segments202aand202bare pivotable on the ends of extension214aand214bin the hooked surfaces of C-clip206. Segments202aand202bpivot about different pivot points P1and P2separated by a distance d. The C-clip216can be interchanged with another clip having a different distance between hooked surfaces218aand218bto adjust the distance between pivot points P1and P2of the segments, thereby adjusting properties of the crimp produced with crimp ring200.

Referring toFIGS. 12C–G, crimp ring assemblies are illustrated, which eliminate the need for a separate pivot pin. InFIG. 12C, a crimp ring220includes a first segment222aand a second segment222b. The first segment222ahas a bulbous or rounded extension224. Second segment222bincludes a hooked extension226. The rounded extension224is disposed in the hooked extension226. Rounded extension224is rotatable on a surface227of hooked extension226, allowing segment222ato pivot relative to segment222b. First segment224preferably defines a space225for providing sufficient room for the end of hooked extension226when the segments are opened and for stopping the segments from opening beyond a certain point.

InFIGS. 12D and 12E, a crimp ring230includes a first segment232aand a second segment232b. First segment232ahas a pin234, which can be integrally cast thereon, machined, or affixed by a number of methods known in the art. Second segment222bhas a hook236, which can be integrally cast or machined thereon. The hook236disposes on pin234, allowing segment222ato pivot relative to segment222b.

InFIGS. 12F and 12G, a crimp ring250includes a first segment252aand a second segment252b, which are only partially shown. First segment252adefines a female feature or hooked pocket254, which can be integrally cast or machined therein. Second segment222bhas a male feature260with a catch or cross member266, which can be integrally cast or machined on the second segment. Male feature260couples with female feature254by positioning cross member266through a widened portion256of hooked pocket254and engaging cross member266in a hook257of pocket254. A portion268of male feature260passes through a slot258in first segment252a.

E. Positive Stopping Apparatus on Actuator Arms or Crimp Jaws

In accordance with the present invention, non-adjustable/adjustable positive stopping apparatus can also be provided on crimp jaws for crimping a fitting or on actuator arms for actuating a crimp ring. These positive stopping apparatus can be used in combination with or independent from any positive stopping apparatus on crimp rings disclosed herein.

Referring toFIGS. 13A–E, adjustable and non-adjustable positive stopping apparatus for an assembly300are illustrated. Assembly300includes first and second arms302aand302bsymmetrically arranged in the assembly. Each of the first and second arms302aand302bincludes a pivot point304aand304b, a cam portion306aand306b. Pivot pins (not shown) are disposed in pivot points304aand304band connect to side plates (not shown) to complete the assembly. Rollers within a crimping tool (not shown) contact cam portions306aand306bof jaws302aand302bcausing them to pivot about pivot points304aand304b. The completion of the crimp cycle occurs as tips309aand309bare brought together.

InFIG. 13A, an existing example of a positive stopping apparatus310for crimp arms302aand302bincludes a positive stop or boss312. Positive stop or boss312may be disposed on a tip309of one or both arms302. Boss312may be integrally cast with arm302and machined to provide appropriate tolerances for the closure of jaw portions308aand308babout a fitting disposed therebetween.

InFIG. 13B, another example of a positive stopping apparatus320includes an adjustable or threaded member322. Adjustable or threaded member322may be disposed on a tip309aof arm302a. Adjustable or threaded member322may be adjusted to change the point of engagement with tip309bof adjacent arm302band provide appropriate tolerances for the closure of jaw portions308aand308babout the fitting disposed therebetween.

InFIGS. 13C–E, the positive stopping apparatus discussed below can be used with assembly300having jaw portions that directly contact and crimp the fitting. In addition, the positive stopping apparatus discussed below can be used on actuator arms in an assembly that actuates a crimp ring (not shown).

InFIG. 13C, yet another example of a positive stopping apparatus330is illustrated. First arm302aincludes a first positive stopping surface332, and second arm302bincludes a second positive stopping surface334. As arm302aand302bare pivoted together to crimp a fitting or to actuate a crimp ring, first and second positive stopping surfaces332and334engage one another, defining an end point to the crimping motion of assembly300. First and second positive stopping surfaces332and334may be premachined and calibrated to provide an appropriate crimp for a specific fitting or fitting size.

Alternatively, as illustrated inFIG. 13D, at least one of the positive stops on one of the arms may be adjustable. As shown here, first positive stop342includes an adjustable or threaded member344disposed in first arm302a. The position of adjustable member344may be changed to fine tune its engagement with second, fixed positive stopping surface346on second arm302b.

As shown inFIGS. 13A–D, positive stopping apparatus may be disposed in or between the arms. In an alternative design illustrated inFIG. 13E, a positive stopping apparatus350may be disposed outside the arms of assembly300. An extension352on the side of first arm302aincludes a threaded bore with an adjustable member354disposed therein. An extension356on the side of second arm302bdefines a positive stopping surface356. Engagement of adjustable member354and positive stopping surface356may be changed by adjusting member354within the bore of extension352.

II. Sensing Systems for Assuring or Determining Appropriate Closure of a Crimp Ring Assembly About a Fitting

A. Sensing Apparatus for a Crimp Ring Assembly

Referring toFIGS. 14A–D, wherein the same reference numbers indicate like elements between Figures, sensing apparatus and systems for assuring or determining appropriate closure of a crimp ring are shown. The sensing apparatus can be used in combination with or independently from the various positive stopping apparatus, adjustable pivot connections, laminated structures, etc. disclosed herein.

The sensing apparatus include one or more sensors or transducers. The sensors can be positioned on either a crimp ring, actuator arms, or crimp jaws. The sensors can communicate with a number of devices for assessing, assuring, or determining an appropriate crimp on a fitting. The devices can include, but are not limited to, an indicator, a control device, a release mechanism, or a locking mechanism. In the embodiments of sensing apparatus disclosed below, the sensors or transducers can include all desirably applicable sensors known in the art for sensing or indicating. Various sensors based on the principles of induction, eddy current, capacitance, magnetism, or resistance can be used. In addition, optical sensors, pressure sensors, or travel sensors can also be used. Moreover, mechanical switches triggering an electric or visual signal can also be used with sensing apparatus according to the present invention.

Referring toFIGS. 14A–B, crimp ring10includes sensors400and410at pivot point16to measure annular movement of ring segments11aand11b. In one embodiment illustrated inFIG. 4A, sensor400is a rotary displacement sensor, such as a potentiometer or rotary capacitive displacement transducer, or is a rotary position encoder disposed adjacent pivot16and outside crimp ring10. Sensor400is attached to segments11aand11b. Sensor400measures the angular relation between the segments by producing varied resistances or capacitance at different angular orientations of the segments.

A signal from sensor400is transmitted to a device (not shown) to indicate the angular relation of the segments. Transmission of the signal from the sensor400can include a number of techniques and methods known in the art. In one example, the signal can be transmitted via UHF, VHF, or 900 MHz radio waves. The device can use the angular relation to assure or determine appropriate closure of the crimp ring. In other words, the device can be a release mechanism that electrically stops the crimping tool during the crimp operation once a predetermined resistance or capacitance level is reached by sensor400.

In addition, sensor400can be used in concert with a microcontroller (not shown). Processing the signal, the microcontroller can correlate the angular position of ring segments13aand13bwith other measured parameters of the crimp tool, such as ram force to produce a fault signal. For example, the microcontroller can produce an audible alarm, if the proper angular signal is not detected in sensor400when a ram force sensor in the tool indicates that a preset value has not been attained, such as 32 kN.

In another embodiment illustrated inFIG. 14B, sensor410is a linear sensor attached to first and second segments11aand11badjacent pivot16. For example, sensor410can be a linear variable differential transformer (LVDT) with each end attached to segments11aand11b. Pivoting of segments11aand11bin relation to one another alters the distance between points on the segments and changes the voltage output of sensor410. The signal from sensor410is communicated to a device (not shown) to indicate the angular relation of segments11aand11b. The device can use the angular relation to electrically stop a crimping tool during a crimp operation once a predetermined voltage level is output by gauge410.

Referring toFIGS. 14C–D, crimp ring10includes sensors420and430for sensing contact of positive stops or for measuring the proximity of ring segments11aand11b. Sensors420or430can be, for example, piezoelectric elements, pressure sensitive elements, or proximity sensors. With reference toFIG. 14C, a proximity sensor, strain gauge, or load cell420is disposed on a first positive stopping surface52adjacent pivot point16. A second positive stopping surface54on second segment11aengages contact sensing element420as segments11aand11bare brought together. The angular relation of segments11aand11bmay be measured by the voltage generated by contact sensing element420. In an alternative arrangement, a contact sensing element420′ can be attached to free end12aof first segment11a. This contact sensing element420′ engages free end12bof second segment12bas crimp ring10is closed. At least one of the free ends12aand12bincludes an adjustable stop to change the point of engagement and indication of the element.

InFIG. 14C, a pressure sensitive element or switch422can be disposed between first and second positive stopping surfaces52and54adjacent pivot point16of the first and second segments. Pressure sensitive element422, such as a capacitive displacement linear position sensor, for example, includes a first conductive plate affixing to first positive stopping surface54and includes a second conductive plate affixing to second positive stopping surface54. A non-conductive material, such as foam, is disposed between the first and second plates.

The plates are connected to additional electronics to measure their proximity to one another, which is proportional to the capacitive signal. Pressure sensitive element422acts as a switch as the first and second plates are moved closer to each other. At a predetermined or calibrated distance, capacitance is measured from one plate to the other indicating a completed, pre-determined closure of the segments. The indication from pressure sensitive element422can be used to shut off a crimping tool at a specified dimension to assure an appropriate crimp of the fitting or else send an alarm if the proper closure is not attained during the crimp cycle.

As shown inFIG. 14D, a proximity sensor or switch430is disposed in end13aof first segment11a. Proximity sensor430, which can be, for example, inductive or capacitive, is used to measure the distance to a positive stopping surface54defined in end13bof second segment11b. By measuring the distance, the angular relation of segments11aand11bcan be determined. Alternatively, proximity sensor430can be used to indicate when a predetermined distance is reached from positive stopping surface54.

Instead of being disposed on end13b, a proximity sensor430′ can be disposed on free end12aof first segment11a. Proximity sensor430′ can be used to indicate when a predetermined distance is reached between ends12aand12bas the crimp ring is closed. Furthermore, an additional element432can be positioned on free end12bof second segment12band can act as a relational point for proximity sensor430′. For example, additional element432can be composed of a material or metal with a dielectric constant other than that used in segments11aand11b. In this way, proximity sensor430can be designed or calibrated to be more sensitive to the particular material of additional element432.

B. Sensing Apparatus for Actuator Arms or Crimp Jaws

In further embodiments of sensing apparatus, the present invention may include apparatus for assuring/determining appropriate closure of arms of an actuator assembly or jaws of a crimp assembly. The arms of the actuator assembly actuate a ring or chain to crimp the fitting. The jaws of the crimp assembly are used to directly crimp a fitting. Transducers or sensors, such as those discussed above for use with the crimp ring, can be used with the arms or jaws and positive stopping apparatus to assure or determine an appropriate point of closure.

III. Diagnostics and Analysis

Once the sensors or transducers are engaged or triggered, data from the sensing systems is used to analyze and diagnose the crimp produced during the crimp operation. The analysis and diagnosis, in turn, is used to recalibrate or fine tune the adjustable positive stopping apparatus on the crimp ring, arms, or jaws to improve the crimp produced on the fittings. In addition, the analysis and diagnosis is used to adjust the adjustable pivot connection between the segments of the crimp ring to improve the crimp produced on the fittings.

Referring toFIG. 15, exemplary force versus displacement profiles are schematically illustrated for crimping a fitting with a crimp ring. On the graph, the vertical axis denotes the output force, and the horizontal axis denotes the displacement of the actuating mechanism, such as a hydraulic piston or driven rod. As noted above, a typical crimping tool has a maximum output force at which the tool shuts off. A release mechanism may be used to shut-off the tool when the maximum output force is reached. For example, a typical crimping tool may have a maximum hydraulic output of about 32 kN at which point the tool shuts off.

An ideal force versus displacement curve510is illustrated. The area under the curves represents the amount of work used to produce a crimp on a fitting. As noted above, for a given fitting used to join pipes, variations may unfortunately exist in the crimping operation due to differences in materials, wall thickness, elasticity of the crimping tool, differences in manufacturing tolerances, heat expansion, etc. Curve520schematically shows a more realistic, nearly ideal force versus displacement profile.

Output force is measured from the drive mechanism during the crimping operation. When measured from the drive mechanism, the output force is directly related to actual forces applied to a fitting with crimp jaws or a crimp ring, but it is understood that the output force is less than the actual crimping forces applied to the fitting. Fluctuations in the output forces measured in the graph result from changes in resistance and deformation of the fitting, pipe, actuator arms, crimp jaws and/or crimp ring during the crimp operation. Such force profile data is useful in adjusting, selecting, or calibrating the crimp ring, arms, or jaws to improve the crimp produced on a given fitting. The adjustment, selection, or calibration is made to account for variations in a given fitting, wear of the tool, differing tolerances, etc.

FIG. 15also includes curves530and540with deviations of the output force that produce less than ideal crimps on a given fitting. For example, curve530is characteristic of crimping a given fitting with a crimp ring or crimp jaws defining an inner dimension that is too small for the fitting, resulting in over-pressing of the fitting. Due to over-pressing, the force increases and departs from the ideal or near ideal profiles510and520. Force profile530prematurely peeks higher than is ideally desirable when crimping the fitting. This premature peaking can cause the tool to shut off before a completed crimp is formed, if the hump in curve530climbs above 32 kN before the appropriate displacement is attained.

In addition, a sustained portion532of force profile530can in general have a higher force than is desirable when crimping the fitting. In such a situation, more work is used than is necessary to crimp the fitting. The peaking and large output force indicate to an operator that adjustment of the pivot point or the positive stopping apparatus of the crimp ring is necessary to reduce over-pressing the slightly larger fitting with the crimp ring or jaws. When used in combination with other aspects of the present invention, the crimp ring, actuator arms, or jaws can be adjusted, selected, or calibrated to improve the crimp produced on the given fitting based on force profile530.

Curve540results from crimping the given fitting with a crimp ring, chain, or jaws that define an inner dimension that is too large for the fitting. Resistance from the fitting against the ring, chain, or jaws is low, and the output force remains low. A ramp portion546of the force profile540extends for a longer displacement of the drive mechanism than is desirable when crimping the fitting. Preferably, the force ramps rapidly to the shut-off force in a shorter portion of the drive mechanism's stroke. When used in combination with other aspects of the present invention, the crimp ring, actuator arms, or crimp jaws can be adjusted, selected, or calibrated to improve the crimp produced on the given fitting based on such a force profile540.

As illustrated inFIG. 15, the crimping tool can have a maximum force output of about 32 kN, at which point the tool is shut off. Use of positive stopping apparatus as disclosed above can advantageously act in conjunction with the conventional tool shut-off mechanisms known in the art. The positive stopping apparatus of the present invention can be pre-calibrated or adjusted to produce a ramping portion of the force during the crimp operation. This ramping of the force can be used to rapidly reach the tool shut-off force, as desired to produce an appropriate crimp on the fitting.

It may be useful to monitor the time of a crimp operation and to measure distance between the actuator arms or jaws on the tool. In other words, it is useful to monitor contact between the correct elements at the correct time. However, the present preference is to monitor the position or displacement of the tool and the force applied rather than time.

The force verses displacement of a crimp operation is time independent and is highly repeatable. However, the force versus displacement of a crimp operation is different for each sized fitting. Therefore, a start position of the crimp operation can be used in combination with a position at a mechanical positive stop to access an appropriate crimp. The use of a sensor with the mechanical positive stop helps to confirm when the pre-calibrated or adjustable stop is reached. The sensor can then turn off the tool, allowing for confirmation of adequate force without over-stressing the crimping tool, the jaws, the actuator arms, or the crimp ring.

In some embodiments of the present invention, the sensors on the crimp ring, actuator arms, or crimp jaws can actively transmit to the tool. For example, the sensors on the crimp ring or jaws can transmit radio frequencies or wireless signals to a processor or control device in the crimping tool or in a remote unit. On the other hand, a diagnostic telemeter, indicator, or controller can be included on the crimp ring, actuator, or jaws.

For example, a diagnostic telemetry device can be embedded in the crimp ring. The telemetry device can measure the relative distance of one ring segment in relation to another. Alternatively, the telemetry device can measure the pressure produced on the inner surface of one or more of the segments during a crimp operation. In addition, the telemetry device can be used to measure physical characteristics of the segments or fitting, such as temperature, strain, etc. The measured distance, pressure, or other data can then be sent to a control device, assessment device, or indicator on the crimping tool or a separate unit.

The telemetry device can include a transmitter using UHF, VHF, or 900 MHz. For example, radio frequencies from the transmitter can carry the data to a receiver in the control device. The control device can use the telemetric data to indicate or record the crimp operation. The data can further be processed and used in diagnosing the crimp produced on the fitting.

In one embodiment of the present invention, a control or assessment device acts in conjunction with the sensors and the positive stopping apparatus or the adjustable/cam operating pivot connections as discussed above. When the ring segment, actuator arms, or jaws are in an open position, the positive stopping surface is calibrated not to trigger or engage the sensor. Contact or activation occurs between the sensor and the positive stop at final closed position, creating a signal that is processed in the control or assessment device.

The control or assessment device can include a microprocessor, software, receiver, transmitter, or additional hardware and electronics. Specific specifications can be input or communicated to the control or assessment device, including the type and or size of the fitting to be crimped, the crimping ring to be used, and the tool to be used. In addition, the control or assessment device can include programming for an operator to manually set boundary conditions for the crimp operation.

The control or assessment device stores force versus displacement profiles. The stored profiles, such as the characteristic or near ideal curve520inFIG. 15, are used in analyzing and processing signals, measurements, or data from the crimp ring, the jaws, or the tool during the crimp operation. The signals, measurements, or data are compared to the stored profiles to determine the likelihood of a proper crimp. It is understood that the profiles include a range or band of appropriate tolerances for the data. The profiles can be stored in the form of functions or as sets of points. Each profile can be specific for a certain crimping tool, actuator, jaws, crimp ring, and/or fitting. When a certain tool, actuator, jaws, ring, and/or fitting are to be used, the appropriate force versus displacement profile can then be selected.

From the sensors as discussed above, signals corresponding to the output force, the displacement, the contact of the positive stopping apparatus, or the measurements of the sensor are sent to the control or assessment device, which processes these signals. The control or assessment device compares data or measurements of the signal to the profile for the selected crimping tool, actuator, jaws, crimp ring, and/or fitting. A check is made as to whether the values lie within limits of the stored profile. The comparison is used to determine whether a malfunction is present. For example, the malfunction may be due to the pressing of a fitting of incorrect size, a pipe end that is not pushed completely into the fitting, or a jam due to trapped foreign objects or creasing at the fitting. The control or assessment device indicates the malfunction or shuts down the crimping tool during the operation.

The signals, measurements, or data can undergo a mapping analysis of the force versus displacement. Divergence in the force/displacement profiles or rapid changes in the same during a crimp operation can be used as indicia of fatigue, cracking, breakage, malfunction, under-pressing, over-pressing, or stressing, etc. of the crimp ring, crimp ring actuator, crimp jaw assembly, or tool. In addition, divergence in force/displacement profiles or rapid changes in the same can indicate that the crimp ring is not properly sized or that the stopped distance between closed crimp jaws is incorrect, etc. With such an analysis, a positive stop or an adjustable crimp ring can be adjusted or fine-tuned to improve the crimp operation. By adjusting the stop of the crimp operation or the pivoting of the ring segments, more appropriate force versus displacement profiles can be produced. The sensing can also determine if there an obstruction is limiting travel of the crimp rings or jaws to prevent proper closure.

As used in the present disclosure and in the appended claims, a crimping member refers to a segment of a crimp ring for crimping a fitting, an actuator arm for actuating a crimp ring, or to a jaw arm for crimping a fitting.

The foregoing description of preferred and other embodiments is not intended to limit or restrict the scope or applicability of the inventive concepts conceived of by the Applicants or defined in the appended claims. In exchange for disclosing the inventive concepts contained herein, the Applicants desire all patent rights afforded by the appended claims. It is intended that the inventive concepts defined by the appended claims include all modifications and alterations to the full extent that such modifications or alterations come within the scope of the appended claims or the equivalents thereof.