WIRE STRIP AND CRIMP TOOL

A system includes a tool having a first arm disposed along a motion plane, a hand-tool body coupled to the first arm, and a second arm rotatably coupled to the hand-tool body and disposed along the motion plane. The hand-tool body includes a first channel, a second channel, and a wire slot configured to receive an insulated wire, wherein the first channel intersects the second channel proximate to the wire slot. The second arm includes a stripping portion configured to reciprocate within the first channel, to cut insulation of the insulated wire, and to strip the insulation from an end portion of the insulated wire. The second arm also includes a crimping portion configured to reciprocate within the second channel and to crimp a terminal lug about the end portion of the insulated wire.

BACKGROUND

The subject matter disclosed herein relates to a hand-tool, and more specifically, a wire strip and crimp hand-tool.

Wires of various sizes carry electrical signals for power and communications. Wire insulation helps to isolate wires from environmental conditions that may affect the carried signals. Insulation also isolates carried current from other conductors that may contact the wire. Terminal lugs mechanically attached to ends of a wire interface the wire with electrical components, enabling signal transmission between the wire and the electrical components. The insulation at the ends of the wire may be removed to provide a desired electrical interface between the terminal and the wire. Some systems may be automated to place terminal lugs on wires; however, such systems may be relatively large, may require an external power source, and/or may not be readily used and carried by an operator. Improper sizing with manual wire strippers may cut into the conductor surface, which may decrease the quality of the interface with the terminal lug. Separate manual crimpers require additional steps to crimp the terminal lug after stripping the wire. Moreover, carrying a manual wire stripper and a manual crimper may be cumbersome.

BRIEF DESCRIPTION

In a first embodiment, a system includes a tool having a hand-tool body, a stripping portion, and a crimping portion. The hand-tool body includes a wire slot, a first channel, and a second channel that are within a motion plane and that intersect at a process area. The wire slot is configured to receive an insulated wire. The stripping portion is arranged within the first channel and is configured to reciprocate along the first channel to strip insulation from an end portion of the insulated wire. The crimping portion is coupled to the stripping portion and is arranged within the second channel. The crimping portion is configured to reciprocate along the second channel to crimp a terminal lug about at least part of the end portion of the insulated wire. The reciprocation of the stripping portion along the first channel relative to the process area is substantially opposite to the reciprocation of the crimping portion along the second channel.

In a second embodiment, a system includes a tool having a first arm disposed along a motion plane, a hand-tool body coupled to the first arm, and a second arm rotatably coupled to the hand-tool body and disposed along the motion plane. The hand-tool body includes a first channel, a second channel, and a wire slot configured to receive an insulated wire, wherein the first channel intersects the second channel proximate to the wire slot. The second arm includes a stripping portion configured to reciprocate within the first channel, to cut the insulation of the insulated wire, and to strip the insulation from an end portion of the insulated wire. The second arm also includes a crimping portion configured to reciprocate within the second channel and to crimp a terminal lug about the end portion of the insulated wire.

In a third embodiment, a method includes rotating a second arm of a hand-tool relative to a first arm of the hand-tool from a first position to a second position within a motion plane, cutting insulation from an end of an insulated wire with a stripping portion of the hand-tool, removing insulation from the end of the insulated wire with the stripping portion of the hand-tool, arranging a terminal lug about the end of the insulated wire, and crimping the terminal lug about the end of the insulated wire with a crimping portion of the hand-tool. The stripping portion is actuated along the motion plane by the second arm to remove insulation, and the crimping portion is actuated along the motion plane by the second arm.

DETAILED DESCRIPTION

A strip/crimp hand-tool as described herein is a hand-tool that strips an end portion of an insulated wire and crimps a terminal lug thereto. The strip/crimp hand-tool is a hand-tool that may be readily carried by an operator and used in a variety of environments. Embodiments of the strip/crimp hand-tool described herein include a manually driven system; however some embodiments of the strip/crimp hand-tool may include one or more components driven by an electric drive system, a pneumatic system, a hydraulic system, or a spring-loaded system. The strip/crimp hand-tool may utilize substantially one motion by the operator (e.g., opening or closing arms relative to one another) to cut the insulation at an end of a wire, strip the insulation from the end of the wire, and crimp a terminal lug about at least a portion of the exposed end of the wire. A stripping portion cuts the insulation and removes the insulation from the wire. In some embodiments, the strip/crimp hand-tool cuts the insulation to a cut depth based at least in part on a size of the wire, which may be determined by the strip/crimp hand-tool. The stripping portion may actuate (e.g., reciprocate) along a first axis within a first channel of the strip/crimp hand-tool. The crimping portion may actuate (e.g., reciprocate) along a second axis within a second channel of the strip/crimp hand-tool. The stripping portion and crimping portion may be coupled to an adjustable member (e.g., arm, turnkey, knob) controlled by the operator to control the cutting, stripping, and crimping actions in substantially one operator motion. In some embodiments, the operator motion may be substantially within the same motion plane as the reciprocating stripping portion and the reciprocating crimping portion. In some embodiments, a separate operator motion (e.g., actuating a cutting lever) may cut the insulation. The terminal lug may be manually placed about the exposed wire end or placed about the exposed wire end by a lug loading system. The lug loading system may include a lug magazine configured to automatically reload another terminal lug after placement of a terminal lug, thereby enabling an operator to strip multiple wire ends and to crimp multiple terminal lugs without manually reloading the terminal lug after each crimping action.

Turning to the drawings,FIG. 1illustrates an embodiment of an electrical system10with multiple insulated wires12to be coupled to respective terminals14. Each insulated wire12may have a conductor16at least partially surrounded by one or more layers of insulation18. Each conductor16may include one or more wires. For example, the conductor16may be a solid wire or hollow wire, and the conductor16may include multiple wires in a twisted or braided arrangement. A section20of the insulation18, shown by dashed lines inFIG. 1, may be removed from the insulated wire12to expose an end portion22of the conductor16. The strip/crimp hand-tool described below may be used to cut and remove the section20of the insulation18. A terminal lug24may be coupled (e.g., crimped) onto the exposed end portion22to facilitate interfacing the insulated wire12with the respective terminal14. A cap26of a terminal lug24receives the end portion22of the conductor16, and the cap26may be crimped about at least part of the exposed end portion22. The strip/crimp hand-tool described below may be used to place and crimp the terminal lug24on the end portion22.

As may be appreciated, a connection end28of the terminal lugs24may be shaped to interface with particular types of terminals14. For example, the connection ends28A and28C may receive terminal prongs14A and14C, and the connection end28B may be received by the terminal port14B. At least a portion of the cap26and the connection end28are electrically conductive to transmit electrical signals and/or power between the wire12and the terminal14. Each wire12and terminal14may be sized based at least in part on a type (e.g., data signal, power signal) and/or a magnitude of the electrical signal carried along the wire12. For example, a larger diameter wire12may carry more current with less resistance than a smaller diameter wire12. The strip/crimp hand-tool may be used to crimp different sizes and types of terminal lugs24, and is not limited to any particular variety.

The terminals14conduct electrical signals between system components32of the electrical system10. The terminals14may include electrical power transmission terminals, communications terminals, and so forth. The system components32with terminals14may include, but are not limited to, processors34, memory storage devices36, sensors38, buses, output components40(e.g., displays), operator input components42, network interfaces43for connection to the cloud45or to network of computers, electrical components (e.g., resistors, capacitors, inductors, transistors, etc.), power supplies44, cooling systems46, transformers, and so forth. Data acquisition systems48, communications systems50, and support systems52have system components32connected within the electrical system10by the terminals14. In some embodiments, the data acquisition system48monitors and/or controls an industrial system54. The industrial system54may include, but is not limited to a load56(e.g., electrical generator) driven by a steam turbine58and/or a gas turbine60. In some embodiments, one or more of the data acquisition systems48, one or more communications systems50, and one or more support systems52may be arranged in one or more control cabinets. Among other uses, the strip/crimp hand-tool described below may be utilized to prepare insulated wires12for connection to terminals14between multiple system components32in control cabinets of the electrical system10.

FIG. 2illustrates an embodiment of the strip/crimp hand-tool80and an insulated wire12in a first position. The strip/crimp hand-tool80may have a first arm82, a second arm84, and a hand-tool body86. Embodiments of the strip/crimp hand-tool80are described herein relative to a consistent set of coordinate axes88. The Y-axis is the vertical direction, the X-axis is a first horizontal direction, and the Z-axis is a second horizontal direction. The strip/crimp hand-tool80may move primarily along an X-Y plane90, herein referred to as a motion plane. For example, the second arm84is rotatably connected to the first arm82and to the hand-tool body86, so that the second arm84rotates relative to the first arm82along the motion plane90. The second arm84is connected to a stripping portion92and to a crimping portion94. The hand-tool body86receives the insulated wire12in a wire slot96. The stripping portion92moves within a first channel98, and the crimping portion94moves within a second channel100. The first channel98intersects the second channel100at a process area102. The first channel98, the second channel100, and the process area102lie within the motion plane90. The wire slot96is open to the process area102such that the insulated wire12may be inserted through the wire slot96into the process area102. Within the process area102, the stripping portion92cuts and removes the section20of insulation from the insulated wire12, and the crimping portion94crimps a terminal lug24on the exposed end portion22of the conductor16.

The stripping portion92and the first channel98are substantially parallel with the insulated wire12and the wire slot96, and the crimping portion94and the second channel100are substantially perpendicular (e.g., radial) to the insulated wire12. In some embodiments, the wire slot96and first channel98lie along the X-axis, and the second channel100lies along the Y-axis, as illustrated inFIG. 2. In some embodiments, the stripping portion92and the crimping portion94reciprocate along respective axes oriented between approximately 80 to 100, 70 to 110, 60 to 120, or 45 to 135 degrees relative to each other. The stripping portion92reciprocates along an axis substantially parallel to an axis103of the insulated wire12, and the crimping portion94reciprocates along an axis substantially perpendicular (e.g., radial) with the axis103of the insulated wire12. As used herein, the term substantially includes, but is not limited to, within approximately 10 degrees or less.

The stripping portion92and the crimping portion94are coupled to one another (e.g., via the second arm84) such that as the stripping portion92moves within the first channel98in a first direction104from process area102along the X-axis, the crimping portion94moves within the second channel100in a second direction106along the Y-axis. The stripping portion92and the crimping portion94may each be fixed or rotatably coupled to the second arm84, such that the stripping portion92moves in the first direction104and the crimping portion94moves in the second direction106as the second arm84moves from a first position108(e.g., open position) to a second position110(e.g., closed position) as shown by arrow112along the motion plane90. That is, the stripping portion92moves relative to the process area102substantially opposite to the movement of the crimping portion94relative to the process area102. As may be appreciated, in some embodiments the arrangement of the stripping portion92and the crimping portion94may be switched such that the wire slot96may extend through the hand-tool body86at location114along the Y-axis with the first channel98, and the second channel100lies along the X-axis. When the wire slot96is at location114, as the second arm84moves from the second position110to the first position108along the motion plane90, the stripping portion92moves in a third direction116from the wire slot96, and the crimping portion94moves in a fourth direction118. In some embodiments, the stripping portion92may be coupled to the crimping portion94via a rotating member (e.g., knob, dial, turnkey) that rotates within the motion plane90(e.g., about an axis parallel to the Z-axis), thereby enabling the strip/crimp hand-tool80to operate without the first arm82and/or the second arm84.

In some embodiments, moving the second arm84actuates one or more cutting blades within the stripping portion92to cut the section20of insulation18from the insulated wire12. As described in detail below, the one or more cutting blades may be actuated via motion of the second arm84and/or a stored energy component (e.g., spring, battery). Actuating the one or more cutting blades while moving the second arm84may enable the operator to cut, strip, and crimp the end portion of the insulated wire12with substantially one continuous motion (e.g., from the first position108to the second position110). Moreover, the continuous motion may be substantially within the motion plane90, thereby decreasing the effort and complexity of movement by the operator to add the terminal lug24. Additionally, or in the alternative, a cutting lever120coupled to the stripping portion92actuates the one or more cutting blades. The cutting lever120may move within the motion plane90. In some embodiments, the cutting lever120may actuate the one or more cutting blades via a cable122.

FIG. 3illustrates an embodiment of the hand-tool body86and the stripping portion92of the strip/crimp hand-tool80, taken along line3-3ofFIG. 2. A top face of the hand-tool body86opposite the bottom face130is not shown in order to better show the embodiment of the one or more cutting blades132of the stripping portion92. The insulated wire12is inserted through the wire slot96into the process area102. In some embodiments, the wire slot96includes a groove134to aid centering the insulated wire12within the one or more cutting blades132. A wire retention system136may engage the insulated wire12within the wire slot96, thereby restricting movement of the insulated wire12along the Z-axis. In some embodiments, the wire retention system136includes one or more set screws138through the top face or the bottom face130that forces the insulated wire12against the groove134. Additionally, or in the alternative, one or more rollers140may engage the insulated wire12within the wire slot96along the Z-axis and/or the Y-axis. The one or more rollers140may be biased to exert a force against the insulated wire12, such as via one or more springs142. In some embodiments, the wire retention system136may be engaged by an operator via a lever similar to the cutting lever120shown inFIG. 2or by movement of the second arm84from the first position108to the second position110.

The stripping portion92may have a stop144that interfaces with the end portion22of the insulated wire12and positions the one or more cutting blades132to cut the section20of insulation18at a desired length. In some embodiments, the stop144is adjustable along the X-axis to accommodate terminal lugs24of various sizes. The one or more cutting blades132may actuate along an axis substantially perpendicular (e.g., radial) to the insulated wire12, thereby cutting the section20of insulation18to a cut depth. One cutting blade132may move along the Z-axis to cut the section20of insulation18from the insulated wire12. In some embodiments, two or more cutting blades132may converge on the insulated wire12. Converging cutting blades132may enable the section20of insulation18to be cut without bending the insulated wire12. Multiple cutting blades132may be used to cut around substantially the entire circumference of the section20of insulation18. In some embodiments, the one or more cutting blades132are biased with one or more springs142to a default open position. For example, actuating the cutting lever120may pull the cable122along the X-axis as shown by arrow146, thereby actuating the one or more cutting blades132by the blade cables148.

In some embodiments, the one or more cutting blades132are coupled to the wire retention system136, such that the cutting depth is based at least in part on the wire size determined by the wire retention system136. Blade stops150coupled to the one or more cutting blades132may be adjusted based at least in part on a position of the set screw138, the roller140, the spring142, or other component of the wire retention system136. As may be appreciated, the cutting depth may be otherwise adjusted by controlling the travel of the cable122and/or blade cable148based on a position of a component of the wire retention system136. By setting the cut depth based at least in part on the wire size, the one or more cutting blades132may cut through substantially the entire section20of insulation about the conductor16without cutting or abrading the surface of the conductor16.

FIG. 4illustrates a front view of the strip/crimp hand-tool80in an intermediate position160in which the section20of insulation18has been cut and removed from the insulated wire12, and the terminal lug has not yet been positioned and crimped onto the exposed end portion22of the conductor16. As the second arm84moves towards first arm82as shown by arrow112, the stripping portion92moves in the first direction104in the first channel98, removing the cut section20of insulation18from the insulated wire12. As discussed above, the wire retention system136retains the insulated wire12so that the stripping portion92removes only the cut section20of the insulation while the end portion22remains within the process area102. After the stripping portion92removes the section20of insulation18, the terminal lug24may be positioned about the exposed end portion22of the conductor16. The operator may manually place the terminal lug24about the end portion22prior to moving the crimping portion94in the second direction106(e.g., via moving the second arm84in direction112) to crimp the terminal lug24. In some embodiments, a lug loading system162positions the terminal lug24about the end portion22.

The lug loading system162may be manually actuated by the operator, or actuated automatically while the operator moves the stripping portion92and the crimping portion94. In some embodiments, a loading arm164with a terminal lug24moves in direction166along the X-axis up to or past the end portion22of the conductor16. A loading slot168facilitates rotation of the loading arm164and terminal lug24to align the terminal lug24with the end portion22of the conductor16. Once aligned with the end portion22, the loading arm164may be moved in direction170(e.g., axial direction relative to the insulated wire12) along the X-axis, thereby positioning the terminal lug24about the end portion22. In some embodiments, the lug loading system162may position the terminal lug about the end portion from a radial direction (e.g., along the Z-axis) relative to the insulated wire12.

In some embodiments, the lug loading system162receives a lug magazine163with multiple terminal lugs24, thereby enabling the strip/crimp hand-tool80to crimp multiple terminal lugs24on multiple respective conductors16before reloading the lug loading system162with additional terminal lugs24(e.g., via replacement of the lug magazine). A lug magazine163may include multiple terminal lugs24coupled together via respective terminal caps26and/or respective connection ends28. The lug loading system162may separate a terminal lug24of the lug magazine163from other terminal lugs24to arrange the terminal lug24about the end portion22.

FIG. 5illustrates a perspective view of an embodiment of the strip/crimp tool80in an intermediate position180in which the terminal lug24is about the end portion22of the conductor16, and the operator may operate the strip/crimp tool80to crimp the terminal lug24on the insulated wire12. Actuating the second arm84moves the crimping portion92, as shown by arrow182, within the second channel100towards the end portion22and the terminal lug24in the process area102. A crimping face184of the crimping portion94is configured to interface with the cap portion26of the terminal lug24. The crimping portion94converts operator force on the second arm84to a force from the crimping face184on the cap portion26, mechanically coupling the cap portion26to the end portion22. As may be appreciated, the force on the cap portion26from the crimping face184causes the cap portion26to yield and collapse (e.g., crimp) about the end portion22.

FIG. 6illustrates a perspective view of the crimping portion94and the terminal lug24about the end portion22. In some embodiments, movement of the second arm84may reciprocate the crimping portion94within the second channel100along a crimping guide186(e.g., axial rail). The crimping portion94moves in direction182to crimp the terminal cap26of the terminal lug24about the end portion22, and the crimping portion94moves in direction188to facilitate removal of the crimped terminal lug24and insulated wire12, and insertion of another insulated wire12. The crimping face184may be complementary to the loading arm164, thereby enabling the crimping portion94to crimp the terminal cap24substantially about the circumference of the end portion22.

Returning toFIG. 5, the insulated wire12with the crimped terminal lug24may be removed through the wire slot96after the crimping face184interfaces (e.g., crimps) with the terminal lug24. Upon removal of the insulated wire12, the strip/crimp hand-tool80may be reset to enable cutting, stripping, and crimping of another insulated wire12. To reset the strip/crimp hand-tool80, the second arm84moves to the first position108, thereby moving the crimping portion94in direction188from the process area102in the second channel100and moving the stripping portion92in direction118to the process area102in the first channel98. In some embodiments, the stripping portion92moving in direction118ejects the insulated wire12and crimped terminal lug24through the wire slot96. In some embodiments, the operator manually resets the lug loading system162separately from moving the second arm84.

In some embodiments, the lug loading system162and/or the one or more cutting blades132are coupled to the second arm84and actuated by movement of the second arm84. For example, the lug loading system162may be coupled to the second arm84such that resetting the second arm84to the first position108automatically removes the loading arm164or other lug loading system162component from the process area102. In some embodiments, springs142coupled to the one or more cutting blades132are biased (e.g., loaded) by resetting the strip/crimp hand tool80to the first position108, enabling the one or more cutting blades132to automatically cut the section20of insulation18of another insulated wire12as the second arm84moves to the second position110. As may be appreciated, components coupling the lug loading system162and/or the one or more cutting blades132to the second arm84may include, but are not limited to, springs142, pulleys, cams, geared linkages, or any combination thereof.

FIG. 7illustrates an embodiment of a method200for utilizing the strip/crimp hand-tool80to strip an end portion22of an insulated wire12and crimp a terminal lug24about the end portion22. An operator configures (block202) the strip/crimp hand-tool in a starting position (e.g., first position108). The orientation of the first and second arms82,84may be based at least in part on the orientation of the stripping portion92and the crimping portion94within the respective first and second channels98,100. For example, as shown inFIG. 2, the second arm82may be opened to the first position108, thereby positioning the stripping portion92in the process area102and moving the crimping portion94from the process area102. The operator inserts (block204) an insulated wire12through the wire slot such that the end portion22of the insulated wire12extends into the process area102of the strip/crimp hand-tool80.

The insulated wire12may be secured (block206) to the strip/crimp hand-tool80by a wire retention system136. As may be appreciated, securing the insulated wire12may aid removal of the section20of insulation18from the insulated wire12. One or more cutting blades132cut (block208) a section20of insulation18around the end portion22of the conductor16. As described above, the one or more cutting blades132are coupled to the stripping portion94. The one or more cutting blades132may be actuated by movement of the second arm84and/or a cutting lever120. In some embodiments, the cut depth132of the one or more cutting blades132is based at least in part on a size or gauge of the insulated wire12as determined by the wire retention system136. Upon cutting the section20of insulation18with the one or more cutting blades132, movement of the second arm84towards the ending position (e.g., second position110) reciprocates the coupled stripping portion94within the first channel98to remove (block210) the section20of insulation18from the end portion22of the insulated wire12.

In some embodiments, the operator loads (block214) each terminal lug24in the lug loading system162prior to positioning (block212) the terminal lug24about the end portion22. Upon removal (e.g., stripping) of the section20of insulation18, the operator positions (block212) a terminal lug24about the exposed end portion22of the conductor16. The terminal lug24may be positioned manually or automatically via a lug loading system162. The terminal lug24may be loaded (block214) into the lug loading system162at different times, including but not limited to after a previous terminal lug24is crimped onto the end portion22via an automatic lug loading system162or during any of the actions of blocks202-210. The lug loading system162may be coupled to the second arm84and actuated to position (block212) the terminal lug24via movement of the second arm84to the ending position110. After the terminal lug24is positioned about the end portion22, the crimping portion94of the strip/crimp hand-tool80reciprocates within the second channel100toward the process area102to crimp (block216) the terminal lug24about the end portion22. In some embodiments, each terminal lug24in the lug loading system162is loaded prior to one of the blocks202-210. For example, a subsequent terminal lug from a lug magazine may be loaded into the lug loading system immediately after a prior terminal lug is positioned (block212) or crimped (block216) about the end portion of an insulated wire. As may be appreciated in view of the above description andFIGS. 2-6, the actions of blocks206-216may be initiated by actuating the second arm84to the end position110from the starting position108. Additionally, or in the alternative, the stripping portion92and the crimping portion94may be actuated by a knob or other member. After the terminal lug24is crimped, the operator may remove (block218) the crimped wire from the strip/crimp hand-tool80. In some embodiments, the strip/crimp hand-tool80may eject the insulated wire12and crimped terminal lug24when the method200restarts by configuring (block202) the strip/crimp hand-tool80in the start position108. The strip/crimp hand-tool80may eject the crimped wire after the crimping portion94crimps (block216) the terminal lug24.

A lug magazine163and an automated lug loading system162may increase the speed at which the operator may crimp terminal lugs24about multiple insulated wires12. The strip/crimp hand-tool80may enable an operator to strip an insulated wire12and to crimp a terminal lug24about the end portion22in less than approximately 30, 15, 10, or 5 seconds. The lug magazine163and lug loading system162may enable the operator to strip multiple (e.g., 2, 3, 4, 5, 6, 7, 8, 9, 10 or more) insulated wires12and to crimp multiple respective terminal lugs24about the corresponding end portions22without stopping to reload the terminal lugs24. For example, the strip/crimp hand-tool80may enable an operator to strip an insulated wire12and to crimp a respective terminal lug24about the end portion22in approximately 10 seconds, and the lug magazine163may enable the operator to strip approximately 4 to 6 insulated wires12and to crimp respective terminal lugs24about the corresponding end portions22of the 4 to 6 insulated wires12within approximately 1 minute without manually reloading additional terminal lugs24.

As described above, the strip/crimp hand-tool enables an operator to strip an end portion of an insulated wire and to crimp a terminal lug about the end portion in substantially one motion along a motion plane. The strip/crimp hand-tool enables the operator to strip and crimp an insulated wire without utilizing multiple separate tools (e.g., stripping tool, crimping tool) and/or without manual repositioning of the wire relative to the hand-tool, such as to reposition the wire after removal of the insulation and prior to crimping the terminal lug. Accordingly, the strip/crimp hand-tool may increase the speed at which an operator may process (e.g., strip and crimp) multiple insulated wires. For example, the strip/crimp hand-tool may enable the operator to process an insulated wire in less than approximately 15 seconds. Reducing the time to process an insulated wire for connection to a terminal may substantially reduce labor costs for projects involving hundreds or thousands of terminals for connecting with crimped terminal lugs on insulated wires. The strip/crimp hand-tool may also reduce the quantity of operator actions on the hand-tool to process the insulated wire. In some embodiments, one or more processes (e.g., actuating the one or more cutting blades, loading subsequent terminal lugs within the lug loading system) may be at least partially automated to be performed as the operator actuates the stripping portion and the crimping portion within the motion plane.