Patent Publication Number: US-2021178533-A1

Title: Mechanical variable gap crimp tool

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Application No. 62/765,049 filed Aug. 17, 2018. The disclosures of the above application are incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to mechanical variable gap crimp on flange tool. 
     BACKGROUND OF THE INVENTION 
     Crimp tools are known in automotive and used to put a seal or weatherstripping on a structure such as flanges of liftgates, trunks and doors. An operator orients the tool against the seal in position relative to the flange. The tool is activated and the operator manually moves the tool to follow the path of the flange to mount the seal to the flange. Current tooling requires the rollers of the crimp tool to move or start in an open gap position. Once activated the rollers are required to close to a set gap to crimp/squeeze the seal onto a vehicle flange. This is done by means of a pneumatic system utilizing a pneumatic cylinder. A pneumatic system cannot reliably give feedback to verify the tool has been used for the correct amount of time. Current DC or battery tools have this capability and are used in plants currently. To use this drive, however, eliminates the ability to open and close the rollers as there is no longer a pneumatic power source to do this. To not open the rollers causes damage to the seal during the crimp process. While crimping tools have used commercially available battery drives, they have not had the ability to open and close the roller gap. These tools rely on a set gap size and the tool is rolled onto a seal under power causing damage to the seal in that area. Further, a spring loaded head mounted on a drive would need the ability to open/close for proper processing without damage, however, until the present invention, such parameters could not be met because it was not strong enough to do with electric (e.g., not powerful enough servos to open/close). 
     Accordingly, there exists a need for an electric drive tool that retained the functionality of a pneumatic tool while adding no size or weight to the head. Furthermore, for cabatability with current functions that provide a feed back showing the tool has been used and for the correct amount of time and any other predetermined process/operator parameters. 
     SUMMARY OF THE INVENTION 
     There is provided a tool head assembly to crimp a seal or weatherstrip, in particular, to crimp to a flange in any automotive application (e.g., lift gate, side doors, trunk, etc) or any other application requiring crimping. The tool head assembly is operably mountable on any tooling drive mechanism/system under any source of power (e.g., servo on robotic arm, DC drive, programmable DC drive, battery cordless drive, programmable battery cordless drive, etc). Thus, the source of power is interchangeable without departure from the scope of the present invention. The present invention generally incorporates a mechanical cam in the tool head. The tool head is utilyzed to put a seal, weatherstripping or any other part on on a structure such as flanges of liftgates, trunks, doors and any other vehicle structure. 
     The tool head includes at least one of each of the following: drive shaft, cam, oneway locking bearing, and a movable slide. The developed head utilized the ability to program the drive to a specific process. The head was designed to have an internal cam that would spin freely on the drive shaft in one direction and lock onto the shaft in the other direction. That cam would rotate against the moving slide forcing it to move away from the drive shaft opening the gap between rollers. A controller is programmed to have the drive rotate in one direction for a set time period when the trigger was pulled then reverse the rotation to begin the crimp process. The start rotation of the drive rotated the cam and opens the roller gap. The forward rotation would allow the cam to swing, closing the gap and rotating the rollers around the seal. This design now allows the tool to function the same as the pneumatic style tool, eliminates the air cylinder and related pneumatic hoses and valve making the head smaller and allows a controller to communicate with any OEM production system to verify the tool has been used and was used for the correct amount of time. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein: 
         FIG. 1 , is an exploded perspective view of the tool head assembly, in accordance with the present invention; 
         FIG. 2 a    is a top plan sectional view of the tool head assembly depicting a gap change closed/gap change opened, in accordance with the present invention; 
         FIG. 2 b    is a top plan view of a movable slide and a cam of the tool head assembly, in accordance with the present invention; 
         FIG. 3  is a top plan sectional view of the cam biased to a closed position; in accordance with the present invention; 
         FIG. 4  is a top perspective view of the cam rotating in a first direction pushing the movable slide longitudinally in an opening direction; in accordance with the present invention; 
         FIG. 5  is a top plan view of the cam rotated further in the first direction and the movable slide in an exemplary open position; in accordance with the present invention; 
         FIG. 6  is a perspective view of an exemplary lockable bearing; in accordance with the present invention; 
         FIG. 7  is a perspective view of the tool head assembly with rollers in a gap closed position, in accordance with the present invention; 
         FIG. 8  is a perspective view of the tool head assembly with rollers in a gap opened position; in accordance with the present invention; 
         FIG. 9  is a perspective view of the tool head assembly operably mounted to an illustrative drive/power source as an example of an environment use, in accordance with the present invention; and, 
         FIG. 10  is a perspective view of the tool head assembly depicting a crimping head putting an exemplary seal onto a vehicle flange. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. 
     Referring to  FIGS. 1-10  generally, there is provided a tool head assembly, shown generally at  10 , in accordance with the present invention. The tool head assembly  10  includes at least one cam  12 , drive shaft  14  or “stationary shaft”, movable slide  16 , and a oneway locking bearing. The head assembly  10  has the internal cam  12 , which spins freely on the drive shaft  14  in one direction and locks onto the shaft  14  in the other direction. That cam  12  rotates against the movable slide  16  forcing it to move away from the drive shaft  14  opening a gap, shown generally at  18 , between rollers, e.g., a first and second roller  20 , 22  or “post”. 
     It is understood that the drive shaft  14  is preferably a rotating shaft, however, the shaft  14  is stationary in that the shaft  14  does not move in a lateral direction. The drive shaft  14  keeps the position of the first roller  20 , including, as the second roller  22  selectively translates away from or toward the first roller  20  to change the gap  18 . As the second roller  22  moves toward and away from the first roller  20 , which is stationary, the gap  18  between the rollers  20 , 22  decreases and increases (closes/opens), respectively.  FIGS. 7 and 9  generally depict an expemplary narrowed gap  18  compared to the more open position of exemplary  FIG. 8 . 
     Preferably, the developed tool head assembly  10  utilizes the ability to program a predetermined drive to a specific process depending on the application. 
     A controller  24  (see  FIG. 9 ) is programmable to have the drive rotate in one direction for a predetermined set time period (e.g., generally about 5-60 seconds, typically 5-30 seconds, preferably 2-20 seconds, most preferably 2-10 seconds) when a trigger  26  or “button” is actuated (e.g., pulled, compressed, pushed, slid, rotated, etc) then reverse the rotation to begin the crimp process. The controller  24  utilizes wireless or hardwired protocols, preferably, wireless. Preferably, the controller  24  operably incorporates with at least one sensor, electric sensor, gyroscope, acceleramator, and/or camera, etc. 
     The start rotation of the drive rotates the cam  12  and opens the roller gap  18 . The forward rotation then allows the cam  12  to swing, closing the gap  18  and allowing translating the rollers  20 , 22  around the seal (e.g., seal or weatherstrip of a lift gate, car trunk, front side doors, rear side doors, windshield, flange or any other predetermined part, any predetermined cover part to secure the cover part to any predetermined structural member). This design allows the head tool assembly  10  to function similarly as a pneumatic style tool, but eliminates the air cylinder and related pneumatic hoses and valve making the tool head assembly  10  smaller. Preferably, at least the second roller  22  spins while applying the seal, as indicated in  FIG. 9 . Most preferably, the second roller  22  spins and the first roller  20  does not spin while applying the seal. 
     Preferably, the system allows the controller  24  to communicate with any production feedback device  66  or system  66  (e.g., any OEM production system) to verify and operably communicate feedback to a database, any other predetermined operable data compiler, and/or tool operator in real time that the tool is/has been used and is/has been used properly according to predetermined perameters, e.g., used in the correct predetermined orientation(s), angle(s) and/or position feedback, used for the correct predetermined amount of time, used at correct predetermined speed, used at correct predetermined pressure or force, etc. 
     At least one biasing member  28 , preferably two biasing members  28 , 30  (most preferably, spring(s)), biases the movable slide  16  against the cam  12  in the closed direction to urge the first and second rollers  20 , 22  together. Most preferably, to urge the second roller  22  toward the first roller  20  and the first roller  20  is laterally stationary. The drive shaft  14  preferably extends through an aperture formed in a block  32  and is operably coupled to the first post  20 . The block  32  is operably coupled to a housing shown generally at  34 . Preferably, a plurality of fasteners connect the block  32  to the housing  34  via a plurality of apertures  36 , 38 . 
     The second post  22  is operably coupled to the movable slide  16  to move in the direction of the moveable slide  16  (in a closed direction or biased direction toward the drive shaft  14  and in an open direction away from the drive shaft  14 ). Preferably, the second post  22  is operably connected to a second shaft  40  extending through an aperture  42  (e.g., elongated aperture) formed in the block  32 . The second shaft  40  or “slide shaft” or “moveable shaft” is operably connected to the moveable slide  16 . 
     The drive shaft  14  preferably extends through a locking bearing  44  or “cam bearing”. The locking bearing  44  is a one way locking bearing that spins free in one direction, and locks on drive shaft  14  in the other direction. 
     The tool head assembly  10  is operably arranged to allow movement of the second shaft  40  towards/away from the drive shaft  14  during operation of the tool head assembly  10  to accommodate variations in structural member/flange thicknesses. 
     The drive shaft  14  is rotatable about a first axis of rotation. Preferably, a predetermined tooling drive mechanism is operably coupled to the drive shaft  14 , and the first roller  20  is operably fixadly connected to the drive shaft  14  toward an end of the shaft outside the housing  34 , such that the drive shaft  14  and first roller  20  rotate together, or operably coupled to the second roller  22  and shaft such that the shaft and second roller  22  rotate together. A first gear  50  or “drive gear” is operably mounted on the drive shaft  14 . The cam  12 , first gear  50  and first roller  20  rotate with the drive shaft  14 . The drive shaft  14  is stationary in that the shaft  14  does not slide in the block  32 . Preferably, at least one support bearing  52  including bearing surfaces  53  is operably mounted along the drive shaft  14  at a predetermined location. Alternatively, the first roller  20  does not rotate. 
     The second roller  22  is operably connected to the slideable shaft  40  toward an end of the shaft outside the housing  34 , such that the slideable shaft  40  and second roller  22  rotate together. A second gear  54 , e.g., driven gear, is operably mounted on the slideable shaft  40  and in meshing engagement with the first gear  50 . Rotation of the first gear  50  in one direction rotates the second gear  54  in an opposite direction. The slideable shaft  40  rotates about a second axis of rotation and is also slideable along the aperture  42  as indicated by arrow “ 5 ”. Preferably, at least one support bearing  56  is operably mounted along the shaft  40 . 
     An intermediate rotary member  58  is operably coupled, e.g., rotatably coupled, to the second gear  54  by at least one member  60  to allow the intermediate rotary member  58  to rotate about an axis, preferably, about an axis that is offset from the first and second axes of rotation of the shafts  14 , 40 . An output rotary member  62  is operably coupled, e.g., rotatably coupled, to the intermediate rotary member  58  by at least one second member  64  to allow the output rotary member  62  to rotate about one of the axes of rotation. The arrangement provides for torque transfer from the drive shaft  14  to the slidable shaft  40 , and thereby from the cam  12  to the moveable slide  16 . 
     The tool head assembly  10  is operably connected to a handle shown generally at  46  of a crimping assembly or any other predetermined assembly. Preferably, at least one guiding member  48  is provided to assist the operator in moving the assembly  10  along the desired path during crimp processing. The tool head assembly  10  applies a force against the part (e.g., seal strip) to position the part relative to the the strucutral member (e.g., part over the flange). The partially closed gap rollers (e.g., exemplarily depicted in  FIGS. 9-10 ) apply a generally inward force to crimp the part against the side(s) of the structural member. 
     The tool head assembly  10  is arranged with the rollers  20 , 22  axis of rotations generally parallel with the longitudinal axis of the handle  46 . Alternatively, tool head assembly  10  is arranged with the rollers  20 , 22  axis of rotations generally about 90 degrees with respect to the longitudinal axis of the handle  46 . Alternatively, the tool head assembly  10  is any predetermined angle with respect to the handle  46 , generally about 0-180 degrees, typically about 0 to 125 degrees, preferably about 0 to 45 degrees, most preferably about 0 to 90 degrees. It is understood that the tool head assembly  10  rollers  20 , 22  are positioned with respect to the handle  46  in any predetermined orientation or angle depending on the application without departure from the scope of the present invention. 
     The rollers  20 , 22  can be metal or any predetermined durable material suitable to prevent damage to the part and provide crimping. 
     According to an aspect of the present invention, an operator engages a trigger  26  to open/widen the gap. The cam rotates in a first direction to push the block and open the gap, then when the tool is in place to the molding/flange, releases the trigger narrowing the gap and moving the assembly  10  along the predetermined path during crimp processing. 
     According to an aspect of the present invention, there is provided a method for mechanical variable gap crimping including providing the tool head assembly  10  described previously. Determining predetermined parameters, e.g., orientation(s), angle(s) and/or position feedback, crimping time, total crimping time, crimping time by predetermined area(s)/portion(s) being applied to the vehicle (e.g., curved regions, corners, generally straight paths, etc), correct speed, variable speeds, speeds based on location, pressure or force, etc. Optionally, programing predetermined parameters into a controller  24 . Setting/inputting predetermined parameters into a controller  24  (e.g., to have the drive rotate in one direction for a predetermined set time period, such as, generally about 5-60 seconds, typically 5-30 seconds, preferably 2-20 seconds, most preferably 2-10 seconds). Providing a feedback device  66 . Applying the predetermined part (e.g., weather strip) to the vehicle using the assembly  10  (e.g., vehicle flange). Compiling data that the assembly  10  is being and/or was used and used properly (e.g., according to the predetermined parameters). Communicating that the assembly  10  is being and/or was used and used properly (e.g., according to the predetermined parameters). Storing said data. Preferably, the method includes a processing capability to run reports, etc for manufactuers (OEM, weatherstrip manufactuerer) for quality assurance, recall purposes, etc. 
     Conventional liftgate decklid tools crimp a liftgate decklid strip to a flange using crimping posts. Current tooling requires the rollers of the crimp tool to move or start in an open gap position. Once activated the rollers are required to close to a set gap to crimp/squeeze the seal onto a vehicle flange. This is done by means of a pneumatic system utilizing a pneumatic cylinder. A pneumatic system cannot reliably give feedback to verify the tool has been used for the correct amount of time. Current DC or battery tools have this capability and are used in plants currently. To use this drive, however, eliminates the ability to open and close the rollers as there is no longer a pneumatic power source to do this. To not open the rollers causes damage to the seal during the crimp process. While crimping tools have used commercially available battery drives, they have not had the ability to open and close the roller gap. These tools rely on a set gap size and the tool is rolled onto a seal under power causing damage to the seal in that area. Further, a spring loaded head mounted on a drive would need the ability to open/close for proper processing without damage, however, until the present invention, such parameters could not be met because it was not strong enough to do with electric (e.g., not powerful enough servos to open/close). 
     The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.