Patent Description:
The present disclosure relates to power crimping tools and, more particularly, to dieless, portable, hand-held power crimping tools with a partially open head for easy access to a working area of the head.

Many portable power tools are hand held tools that have electric motors to drive a working head used to perform various tasks, such as crimping, drilling, shaping, fastening, grinding, polishing, heating, etc. There is a segment of the portable tool market that incorporates a hydraulic pump to enable the working head to apply a relatively large amount of force or pressure for a particular task. Such tools may operate with a hydraulic pump actuated by a battery powered electric motor. Battery powered hydraulic power tools are employed in numerous applications to provide an operator with a desired flexibility and mechanical advantage. For example, operators of crimping tools used for making crimping connections, such as crimping large power connectors onto large conductors, may need added force to crimp such large conductors, e.g., #<NUM> conductors and larger, to suitable connectors. Such battery powered hydraulic power tools can come with dies to perform the crimping operation, and other battery powered hydraulic power tools have a dieless crimping operation. With a dieless crimping operation, an indentor is used to impact a wire lug resting within a nest within a working area of the tool head. An example of a dieless crimping tool is known from <CIT>. In such portable dieless power tools, the nest structure is locked to the main body or frame of the tool head to withstand the crimping forces exerted by the tool. Such locking nest structures are not suitable in certain environments, for example, when making connections to or on splices of overhead high tension power lines.

The invention relates to a dieless crimping tool according to claim <NUM>. The present disclosure provides exemplary embodiments of dieless crimping tools. In one embodiment, the dieless crimping tool includes a working head having a head frame, a movable indentor, and an indentor guide assembly. The head frame has open access to a working area of the working head, and a nest within the working area for receiving a crimping member, such as crimps, wire lugs, connectors and couplers. The dieless crimping tool also includes a tool frame having a piston coupled to the indentor that moves the indentor along the indentor guide assembly between a home position adjacent the tool frame and an impacting position adjacent the nest.

In another embodiment, the dieless crimping tool includes a working head and a tool frame. The working head includes an indentor, a head frame and an indentor guide assembly. The head frame has an I-beam structure comprising an upper flange, a lower flange and a web between the upper flange and the lower flange. An open access to a working area of the working head is provided in the I-beam structure. A nest is positioned within the working area for receiving a crimping member. The nest is adjacent at least a portion of the upper flange. The indentor guide assembly is positioned within the working area of the working head adjacent at least a portion of the upper flange. The tool frame has a piston coupled to the indentor that moves the indentor along the indentor guide assembly within the working area of the working head between a home position adjacent the tool frame and an impacting position adjacent the nest.

A dieless crimping tool includes a working head and a tool frame. The working head has a head frame, an indentor and a nest. The head frame has open access to a working area of the working head and the nest is positioned within the working area for receiving a crimping member. The tool frame has a piston coupled to the nest that moves the nest within the working area between a home position adjacent the tool frame and an impacting position adjacent the indentor.

A more complete appreciation of the present disclosure and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:.

Illustrative embodiments of the present disclosure may be provided as improvements to portable, hand held, battery operated, dieless, hydraulic crimping tools. For example, a portable, hand held, battery operated, dieless, hydraulic crimping tool may be provided with a working head having a head frame with an open access path to a working area of the working head. An example of such a working head is a C-shaped working head. For ease of description, the portable, battery operated, dieless, hydraulic crimping tools according to the present disclosure may also be referred to as the "crimping tools" in the plural, and the "crimping tool" in the singular. The features of the crimping tool of the present disclosure could also be used in other types of dieless power tools. In addition, any suitable size, shape or type of elements or materials can be used to form the shape of the tool frame of the crimping tool. The crimping tool is configured to crimp a crimping member. Examples of crimping members include crimps, connectors, wire lugs, couplers and pulling lugs. For ease of description, the crimping members may also be referred to herein as a "wire lug" in the singular and "wire lugs" in the plural.

Referring to <FIG>, an exemplary embodiment of a crimping tool according to the present disclosure is shown. The crimping tool <NUM> includes a tool frame <NUM>, a working head <NUM>, a pump <NUM>, a motor <NUM>, a battery <NUM>, a fluid reservoir <NUM>, a controller <NUM> and a hydraulic drive conduit system <NUM>. The tool frame <NUM> includes a main body <NUM> and a handle <NUM> that form a pistol-like shape. However, the tool frame <NUM> could be in any suitable type of shape, such as, for example, an in-line shape, seen in <FIG>, or a suitcase shape, seen in <FIG>, and described herein below.

The pump <NUM>, motor <NUM>, fluid reservoir <NUM>, controller <NUM>, and hydraulic drive conduit system <NUM> are located within the main body <NUM> of the tool frame <NUM>. The crimping tool <NUM> may also include a camera <NUM>, seen in block form in <FIG>, mounted to the tool frame <NUM> and oriented to provide a video of a working area <NUM> of the working head <NUM>. The crimping tool <NUM> may also include a tool tracking system <NUM>, seen in block form in <FIG>, for tracking the location of the tool. In an exemplary embodiment, the tool tracking system <NUM> may include known GPS tracking components that receive GPS satellite signals and transmits the location of the tool to a remote station allowing a user to track the position of the tool. Such transmissions to remote stations may be achieved using known communication systems, such as for example, cellphone networks.

The battery <NUM> is removably connected to the bottom of the handle <NUM>. In another embodiment, the battery <NUM> could be removably mounted or connected to any suitable position on the tool frame <NUM>. In another embodiment, the battery <NUM> may be affixed to the crimping tool <NUM> so that it is not removable. The battery <NUM> is preferably a rechargeable battery, such as a lithium ion battery, that can output a voltage of at least <NUM> VDC, and preferably in the range of between about <NUM> VDC and about <NUM> VDC. In the exemplary embodiment shown in <FIG>, the battery <NUM> can output a voltage of about <NUM> VDC.

Referring to <FIG> and <FIG>, the motor <NUM> is coupled to the battery <NUM> and the controller <NUM>, and its operation is controlled by the controller <NUM>. Generally, the motor <NUM> is adapted to operate at a nominal voltage corresponding to the voltage of the battery <NUM>, e.g., between about <NUM> VDC and about <NUM> VDC. For example, if the battery <NUM> is adapted to output a voltage of about <NUM> VDC, then the motor <NUM> would be adapted to operate at a voltage of about <NUM> VDC. Under a no-load condition, such a motor <NUM> can operate at about <NUM>,<NUM> rpm with a current of about <NUM> amps. At maximum efficiency, the motor <NUM> can operate at about <NUM>,<NUM> rpm with a current of about <NUM> amps, a torque of about <NUM> mN-m (<NUM>-cm), and an output of about <NUM> W. An example of such an <NUM> VDC motor <NUM> is the RS-775WC-<NUM> motor, manufactured by Mabuchi Motor Co. of Chiba-ken, Japan. However, as noted above, any suitable type of motor adapted to operate above a <NUM> VDC nominal voltage could be used. For example, the motor may be a RS-775VC-<NUM> motor, also manufactured by Mabuchi Motor Co. , which has a nominal operating voltage of about <NUM> VDC. As another example, the motor may be a motor adapted to operate at a <NUM> VDC nominal voltage. The output shaft of the motor <NUM> is connected to the pump <NUM> by a gear reduction assembly or gearbox <NUM>, shown in block form in <FIG>. Any suitable type of gear reduction assembly <NUM> could be used.

The handle <NUM> includes one or more operator controls, such as trigger switches <NUM> and <NUM>, which can be manually activated by an operator. The handle <NUM> of the tool frame <NUM> may include a hand guard <NUM> to protect an operators hand while operating the crimping tool <NUM> and to prevent unintended operation of trigger switches <NUM> and <NUM>. According to an embodiment of the present disclosure, one of the trigger switches (e.g., trigger switch <NUM>) may be used to activate the piston <NUM> to move the indentor <NUM> towards the impacting position. The other trigger switch (e.g., trigger switch <NUM>) may be used to retract the piston <NUM> to the home position, shown in <FIG>. The operator controls, e.g., trigger switches <NUM> and <NUM>, are operably coupled to the controller <NUM>.

The crimping tool <NUM> may include a poppet valve <NUM>, seen in block form in <FIG>, connected to the hydraulic drive conduit system <NUM>. The poppet valve <NUM> is adapted to open when the conduit system <NUM> reaches a predetermined hydraulic pressure threshold, such as between about <NUM>,<NUM> psi and about <NUM>,<NUM> psi. When the poppet valve opens, hydraulic fluid being pumped by the pump <NUM> can exit the conduit system <NUM> and return to the fluid reservoir <NUM>. The poppet valve <NUM> can be adapted to generate an audible sound when it opens. This audible sound can signal to the operator that the crimping tool <NUM> has reached its maximum predetermined hydraulic pressure and, thus, the action of the working head <NUM>, e.g., crimping action, is completed.

In the exemplary embodiment shown in <FIG>, the controller <NUM> is adapted to sense a current drop of electricity to the motor <NUM>. When the poppet valve <NUM> opens, resistance to rotation of the motor <NUM> is reduced such that the motor draws less current. The controller <NUM> senses this current drop via a current sensor (not shown), and automatically deactivates the motor <NUM> for a predetermined period of time. In one embodiment, the predetermined period of time is between about <NUM> seconds and about <NUM> seconds. However, any suitable predetermined period of time could be set. In another embodiment, the controller <NUM> could be adapted to deactivate the motor <NUM> until a reset button or reset like procedure is performed by the operator. With this type of system, an operator can sense via tactile feedback that the motor <NUM> and pump <NUM> have stopped and would not need to rely on an audible signal being heard or a visual signal from an LED positioned on the crimping tool <NUM>.

As shown in <FIG>, the working head <NUM> includes a head frame <NUM> and an indentor <NUM>, which will be described in more detail below. The head frame <NUM> may be connected to the front end of the tool frame <NUM> and fixed or locked in position. In another embodiment, the head frame <NUM> may be rotatably connected to the tool frame <NUM>.

Referring to <FIG> and <FIG>, the head frame <NUM> of the working head <NUM> includes a nest <NUM> that is configured to receive a wire lug <NUM> for subsequent crimping by the indentor <NUM>. The nest <NUM> can come in any number of embodiments. For example, in the exemplary embodiment shown the nest <NUM> is a V-nest. The shape of the nest is preferably matched to the shape of the indentor <NUM> so that the indentor is not generally prohibited from impacting a wire lug <NUM> resting within the nest <NUM>. Typically, this is not an issue with larger wire lugs that occupy a larger area within the nest <NUM> such that the indentor may not contact the nest <NUM>. However, there may be instances where the wire lug is sufficiently small so that a front face <NUM> of the indentor <NUM> contacts one or more walls of the nest <NUM>. In such instances it may be desirable to have the front face <NUM> of the indentor <NUM> contact one or more walls of the nest <NUM> as a way to minimize the force applied to the crimping of small wire lugs. In such cases, the walls of the nest <NUM> would absorb a portion of the force exerted by the indentor <NUM>, and the remaining force would be used by an impacting surface <NUM> of the indentor to crimp a wire into the wire lug. In addition, as shown in <FIG>, a piston <NUM> may include a stop <NUM> that contacts the head frame <NUM> to further limit the force applied by the indentor <NUM> when in the impacting position.

The indentor <NUM> is movably connected to the head frame <NUM> using a guide track assembly <NUM>. In such embodiments, the indentor <NUM> is releasably coupled to a piston <NUM>, seen in <FIG>, which is part of the hydraulic drive conduit system <NUM>. The piston, when activated, moves the indentor <NUM> between an impacting position where the indentor impacts a wire lug, as seen in <FIG>, and a home position (or at rest position) where the piston is retracted towards the tool frame <NUM>, as seen in <FIG>. In the exemplary embodiment shown in <FIG>, the distal end 60a of the piston <NUM> includes a slot <NUM> on each side of the piston <NUM>. The slots <NUM> are used to engage pins passed through the indentor <NUM> to releasably secure the indentor to the piston <NUM>. In another exemplary embodiment shown in <FIG>, the distal end 60a of the piston <NUM> includes a radial channel <NUM> used to engage pins passed through the indentor <NUM> to releasably secure the indentor to the piston <NUM>, and to permit the piston to rotate independent of the indentor <NUM> so that rotation of the piston is not translated to rotation of the indentor.

The indentor <NUM> is adapted to move between the home position and the impacting position in conjunction with an indentor guide assembly <NUM>, as indicated by arrow <NUM> in <FIG>. The hydraulic drive conduit system <NUM>, including the piston <NUM>, is connected between the pump <NUM> and the body of the indentor <NUM>. Hydraulic fluid pumped by the pump <NUM> through the hydraulic drive conduit system <NUM> and against a proximal end of the piston <NUM>, which is releasably couple to the indentor <NUM>, causes the indentor to move toward a distal end of the working head <NUM>, i.e., toward the impacting position. As shown in <FIG>, the tool frame <NUM> of the crimping tool <NUM> preferably includes a spring <NUM> which is adapted, as is known in the art, to return the piston <NUM> to the home position when hydraulic fluid pressure is removed from the proximal end of the piston <NUM>. In the exemplary embodiment shown, the piston <NUM> has a diameter of about <NUM>,<NUM> (about <NUM> inch). However, the diameter of the piston could have any suitable size or shape for functioning as a hydraulic fluid contact surface. For example, the piston may have a diameter that is substantially the same size as the indentor body.

Referring now to <FIG>, the indentor <NUM> will be described in more detail. The indentor <NUM> is used to impact a wire lug, connector or coupler positioned or resting within the nest <NUM> of the head frame <NUM>. To perform this operation, the indentor <NUM> is preferably a solid member, made of steel or other hard material capable of withstanding continuous impacts against wire lugs under the forces exerted by the piston <NUM>. The indentor <NUM>, according to this exemplary embodiment, has a body <NUM>, a front face <NUM> extending from the body, and an impact surface <NUM> extending from the front face <NUM>. The front face <NUM> and impact surface <NUM> are preferably configured to fit within a portion of the nest <NUM> of the head frame <NUM>. The impact surface <NUM> is used to impact a wire lug resting within the nest <NUM>.

As noted above, in the embodiment of <FIG>, the indentor <NUM> is releasably coupled to the piston <NUM>. One exemplary embodiment for releasably coupling the indentor to the piston is shown in <FIG>. In this exemplary embodiment, the body <NUM> of the indentor <NUM> includes a piston aperture <NUM>, seen in <FIG> and <FIG>, for receiving the distal end of the piston <NUM>. The body <NUM> includes one or more pin apertures <NUM> that at least partially pass through the piston aperture <NUM>, as shown in <FIG> and <FIG>. When the piston <NUM> is positioned within the piston aperture <NUM>, one or more dowel pins <NUM>, seen in <FIG>, are inserted in to the pin apertures <NUM> so that each pin is at least partially positioned within a slot <NUM> in the distal end of the piston <NUM>, as seen in <FIG> and <FIG>. In another exemplary embodiment, the distal end 60a of the piston <NUM> may include the radial channel <NUM>, shown in <FIG>, so that when the indentor <NUM> is releasably coupled to the piston <NUM>, the piston is able to rotate independent of the indentor as described above.

Referring now to <FIG>, <FIG>, an exemplary embodiment of an indentor guide assembly <NUM> is shown. In this exemplary embodiment, the indentor guide assembly <NUM> is an internal male/female T-track assembly. This T-track assembly includes a carriage <NUM> integrally formed to the indentor <NUM> or secured to the indentor, by for example a weld joint or set screw. The carriage <NUM> has a base <NUM> in the form of a T-shape that is intended to extend into a U-shaped guide <NUM> forming a portion of the head frame <NUM> within the working area <NUM> of the working head <NUM>. The U-shaped guide <NUM> includes retainer arms <NUM> that maintain the base <NUM> within the U-shaped guide <NUM>, as shown in <FIG>, so that the carriage <NUM> can move relative to the U-shaped guide <NUM>. This T-track assembly <NUM> guides the carriage <NUM> and the indentor <NUM> as the indentor moves between the home position and the impacting position. The carriage <NUM> also helps to limit or prevent rotation of the indentor <NUM> relative to the piston <NUM>.

Referring to <FIG>, another exemplary embodiment of the indentor guide assembly <NUM> is shown. In this exemplary embodiment, the indentor guide assembly <NUM> is an external male/female T-track assembly. This T-track assembly includes a carriage <NUM> integrally formed to the indentor <NUM>, or secured to the indentor, by for example a weld joint or set screw. The carriage <NUM> has a base <NUM> with a T-shaped channel <NUM> for receiving a T-shaped guide <NUM> forming a portion of the head frame <NUM> within the working area <NUM> of the working head <NUM>. The T-shaped channel <NUM> in the base <NUM> and the T-shaped guide <NUM> maintain the base <NUM> within the T-shaped guide <NUM>, as shown in <FIG>. The T-track assembly <NUM> guides the carriage <NUM> and the indentor <NUM> as the indentor moves between the home position and the impacting position, seen in <FIG>. The carriage <NUM> also helps to limit or prevent rotation of the indentor <NUM> relative to the piston <NUM>.

<FIG> provide another exemplary embodiment of the indentor <NUM> and the carriage <NUM>. In this embodiment, the carriage <NUM> includes a pair of legs <NUM> secured to or integrally formed into the indentor <NUM>. Each leg <NUM> has a track guide arm <NUM> that extends toward the opposite leg such that the legs <NUM> and track guide arm <NUM> form a T-shaped channel <NUM> for receiving the T-shaped guide <NUM> forming a portion of the head frame <NUM> within the working area <NUM> of the working head <NUM> as described above. The T-shaped channel <NUM> in the carriage <NUM> and the T-shaped guide <NUM> maintain the carriage <NUM> within the T-shaped guide <NUM>. The T-track assembly <NUM> guides the carriage <NUM> and the indentor <NUM> as the indentor moves between the home position and the impacting position. The carriage <NUM> also helps to limit or prevent rotation of the indentor <NUM> relative to the piston <NUM>. In addition, the surfaces <NUM> of the front face <NUM> of indentor <NUM> act as a stop to prevent the legs <NUM> from impacting a wire lug within the nest <NUM>, which may cause stress on the legs and degrade their durability.

Referring to <FIG>, another exemplary embodiment of the indentor guide assembly <NUM> is shown. In this embodiment, the indentor <NUM> has the same diameter as the piston <NUM> and is integrally formed into the distal end of the piston, or secured to the distal end of the piston. The indentor guide assembly <NUM> includes carriage <NUM> and collar <NUM>. The carriage <NUM> can be integrally formed to the indentor <NUM>, or the indentor <NUM> can be secured to the carriage <NUM> by, for example, a weld joint or screw. The collar <NUM> is integrally formed into the head frame <NUM>, or is attached to the head frame. As the indentor <NUM> is moved from the home position to the impacting position, the carriage <NUM> moves along plate <NUM> of the head frame <NUM> maintaining the indentor on a substantially linear path toward the impacting position and limiting or preventing the indentor from flexing downward. The carriage <NUM> also helps to limit or prevent rotation of the indentor <NUM>. As the indentor <NUM> is moved from the home position to the impacting position, the collar <NUM> limits or prevents the indentor <NUM> from flexing upward. Thus, the combination of the carriage <NUM> and the collar <NUM> maintains the vertical orientation of the indentor <NUM> as it moves between the home position and the impacting position.

Referring to <FIG> and <FIG>, another exemplary embodiment of the indentor guide assembly <NUM> is shown. In this embodiment, the indentor <NUM> has the same diameter as the piston <NUM>, and is integrally formed into the distal end of the piston, or secured to the distal end of the piston. The indentor guide assembly <NUM> comprises collar <NUM>, which is integrally formed into the head frame <NUM>, or is attached to the head frame. As the indentor <NUM> is moved from the home position to the impacting position, the arched shape and the arc length of the collar <NUM> limit or prevent the indentor <NUM> from flexing as the indentor moves between the home position and the impacting position. To align the position of the impacting surface <NUM> of the indentor <NUM> and to limit or prevent rotation of the indentor, an alignment slot <NUM> may be provided in the indentor <NUM> and piston <NUM>, and a set screw (not shown) may be inserted into aperture <NUM> in collar <NUM>. When the set screw is inserted into the aperture <NUM> and into the alignment slot <NUM>, the set screw acts as a guide for the indentor and limits or prevents rotation of the indentor.

Referring to <FIG>, another exemplary embodiment of a crimping tool according to the present disclosure is shown. The crimping tool <NUM> includes a tool frame <NUM> and a working head <NUM>. The tool frame <NUM> is the same as the tool frame described above and for ease of description is not repeated. The working head <NUM> includes a head frame <NUM> and an indentor <NUM>, which is the same as the indentor <NUM> described above. The head frame <NUM> may be connected to the front end of the tool frame <NUM> and fixed or locked in position. In another embodiment, the head frame <NUM> may be rotatably connected to the tool frame <NUM>.

Referring to <FIG>, the head frame <NUM> of the working head <NUM> includes a nest <NUM> that is configured to receive a wire lug <NUM> for subsequent crimping by the indentor <NUM>. The nest <NUM> can come in any number of embodiments. For example, in the exemplary embodiment shown the nest <NUM> is a V-nest. The shape of the nest is preferably matched to the shape of the indentor <NUM> so that the indentor is not generally prohibited from impacting a wire lug <NUM> resting within the nest <NUM>. Typically, this is not an issue with larger wire lugs that occupy a larger area within the nest <NUM> such that the indentor may not contact the nest <NUM>. However, there may be instances where the wire lug is sufficiently small so that a front face <NUM> of the indentor <NUM> contacts one or more walls of the nest <NUM>. In such instances it may be desirable to have the front face <NUM> of the indentor <NUM> contact one or more walls of the nest <NUM> as a way to minimize the force applied to the crimping of small wire lugs. In such cases, the walls of the nest <NUM> would absorb a portion of the force exerted by the indentor <NUM>, and the remaining force would be used by an impacting surface <NUM> of the indentor to crimp a wire into the wire lug. In addition, the piston <NUM> used to move the indentor <NUM> between the home position and the impacting position may include a stop, similar to stop <NUM> seen in <FIG>, that contacts the head frame <NUM> to further limit the force applied by the indentor <NUM> when in the impacting position.

Between the nest <NUM> and the outer periphery of the head frame <NUM> and between the indentor guide assembly <NUM> and the outer periphery of the head frame <NUM> is an I-beam like structure with a lower flange <NUM>, an upper flange <NUM> and a web <NUM> between the flanges. The web <NUM> may include one or more openings <NUM> provided to reduce the weight of the head frame <NUM>. The lower flange <NUM> may include one or more bosses <NUM> provided to increase the load capacity that the head frame can withstand. The web <NUM> may also include a break-away region <NUM>. In the embodiment shown in <FIG>, the break-away region <NUM> includes an opening, such as slot <NUM>, that is aligned with a base portion 214a of the nest <NUM> as shown. The break-away region is provided as a fail-safe mechanism such that in the event the nest <NUM> were to fail when the indentor is in the impacting position, the failure would be directed toward the break-away region <NUM>, here opening <NUM>, so that a portion of the lower flange <NUM> and associated portions of the web <NUM> would bend outwardly away from the working area <NUM> of the working head <NUM>, as shown by the arrows in <FIG>. This bending of the lower flange <NUM> and the web <NUM> absorbs the nest failure while maintaining a connection between the portion of the nest that failed and the head frame <NUM>. In the embodiment of <FIG>, the break-away region <NUM> is formed by annealing a portion of the head frame <NUM>. By annealing the metal head frame, the physical and possibly chemical properties of the metal are altered to increase the plastically, e.g., ductility and/or malleability, of the metal to reduce its hardness and allowing the metal to deform under stress, e.g., tensile stress or compression stress, without fracturing. Similar to the embodiment of <FIG>, the break-away region is provided as a fail-safe mechanism such that in the event the nest <NUM> were to fail when the indentor is in the impacting position, the failure would be directed toward the break-away region <NUM> so that a portion of the lower flange <NUM> and associated portions of the web <NUM> would bend outwardly away from the working area <NUM> of the working head <NUM>, as shown by the arrows in <FIG>. This bending of the lower flange <NUM> and the web <NUM> absorbs the nest failure while maintaining a connection between the portion of the nest that failed and the head frame <NUM>.

Referring again to <FIG>, in the exemplary embodiment shown, the indentor <NUM> is releasably coupled to the piston <NUM> as described above. The hydraulic drive conduit system <NUM>, including the piston <NUM>, is connected between the pump <NUM> and the body of the indentor <NUM>. Hydraulic fluid, which is in the fluid reservoir <NUM>, is pumped by the pump <NUM> through the hydraulic drive conduit system <NUM> and against a proximal end of the piston <NUM> causing the indentor <NUM> to move. As described above and indicated by arrow <NUM>, the piston <NUM>, when activated, moves the indentor <NUM> between the impacting position where the indentor impacts a wire lug, as seen in <FIG>, and the home position where the piston is retracted towards the tool frame <NUM>, as seen in <FIG>.

The indentor guide assembly <NUM> shown in this exemplary embodiment is similar to the external male/female T-track assembly described above with reference to <FIG>. In this embodiment, the T-track assembly includes a carriage <NUM> that includes a pair of legs <NUM> that can be integrally formed to the indentor <NUM> or secured to the indentor, by for example a weld joint or set screw. Each leg <NUM> has a track guide arm <NUM> that extends toward the opposite leg such that the legs <NUM> and track guide arms <NUM> form a T-shaped channel <NUM> for receiving the T-shaped guide <NUM> forming a portion of the head frame <NUM> within the working area <NUM> of the working head <NUM> as described above. The T-shaped channel <NUM> in the carriage <NUM> and the T-shaped guide <NUM> maintain the carriage <NUM> within the T-shaped guide <NUM>. The T-track assembly <NUM> guides the carriage <NUM> and the indentor <NUM> as the indentor moves between the home position and the impacting position. The carriage <NUM> also helps to limit or prevent rotation of the indentor <NUM> relative to the piston <NUM>.

Referring to <FIG>, another exemplary embodiment of a crimping tool according to the present disclosure is shown. The crimping tool <NUM> includes a tool frame <NUM> having an in-line shape, and a working head similar to working head <NUM> described above. Within the in-line frame <NUM> is the pump <NUM>, motor <NUM>, fluid reservoir <NUM>, controller <NUM> and a hydraulic drive conduit system <NUM> described above. Battery <NUM> can be releasably coupled or fixed to the in-line tool frame <NUM> as described above. The crimping tool <NUM> may also include a camera <NUM>, seen in block form in <FIG>, mounted to the tool frame <NUM> and oriented to provide a video of a working area <NUM> of the working head <NUM>. The crimping tool <NUM> may also include a tool tracking system <NUM>, seen in block form in <FIG>, for tracking the location of the tool as described above.

Referring to <FIG>, another exemplary embodiment of a crimping tool according to the present disclosure is shown. The crimping tool <NUM> includes a tool frame <NUM> having a suitcase shape, and a working head similar to working head <NUM> described above. Within the suitcase frame <NUM> is the pump <NUM>, motor <NUM>, fluid reservoir <NUM>, controller <NUM> and a hydraulic drive conduit system <NUM> described above. Battery <NUM> can be releasably coupled or fixed to the suitcase frame as described above. The suitcase frame <NUM> includes a carry handle <NUM> and one or more trigger switches <NUM> that can activate the piston to move the indentor <NUM> to the impacting position and to deactivate the indentor <NUM> so that the piston and indentor move to the home position. The crimping tool <NUM> may also include a camera <NUM>, seen in block form in <FIG>, mounted to the tool frame <NUM> and oriented to provide a video of a working area <NUM> of the working head <NUM>. The crimping tool <NUM> may also include a tool tracking system <NUM>, seen in block form in <FIG>, for tracking the location of the tool as described above.

Referring to <FIG>, another exemplary embodiment of a crimping tool according to the present disclosure is shown. The crimping tool <NUM> includes a tool frame <NUM> and a working head <NUM>. The tool frame <NUM> is the same as the tool frame described above and for ease of description is not repeated. The working head <NUM> includes a head frame <NUM>, an indentor <NUM>, which is substantially the same as the indentor <NUM> described above, and a nest <NUM>. The head frame <NUM> may be connected to the front end of the tool frame <NUM> and fixed or locked in position. In another embodiment, the head frame <NUM> may be rotatably connected to the tool frame <NUM>.

In this embodiment, the indentor <NUM> is attached to the distal end of the head frame <NUM> in the working area <NUM>, as shown. The indentor <NUM> may be secured to the head frame <NUM> by for example a welded joint, integrally formed into the head frame or the indentor may be releasably attached to the head frame using for example set screws. The nest <NUM> is secured to the piston <NUM> in a similar manner as the embodiments above where the indentor is secured to the piston. The nest <NUM> is movable between the home position, seen in <FIG>, and the impacting position, seen in <FIG>. More specifically, the hydraulic drive conduit system <NUM>, including the piston <NUM>, is connected between the pump <NUM> and the body of the nest <NUM>. Hydraulic fluid, which is in the fluid reservoir <NUM>, is pumped by the pump <NUM> through the hydraulic drive conduit system <NUM> and against a proximal end of the piston <NUM> causing the nest <NUM> to move. The piston <NUM>, when activated, moves the nest <NUM> between the impacting position where the indentor <NUM> impacts a wire lug, as seen in <FIG>, and the home position where the piston is retracted towards the tool frame <NUM>, as seen in <FIG>.

The nest <NUM> is configured to receive a wire lug <NUM> for subsequent crimping by the indentor <NUM>. The nest <NUM> can come in any number of embodiments. For example, in the exemplary embodiment shown the nest <NUM> is a V-nest. The shape of the nest is preferably matched to the shape of the indentor <NUM> so that the indentor is not generally prohibited from impacting a wire lug <NUM> resting within the nest <NUM>. Typically, this is not an issue with larger wire lugs that occupy a larger area within the nest <NUM> such that the indentor <NUM> may not contact the nest <NUM>. However, there may be instances where the wire lug is sufficiently small so that a front face <NUM> of the indentor <NUM> contacts one or more walls of the nest <NUM>. In such instances, it may be desirable to have the front face <NUM> of the indentor <NUM> contact one or more walls of the nest <NUM> as a way to minimize the force applied to the crimping of small wire lugs. In such cases, the walls of the nest <NUM> would absorb a portion of the force exerted by the indentor <NUM>, and the remaining force would be used by an impacting surface <NUM> of the indentor to crimp a wire into the wire lug.

Turning now to <FIG>, an exemplary embodiment of an adaptor that can be mounted to the indentor is described. The adapter <NUM> releasably attaches to the indentor <NUM> and is provided to permit the crimping tool to crimp differently shaped crimping members. In the embodiment shown, the adapter <NUM> includes a base portion <NUM> and an impacting portion <NUM>. The base portion <NUM> releasable connects to the indentor <NUM> and the impacting portion <NUM> impacts the crimping member. The base portion <NUM> includes a pair of legs <NUM> and <NUM> extending from the impacting portion, as shown in <FIG>, and an indentor receiving channel <NUM> between the legs. Leg <NUM> has an aperture <NUM> that receives a locating pin <NUM>. The aperture <NUM> may be a threaded aperture that receives a threaded locating pin or the aperture may be a smooth bore that receives a dowel like locating pin. Leg <NUM> has an aperture (similar to aperture <NUM>) that receives a locking pin <NUM>. The aperture may be a threaded aperture that receives a threaded locking pin or the aperture may be a smooth bore that receives a dowel like locking pin. In the embodiment shown, the locating pin <NUM> is a set screw and the locking pin <NUM> has a threaded distal end. The indentor receiving channel <NUM> is configured and dimensioned to receive the front face <NUM> and impacting surface <NUM> of the indentor <NUM>, as shown in <FIG>. The impacting portion <NUM> in this exemplary embodiment is a U-shaped member having side walls <NUM> and <NUM> and a bottom wall <NUM> connected between the side walls. The U-shaped member forming the impacting portion <NUM> is shaped to crimp H-frame type crimping members, such as the HYCRIMP and the LOKTAP crimps manufactured by Burndy LLC.

To mount the adapter <NUM> to the indentor <NUM>, the adapter is positioned over the indentor and the locating pin <NUM>, which may be extending into the indentor receiving channel <NUM>, is positioned in a first aperture <NUM> in the side of the indentor <NUM> shown in <FIG>. The aperture <NUM> may be threaded or smooth depending upon the type of locating pin used. With the locating pin in the aperture <NUM>, the locking pin can then be inserted into a second aperture in the opposite side of the indentor <NUM>. The second aperture may be threaded or smooth depending upon the type of locking pin used. With the adapter <NUM> releasably secured to the indentor <NUM>, an H-frame crimp <NUM> having conductors <NUM> and <NUM>, seen in <FIG>, can be inserted in the nest <NUM> of the working head <NUM> and the crimping tool can be activated such that the adapter <NUM> is moved toward the impacting position to crimp the conductors to the H-frame crimp <NUM>.

Claim 1:
A dieless crimping tool (<NUM>) comprising:
a working head (<NUM>) having a head frame (<NUM>), a movable indentor (<NUM>) having a body (<NUM>), a front face (<NUM>) extending from the body (<NUM>) and an impact surface (<NUM>) extending from the front face, and an indentor guide assembly (<NUM>), wherein the head frame (<NUM>) has open access to a working area of the working head (<NUM>) and a nest (<NUM>) having a base portion and at least a pair of side walls extending from the base portion formed into the head frame (<NUM>) and within the working area for receiving a crimping member;
a tool frame (<NUM>) having a piston (<NUM>) coupled to the indentor (<NUM>) that moves the indentor along the indentor guide assembly (<NUM>) between a home position adjacent the tool frame (<NUM>) and an impacting position adjacent the nest (<NUM>); and
wherein the front face (<NUM>) and impact surface (<NUM>) are configured to fit within a portion of the nest (<NUM>), wherein the impact surface (<NUM>) is used to impact a crimping member resting within the nest (<NUM>) and wherein the front surface (<NUM>) may contact one or more walls of the nest (<NUM>) to minimize the force applied to the crimping of small crimping members.