Patent Description:
The present disclosure relates to drive assemblies for portable, battery powered tools having one or more moving jaws. More particularly, the present disclosure relates to hand-held crimping tool drive assemblies that translate rotational movement of a motor into movement of at least one of a pair of jaws used to crimp an object. An example of a rotary hand held power tool is shown in <CIT>.

Hand-held, battery powered crimping tools are known in the art. Such tools are sometimes referred to as a pressing tool. Using such tools, an electrical wire termination is manually held in place between a pair of jaws, namely a fixed jaw and a movable jaw. Crimping of the electrical wire termination is carried out when a motor is activated causing the movable jaw to move toward the fixed jaw so that the jaws impinge the object. However, the motor, gearbox and other hardware used to move the movable jaw are bulky which lead to packaging complications, and are expensive components driving up the cost to manufacture such tools.

The present disclosure provides drive assemblies that can be used with hand-held, battery powered crimping tools that reduce the bulkiness of the drive assembly and the cost to manufacture.

The present disclosure provides exemplary embodiments of portable, hand-held, battery powered crimping tools and drive assemblies for such tool. For example, the crimping tool may be a battery powered crimping tool having an in-line handle assembly and a working head assembly. The handle assembly has a tool frame and an outer housing. The working head assembly has a pair of jaw assemblies mounted to the tool frame such that at least one of the jaw assemblies is movable relative to the other jaw assembly. Each jaw assembly may include a die for crimping an object or a blade for cutting an object.

In one exemplary embodiment, the drive assembly includes a drive assembly housing, a gear assembly, a lead drive shaft and a bearing system. The gear assembly is positioned within the drive assembly housing and is a multi-stage gear assembly having at least an input stage and an output stage. The lead drive shaft has a proximal end extending at least partially into a distal end portion of the drive assembly housing. The proximal end of the lead drive shaft has a tip that is coupled to output stage of the gear assembly. The bearing system is positioned within the drive assembly housing adjacent the output stage of the gear assembly. The bearing system is interactive with the lead drive shaft enabling the drive assembly to withstand radial and axial loads as the lead drive shaft is rotated during an operation of the tool.

In another exemplary embodiment, the drive assembly includes a drive assembly housing, a gear assembly, a lead drive shaft, a bearing system. The gear assembly is positioned within the drive assembly housing and includes a multi-stage planetary gear assembly. The multi-stage planetary gear assembly has at least an input stage and an output stage. The multi-stage planetary gear assembly includes a ring gear used by each stage of the multi-stage planetary gear assembly. The lead drive shaft has a distal end portion, a proximal end portion and an intermediate portion between the distal end portion and the proximal end portion. The distal end portion being threaded and substantially outside the drive assembly housing. The intermediate portion has a smooth exterior surface. In an exemplary embodiment, the proximal end portion is positioned within the drive assembly housing and forms a carrier plate of the output stage of the planetary gear assembly. The bearing system is positioned at least partially within the drive assembly housing, and is interactive with the lead drive shaft enabling the drive assembly to withstand radial and axial loads as the lead drive shaft is rotated during an operation of the tool. In one exemplary embodiment, the bearing system includes a radial bearing and a thrust bearing assembly adjacent the radial bearing. The radial bearing and the thrust bearing assembly are positioned within the drive assembly housing. The thrust bearing assembly rests on the proximal end portion of the lead drive shaft and around the intermediate portion of the lead drive shaft, and the radial bearing is adjacent the thrust bearing assembly around the intermediate portion of the lead drive shaft. In another exemplary embodiment, the bearing system includes a radial bearing, a first thrust bearing assembly adjacent the radial bearing and a second thrust bearing assembly. In this embodiment, the radial bearing and the first thrust bearing assembly are positioned within the drive assembly housing and the second thrust bearing assembly rests on an exterior of the drive assembly housing. Preferably, the first thrust bearing rests on the proximal end portion of the lead drive shaft and around the intermediate portion of the lead drive shaft, and the radial bearing is adjacent the first thrust bearing assembly around the intermediate portion of the lead drive shaft. The second thrust bearing assembly is around a portion of the intermediate portion of the lead drive shaft extending out of the drive assembly housing.

In another exemplary embodiment, the drive assembly includes a drive assembly housing, a gear assembly, a lead drive shaft, a bearing system. The gear assembly is positioned within the drive assembly housing, and includes a first stage planetary gear assembly as an input stage and a second stage planetary gear assembly as an output stage. In this exemplary embodiment, the first stage and the second stage use a common ring gear. The lead drive shaft has a distal end portion, a proximal end portion and an intermediate portion between the distal end portion and the proximal end portion. The proximal end portion is positioned within the drive assembly housing and forms a carrier plate of the output stage of the planetary gear assembly. The distal end portion is threaded and substantially outside the drive assembly housing, and the intermediate portion has a smooth exterior surface. The bearing system is positioned at least partially within the drive assembly housing. The bearing system is interactive with the lead drive shaft enabling the drive assembly to withstand radial and axial loads as the lead drive shaft is rotated during an operation of the tool.

The figures depict embodiments for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the structures illustrated herein may be employed without departing from the principles described herein, wherein:.

The portable, battery-powered, hand-held tools contemplated by the present disclosure include crimping tools that crimp one or more conductors to an object and cutting tools used to cut one or more conductors. The present disclosure will be shown and described in connection with portable, battery-powered, hand-held tools with an in-line handle design. However, handle design of the portable, battery-powered, hand-held tool may be a pistol grip design, a suitcase design or other type handle design. The present disclosure will also be shown and described in connection with a crimping tool. However, the crimping jaws of the tool may be substituted with cutting jaws to create a cutting tool.

For ease of description, the portable, battery-powered, crimping tools according to the present disclosure may also be referred to as the "tools" in the plural and the "tool" in the singular. The objects crimped by the crimping tool may also be referred to herein as the "wire terminations" in plural and the "wire termination" in the singular. Non-limiting examples of the wire terminations include lugs and splices. The conductors, cables, wires or objects to be crimped within the wire terminations or cut by the tools of the present disclosure may also be referred to as the "conductors" in the plural and the "conductor" in the singular. In addition, as used in the present disclosure, the terms "front," "rear," "upper," "lower," "upwardly," "downwardly," "proximal," "distal" and other orientation descriptors are intended to facilitate the description of the exemplary embodiments disclosed herein and are not intended to limit the structure of the exemplary embodiments or limit the claims to any particular position or orientation.

Referring to <FIG> and <FIG>, a battery-powered, hand-held crimping tool <NUM> according to the present disclosure is shown. The tool <NUM> includes a working head assembly <NUM> and a handle assembly <NUM>. The working head assembly <NUM> includes a first jaw assembly <NUM> and a second jaw assembly <NUM>. A biasing member <NUM> is used to automatically bias the second jaw assembly <NUM> in a direction away from the first jaw assembly <NUM>. The first jaw assembly <NUM> includes a first jaw plate <NUM>, a second jaw plate <NUM>, a die <NUM>. The first jaw plate <NUM> and second jaw plate <NUM> are aligned in parallel and spaced apart, as shown in <FIG>. In this exemplary embodiment, the die <NUM> includes one or more impinging regions <NUM> and a mounting member <NUM>. Each of the one or more impinging regions <NUM> may include one or more impacting surfaces <NUM>, each surface being configured and dimensioned to receive a barrel portion of a wire termination (not shown). The die <NUM> is secured to the first and second jaw plates <NUM> and <NUM> by positioning the mounting member <NUM> between the first and second jaw plates so that a fastener <NUM>, e.g., a bolt, can be passed through apertures in the plates <NUM> and <NUM> and the mounting member <NUM>, as shown, and tightened. The second jaw assembly <NUM> includes a first jaw plate <NUM>, a second jaw plate <NUM> and die <NUM>. The first jaw plate <NUM> and second jaw plate <NUM> are aligned in parallel and spaced apart, as shown in <FIG>. In this exemplary embodiment, the die <NUM> includes one or more impinging regions <NUM> and a mounting member <NUM>. Each of the one or more impinging regions <NUM> may include one or more impacting surfaces <NUM>, each surface <NUM> being configured and dimensioned to receive a barrel portion of a wire termination (not shown). The die <NUM> is secured to the first and second jaw plates <NUM> and <NUM> by positioning the mounting member <NUM> between the first and second jaw plates <NUM> and <NUM> so that a fastener <NUM>, e.g., a bolt, can be passed through apertures in the plates <NUM> and <NUM> and the mounting member <NUM>, as shown, and tightened.

Continuing to refer to <FIG> and <FIG>, the second jaw assembly <NUM> is operatively coupled to the first jaw assembly <NUM> so that the second jaw assembly <NUM> is movable relative to the first jaw assembly <NUM>. Various known techniques may be used to couple the jaw assemblies <NUM> and <NUM>. For example, in the embodiment of <FIG>, a tang and clevis type configuration is used, where a portion of the first and second jaw plates <NUM> and <NUM> include through apertures <NUM> and <NUM> acting as a clevis <NUM>, and portion of the first and second jaw plates <NUM> and <NUM> include apertures <NUM> and <NUM> acting as a tang <NUM>. In this exemplary embodiment, the biasing member <NUM>, e.g., a helical torsion spring, is positioned within the tang <NUM> of the second jaw assembly <NUM> so that a central opening of the biasing member <NUM> is aligned with the apertures <NUM> and <NUM> in the tang <NUM>. One end 28a of the biasing member <NUM> is inserted into a spring aperture <NUM> in the second jaw plate <NUM> of the second jaw assembly <NUM> to couple the biasing member <NUM> to the second jaw assembly <NUM>. The tang <NUM> is then positioned between the clevis <NUM> of the first jaw assembly <NUM>, and another end 28b of the biasing member <NUM> is inserted into a spring aperture <NUM> in the second jaw plate <NUM> of the first jaw assembly <NUM> to couple the biasing member <NUM> to the first jaw assembly <NUM>. With the tang <NUM> aligned with the clevis <NUM>, a bolt <NUM> is passed through the clevis apertures <NUM> and <NUM>, the tang apertures <NUM> and <NUM>, and the central opening of the biasing member <NUM> to movably secure the second jaw assembly <NUM> to the first jaw assembly <NUM>. In this exemplary embodiment, the second jaw assembly <NUM> pivots relative to the first jaw assembly <NUM> where the bolt <NUM> acts as the pivot pin. As noted above, the biasing member <NUM> normally biases the second jaw assembly <NUM> in a direction away from the first jaw assembly <NUM>.

Referring now to <FIG> and <FIG>, the handle assembly <NUM> houses a drive assembly and one or more electrical controls used to activate and deactivate the tool <NUM>. In the exemplary embodiment shown, the handle assembly <NUM> includes a housing <NUM>, seen in <FIG>, and the drive assembly <NUM>, seen in <FIG>. The housing <NUM> is configured and dimensioned to enclose or wrap around the drive assembly <NUM> and a proximal portion of the working head assembly <NUM>. More specifically, the distal end of the housing <NUM> is a head portion <NUM> configured and dimensioned to enclose a portion of the jaw assemblies <NUM> and <NUM>. An intermediate portion of the housing <NUM> is a grip portion <NUM> that is configured and dimensioned to enclose the drive assembly <NUM>. The proximal end of the housing <NUM> is an end portion <NUM> configured and dimensioned to receive a portion of a battery <NUM> and to house the components used to connect the battery <NUM> to the housing <NUM> using, for example, known battery clips. The head portion <NUM> of the housing <NUM> may also include one or more lights <NUM>, e.g., LEDs, used to illuminate an area between the first and second jaw assemblies <NUM> and <NUM> when, for example, the tool <NUM> is activated.

In the exemplary embodiment shown, the battery <NUM> is removably connected to the end portion <NUM> of the housing <NUM>. In another embodiment, the battery <NUM> could be removably mounted or connected to any suitable position on the housing <NUM>. In another embodiment, the battery <NUM> may be affixed to the housing <NUM> so that it is not removable. The battery <NUM> shown is 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. The battery <NUM> provides power to a motor <NUM> in the drive assembly <NUM> via electrical contacts <NUM> on the motor. To activate the motor and possibly the lights <NUM>, if used, one or more operator control assemblies <NUM> may be used. In the exemplary embodiment shown, the one or more operator controls <NUM> may include a trigger <NUM> and a switch <NUM>, seen in <FIG>. In this exemplary embodiment, the trigger <NUM> pivotally connected to a spring arm <NUM> extending from the first jaw plate <NUM> of the first jaw assembly <NUM> and to a spring arm <NUM> extending from the second jaw plate <NUM> of the first jaw assembly <NUM>. The switch <NUM> may be, for example a single pole micro-switch, that operatively interacts with a camming surface 114a of the trigger <NUM>, seen in <FIG>. The switch <NUM> is electrically connected between the battery <NUM>, the motor <NUM> and the one or more lights <NUM> such that when the trigger <NUM> is depressed to a point where the camming surface 114a of the trigger <NUM> contacts and depresses the switch arm 116a, the switch <NUM> turns "on" causing the motor <NUM> to activate and the one or more lights <NUM> to turn "on" illuminating the area between the first and second jaw assemblies <NUM> and <NUM>.

Turning now to <FIG>, an exemplary embodiment of the drive assembly (or system) <NUM> according to the present disclosure is shown. The drive assembly <NUM> includes the motor <NUM>, a gear assembly <NUM>, a bearing system <NUM>, a lead drive shaft <NUM>, and a jaw drive member <NUM>. A drive assembly housing <NUM> holds or encases the gear assembly <NUM> and the bearing system <NUM>. Extending from a distal end portion 122a of the drive assembly housing <NUM> and operatively coupled to the gear assembly <NUM> is the lead drive shaft <NUM>, seen in <FIG>. In this exemplary embodiment, the lead drive shaft <NUM> includes a distal end portion 130a, a proximal end portion 130b and an intermediate portion 130c between the distal end portion 130a and the proximal end portion 130b. The distal end portion 130a is threaded with, for example, buttress threads typically used for one-directional loading on the lead drive shaft <NUM>, or acme threads typically used for bi-directional loading on the lead drive shaft <NUM>. The proximal end portion 130b of the lead drive shaft <NUM> is threaded with, for example, conventional machine screw threads. At the tip of the proximal end portion 130b of the lead drive shaft <NUM> is a spline or key 130d, seen in <FIG> and <FIG>, that interacts with the gear assembly <NUM>. In the exemplary embodiment shown, the spline 130d is a hex shaped member that interacts with a hex shape keyway <NUM> in the gear assembly <NUM>. The intermediate portion 130c of the lead drive shaft <NUM> has a smooth exterior surface with an outside diameter that is substantially the same as the outside diameter of the distal end portion 130a. The jaw drive member <NUM>, seen in <FIG>, is movably coupled to a distal end portion 130a of the lead drive shaft <NUM> as described in more detail below with reference to <FIG> and <FIG>.

The proximal end portion 130b of the lead drive shaft <NUM> is secured within the distal end portion 122a of the drive assembly housing <NUM> by the bearing system <NUM> and an end cap <NUM> of the drive assembly housing <NUM>, seen in <FIG> and <FIG>. The end cap <NUM> is secured to the distal end portion 122a of the drive assembly housing <NUM> by a mechanical connection. In the exemplary embodiment shown in <FIG> and <FIG>, the mechanical connection is a threaded connection, where threading on the end cap <NUM> is screwed into threading in the drive assembly housing <NUM>. However, other mechanical connections are contemplated, including snap-fit and press-fit connections where the end cap <NUM> is snapped or pressed within the drive assembly housing <NUM>, set screw connections where set screws secures the end cap <NUM> to the drive assembly housing <NUM>, and welds. The end cap <NUM> of the drive assembly housing <NUM> includes a pair of tabs <NUM>, each having a mounting aperture <NUM>. The mounting apertures <NUM> are positioned to align with corresponding mounting apertures <NUM> and <NUM> in the first and second jaw plates <NUM> and <NUM> of the first jaw assembly <NUM>, seen in <FIG>. The first and second jaw plates can then be secured to the tabs <NUM> of the end cap <NUM> using bolts <NUM>, as shown in <FIG>.

Referring to <FIG>, <FIG> and <FIG>, extending from a proximal end portion 122b of the drive assembly housing <NUM> and operatively coupled to the gear assembly <NUM> is the motor <NUM>. The motor <NUM> is secured to the proximal end portion 122b of the drive assembly housing <NUM> via an end cap <NUM>, seen in <FIG> and <FIG>. The end cap <NUM> is secured to the proximal end portion 122b of the drive assembly housing <NUM> by a mechanical connection. In the exemplary embodiment shown in <FIG> and <FIG>, the mechanical connection is preferably a threaded connection between the end cap <NUM> and the drive assembly housing <NUM>. However, other mechanical connections are contemplated, including annular or cantilever snap-fit connections, press-fit connections, set screw connections and welds. The motor <NUM> is secured to the end cap <NUM> by a mechanical connection. In the exemplary embodiment shown in <FIG> and <FIG>, the mechanical connection is a press-fit connection between the proximal end 124a of the motor <NUM> passing through a central opening <NUM> in the end cap <NUM> and an interior surface 135a of the central opening <NUM>. However, other mechanical connections are contemplated, including snap-fit connections, set screw connections and welds. A sealing member <NUM>, e.g., an O-ring, may be positioned within the central opening <NUM> of the end cap <NUM> to seal the connection between motor <NUM> and the end cap <NUM>.

Generally, the motor <NUM> rotates a motor drive shaft <NUM>, seen in <FIG>, that is coupled to the gear assembly <NUM>. The gear assembly <NUM> reduces the rate of rotation of the motor drive shaft <NUM>. The lead drive shaft <NUM> is coupled to the gear assembly <NUM> and rotates at the output rate of the gear assembly. The bearing system <NUM> is provided so that the lead drive shaft <NUM> can withstand radial and axial loads generated during an operation of the jaw assemblies <NUM> and <NUM>. As an example, the motor <NUM> may be configured to rotate the motor drive shaft <NUM> at a rate in the range of about <NUM>,<NUM> rpm and about <NUM>,<NUM> rpm with an output torque in the range of about <NUM> in-lb. and about <NUM> in-lb. In this configuration, the motor current may be in the range of about <NUM> amps and about <NUM> amps, the battery voltage may be in the range of about <NUM> VDC and about <NUM> VDC, and the output motor power may be in the range of about <NUM> watts and about <NUM> watts. The gear assembly <NUM> may reduce the rate of rotation of the motor drive shaft <NUM> to a range of about <NUM> rpm and about <NUM> rpm. As such, the gear ratio of the gear assembly <NUM> may be in the range of about <NUM>:<NUM> and about <NUM>:<NUM>. The output of the gear assembly <NUM> is transferred to the lead drive shaft <NUM>. In this exemplary embodiment, the lead drive shaft <NUM> is a threaded shaft having a diameter in a range of about <NUM> inches and about <NUM> inches, with a lead, e.g., a screw lead, in a range of about <NUM> inches and about <NUM> inches. Under the motor operating configuration described above, the efficiency of the gear assembly <NUM> may be in the range of about <NUM> % and about <NUM> %, and the pull force of the lead drive shaft <NUM> may be in the range of about <NUM> lbs. and about <NUM> lbs. Movement of the lead drive shaft <NUM> is transferred to the jaw drive member <NUM>. In the exemplary embodiment of the present disclosure, the output of the gear assembly <NUM> is rotational motion which is transferred to the lead drive shaft <NUM>. Rotation of the lead drive shaft <NUM> is translated to linear movement of the jaw drive member <NUM>. With a pull force of the lead drive shaft <NUM> in the exemplary range of about <NUM> lbs. and about <NUM> lbs. , the linear travel distance of the jaw drive member <NUM> may be in the range of about <NUM> inches and about <NUM> inches. Linear movement of the jaw drive member <NUM> moves the second jaw assembly <NUM> toward the first jaw assembly <NUM> when crimping a wire termination positioned between the first and second jaw assemblies. It is noted that with the gear assembly <NUM> reducing the rate of rotation of the motor drive shaft <NUM> to a range of about <NUM> rpm and about <NUM> rpm, the total crimp cycle of the tool <NUM> may be in the range of about <NUM> seconds and about <NUM> seconds.

As another example, the motor <NUM> may be configured to rotate the motor drive shaft <NUM> at a rate in the range of about <NUM>,<NUM> rpm and about <NUM>,<NUM> rpm with an output torque in the range of about <NUM> in-lb. and about <NUM> in-lb. In this exemplary embodiment, the motor current may be in the range of about <NUM> amps and about <NUM> amps, the battery voltage may be in the range of about <NUM> VDC and about <NUM> VDC, and the output motor power may be in the range of about <NUM> watts and about <NUM> watts. The gear assembly <NUM> may reduce the rate of rotation of the motor drive shaft <NUM> to a range of about <NUM> rpm and about <NUM> rpm. As such, the gear ratio of the gear assembly <NUM> may be in the range of about <NUM>:<NUM> and about <NUM>:<NUM>. As noted, the output of the gear assembly <NUM> is transferred to the lead drive shaft <NUM>. In this exemplary embodiment, the lead drive shaft <NUM> is a threaded shaft having a diameter in a range of about <NUM> inches and about <NUM> inches, with a lead, e.g., a screw lead, in a range of about <NUM> inches and about <NUM> inches. Under the motor operating configuration described above, the efficiency of the gear assembly <NUM> may be in the range of about <NUM>% and about <NUM>%, and the pull force of the lead drive shaft <NUM> may be in the range of about <NUM> lbs. and about <NUM> lbs. Movement of the lead drive shaft <NUM> is transferred to the jaw drive member <NUM>. In this exemplary embodiment of the present disclosure, the output of the gear assembly <NUM> is rotational motion which is transferred to the lead drive shaft <NUM>. Rotation of the lead drive shaft <NUM> is translated to linear movement of the jaw drive member <NUM>. With a pull force of the lead drive shaft <NUM> in the exemplary range of about <NUM> lbs. and about <NUM> lbs. , the linear travel distance of the jaw drive member <NUM> may be in the range of about <NUM> inches and about <NUM> inches. Linear movement of the jaw drive member <NUM> moves the second jaw assembly <NUM> toward the first jaw assembly <NUM> when crimping a wire termination positioned between the first and second jaw assemblies. It is noted that with the gear assembly <NUM> reducing the rate of rotation of the motor drive shaft <NUM> to a range of about <NUM> rpm and about <NUM> rpm, the total crimp cycle of the tool <NUM> may be in the range of about <NUM> seconds and about <NUM> seconds.

As described above, in the exemplary embodiment shown, the motor <NUM> is electrically connected to the battery <NUM> and the switch <NUM>, seen in <FIG>, and its operation is controlled by the trigger <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 in a range of about <NUM>,<NUM> rpm to about <NUM>,<NUM> rpm with a current in a range of about <NUM> amps and about <NUM> amps, a torque of about <NUM> in-lb. , and an output wattage in a range of about <NUM> W and about <NUM> W.

Turning now to <FIG> and <FIG>, an exemplary embodiment of the gear assembly <NUM> according to the present disclosure will be described. In this exemplary embodiment, the gear assembly <NUM> is a multi-stage gear assembly. Each stage in the gear assembly is a planetary gear assembly that includes a pinion gear, two or more planetary gears, a ring gear and a carrier plate. As an example, in the exemplary embodiment shown there are three planetary gear assemblies. A first planetary gear assembly <NUM> is a first stage (or an input stage), a second planetary gear assembly <NUM> is a second stage (or an intermediate stage) and a third planetary gear assembly <NUM> is a third stage (or an output stage). The first planetary gear assembly <NUM> includes a pinion gear <NUM>, three planetary gears <NUM>, a ring gear <NUM> and a carrier plate <NUM>. The pinion gear <NUM> is attached to the drive shaft <NUM> of the motor <NUM>. The planetary gears <NUM> are attached to shafts <NUM> extending from one side of the carrier plate <NUM> so that the planetary gears <NUM> are rotatable relative to their corresponding shaft <NUM>. The shafts <NUM> are arranged on the carrier plate <NUM> so that the planetary gears <NUM> are spaced apart and independent of each other. The carrier plate <NUM> is positioned adjacent the ring gear <NUM> so that the teeth of the planetary gears <NUM> intermesh with the teeth of the ring gear <NUM>. The pinion gear <NUM> is positioned within the ring gear <NUM> between the planetary gears <NUM> so that the teeth of the pinion gear <NUM> intermesh with the teeth of the planetary gears <NUM>.

Continuing to refer to <FIG> and <FIG>, the second planetary gear assembly <NUM> includes a pinion gear <NUM>, three planetary gears <NUM>, a ring gear <NUM> and a carrier plate <NUM>. The pinion gear <NUM> is attached to a shaft <NUM> extending from a side of the carrier plate <NUM> that is opposite the planetary gears <NUM>. The planetary gears <NUM> are attached to shafts <NUM> extending from one side of the carrier plate <NUM> so that the planetary gears <NUM> are rotatable relative to their corresponding shaft <NUM>. The shafts <NUM> are arranged on the carrier plate <NUM> so that the planetary gears <NUM> are spaced apart and independent of each other. The carrier plate <NUM> is positioned adjacent the ring gear <NUM> so that the teeth of the planetary gears <NUM> intermesh with the teeth of the ring gear <NUM>. The pinion gear <NUM> is positioned within the ring gear <NUM> between the planetary gears <NUM> so that the teeth of the pinion gear <NUM> intermesh with the teeth of the planetary gears <NUM>.

The third planetary gear assembly <NUM> includes a pinion gear <NUM>, three planetary gears <NUM>, a ring gear <NUM> and a carrier plate <NUM>. The pinion gear <NUM> is attached to a shaft <NUM> extending from a side of the carrier plate <NUM> that is opposite the planetary gears <NUM>. The planetary gears <NUM> are attached to shafts <NUM> extending from one side of the carrier plate <NUM> so that the planetary gears <NUM> are rotatable relative to their corresponding shaft <NUM>. The shafts <NUM> are arranged on the carrier plate <NUM> so that the planetary gears <NUM> are spaced apart and independent of each other. The carrier plate <NUM> is positioned adjacent the ring gear <NUM> so that the teeth of the planetary gears <NUM> intermesh with the teeth of the ring gear <NUM>. The pinion gear <NUM> is positioned within the ring gear <NUM> between the planetary gears <NUM> so that the teeth of the pinion gear <NUM> intermesh with the teeth of the planetary gears <NUM>. As noted above, the proximal end portion 130b of the lead drive shaft <NUM> has a spline or key 130d, seen in <FIG> and <FIG>, that interacts with the gear assembly <NUM>. In the exemplary embodiment shown, the spline 130d is a hex shaped member that interacts with a hex shape keyway <NUM> in the carrier plate <NUM> of the third planetary gear assembly <NUM>.

Referring now to <FIG> and <FIG>, an exemplary embodiment of a bearing system <NUM> according to the present disclosure is shown. The bearing system <NUM> is provided so that the drive assembly <NUM> can withstand radial and axial (or thrust) loads as the lead drive shaft <NUM> is rotated during an operation of the tool <NUM>. The bearing system <NUM> is positioned within the distal end portion 122a of the drive assembly housing <NUM> adjacent the gear assembly <NUM> and is held within the drive assembly housing <NUM> by the end cap <NUM>. In the exemplary embodiment shown, the bearing system <NUM> includes an upper radial bearing <NUM>, a thrust washer <NUM>, a thrust bearing <NUM>, a flange bushing <NUM> and a lower radial bearing <NUM>. The flange bushing <NUM> has an upper portion 226a with wider diameter that provides a platform on which the thrust bearing <NUM> can sit. The flange bushing <NUM> has a center bore 226b, seen in <FIG>, that is preferably threaded so that the flange bushing <NUM> can be threaded onto the proximal end portion 130b of the lead drive shaft <NUM>, as shown in <FIG>. The flange bushing <NUM> is used to secure the lead drive shaft <NUM> to the drive assembly housing <NUM>. The lower radial bearing <NUM> is positioned around a smooth exterior wall 226c of the flange bushing <NUM> as shown. The lower radial bearing <NUM> is provided to withstand radial loads on the flange bushing <NUM> as it rotates during an operation of the tool <NUM>. An example of a suitable lower radial bearing <NUM> is the Koyo Bearing No. BK1010 manufactured by JTEKT North America Corporation. The thrust bearing <NUM> is positioned around the intermediate portion 130c of the lead drive shaft <NUM> adjacent the flange bushing <NUM>. The thrust bearing <NUM> is provided to withstand axial (or thrust) loads on the lead drive shaft <NUM>, in the direction of arrow "A" seen in <FIG>, as the lead drive shaft rotates during an operation of the tool <NUM>. An example of a suitable thrust bearing <NUM> is the Koyo Bearing No. NTA613 manufactured by JTEKT North America Corporation. The thrust washer <NUM> is positioned on the thrust bearing <NUM> and is provided to hold the thrust bearing <NUM> in position within the drive assembly housing <NUM>. In addition, the thrust washer <NUM> also resists and transfers thrust loads to the end cap <NUM>. The upper radial bearing <NUM> is positioned around the intermediate portion 130c of the lead drive shaft <NUM> adjacent the thrust washer <NUM> as shown. The upper radial bearing <NUM> is provided to withstand radial loads on the lead drive shaft <NUM> as it rotates during an operation of the tool.

Referring to <FIG> and <FIG>, the jaw drive member <NUM> is movably coupled to the distal end portion 130a of the lead drive shaft <NUM>. In the exemplary embodiment shown, the jaw drive member <NUM> includes a body <NUM> and a camming member <NUM>. The body <NUM> includes a threaded center bore <NUM> that can be screwed onto the distal end portion 130a of the lead drive shaft <NUM>. The camming member <NUM> has a cam surface <NUM> configured to engage a cam roller <NUM>, seen in <FIG>, between the first jaw plate <NUM> and the second jaw plate <NUM> of the second jaw assembly. When the motor <NUM> is activated by the control assembly <NUM>, rotational movement of the lead drive shaft <NUM> is translated to linear motion of the jaw drive member <NUM> in the direction of the end cap <NUM> causing the cam surface <NUM> to contact the cam roller <NUM>. As the cam roller <NUM> traverses the cam surface <NUM> the second law assembly is pivoted clockwise toward the first jaw assembly <NUM>.

Referring now to <FIG>, another exemplary embodiment of a lead drive shaft <NUM> and a bearing system <NUM> according to the present disclosure is shown. In this exemplary embodiment, the lead drive shaft <NUM> includes a distal end portion 240a, a proximal end portion 240b, a first intermediate portion 240c and a second intermediate portion 240d. The first and second intermediate portions 240c and 240d are between the distal end portion 240a and the proximal end portion 240b of the lead drive shaft <NUM>. In this exemplary embodiment, the distal end portion 240a is threaded with, for example, acme threads typically used for bi-directional loading on the lead drive shaft <NUM>. The first intermediate portion 240c of the lead drive shaft <NUM> is adjacent the distal end portion 240a and has an outer diameter that is less than the outer diameter of the distal end portion 240a. The first intermediate portion 240c is threaded with, for example, conventional machine screw threads. The second intermediate portion 240d of the lead drive shaft <NUM> is adjacent the first intermediate portion 240c and has an outer diameter that is less than the outer diameter of the first intermediate portion 240c. The second intermediate portion 240d has a smooth exterior surface. The proximal end portion 240b of the lead drive shaft <NUM> is adjacent the second intermediate portion 240d and has an outer diameter that substantially the same as the outer diameter of the second intermediate portion 240d. The proximal end portion 240b is threaded with, for example, conventional machine screw threads. At the tip of the proximal end portion 240b of the lead drive shaft <NUM> is a spline or key 240e, seen in <FIG> and <FIG>, that interacts with the gear assembly <NUM> as described above. In the exemplary embodiment shown, the spline 240e is a hex shaped member that interacts with a hex shape keyway <NUM>, seen in <FIG>, in the gear assembly <NUM>.

Continuing to refer to <FIG>, the bearing system <NUM> is provided so that the drive assembly <NUM> can withstand radial and axial (or thrust) loads as the lead drive shaft <NUM> is rotated during an operation of the tool <NUM>. The bearing system <NUM> is positioned within a portion of the end cap <NUM> and the distal end portion 122a of the drive assembly housing <NUM> adjacent the gear assembly <NUM>. In the exemplary embodiment shown, the bearing system <NUM> includes an upper bearing assembly <NUM> and a lower bearing assembly <NUM>.

The upper bearing assembly <NUM> includes an upper radial bearing <NUM>, a flange bushing <NUM> and a thrust bearing <NUM>. The flange bushing <NUM> has a lower portion 264a with wider diameter that provides a platform to contact the thrust bearing <NUM>. The flange bushing <NUM> has a center bore 264b, seen in <FIG>, that is preferably threaded so that the flange bushing <NUM> can be threaded onto the first intermediate portion 240c of the lead drive shaft <NUM>, as shown in <FIG>. The flange bushing <NUM> is used to secure the lead drive shaft <NUM> to the drive assembly housing <NUM> and to hold the thrust bearing <NUM> in a fixed position relative to the lead drive shaft <NUM>. The upper radial bearing <NUM> is positioned around a smooth exterior wall 264c of the flange bushing <NUM> as shown in <FIG>. The upper radial bearing <NUM> is provided to withstand radial loads on the flange bushing <NUM> as the flange bushing rotates during an operation of the tool <NUM>. An example of a suitable upper radial bearing <NUM> is the Koyo Bearing No. BK1010 manufactured by JTEKT North America Corporation. The upper thrust bearing <NUM> is positioned around the second intermediate portion 240d of the lead drive shaft <NUM> adjacent the lower portion 264a of the flange bushing <NUM>. The upper thrust bearing <NUM> is provided to withstand axial (or thrust) loads in the direction of arrow "B" on the lead drive shaft <NUM> as it rotates during an operation of the tool <NUM>. An example of a suitable thrust bearing <NUM> is the Koyo Bearing No. NTA613 manufactured by JTEKT North America Corporation.

The lower bearing assembly <NUM> includes a thrust washer <NUM>, a lower thrust bearing <NUM>, a lower flange bushing <NUM> and a lower radial bearing <NUM>. The thrust washer <NUM> is positioned around the second intermediate portion 240d of the lead drive shaft <NUM> between the upper thrust bearing <NUM> and the lower thrust bearing <NUM>. As shown in <FIG>, the thrust washer <NUM> is captured between the drive assembly housing <NUM> and the end cap <NUM>. This permits the thrust washer to resist and transfer thrust loads to either the drive assembly housing <NUM> or the end cap <NUM> depending on the direction of the load. The thrust washer <NUM> is also provided to help secure the lower thrust bearing <NUM> in position within the drive assembly housing <NUM>. The thrust bearing <NUM> is positioned around the second intermediate portion 240d of the lead drive shaft <NUM> between the thrust washer <NUM> and the flange bushing <NUM>. The thrust bearing <NUM> is provided to withstand axial (or thrust) loads on the lead drive shaft <NUM> in the direction of arrow "A" as lead drive shaft <NUM> rotates during an operation of the tool <NUM>. An example of a suitable lower thrust bearing <NUM> is the Koyo Bearing No. NTA613 manufactured by JTEKT North America Corporation. The lower flange bushing <NUM> has an upper portion 296a with wider diameter that provides a platform on which the lower thrust bearing <NUM> can sit. The lower flange bushing <NUM> has a center bore 296b, seen in <FIG>, that is preferably threaded so that the lower flange bushing <NUM> can be threaded onto the proximal end portion 240b of the lead drive shaft <NUM>, as shown in <FIG>. The lower flange bushing <NUM> is also used to secure the lead drive shaft <NUM> to the drive assembly housing <NUM>. The lower radial bearing <NUM> is positioned around a smooth exterior wall 296c of the lower flange bushing <NUM> as shown. The lower radial bearing <NUM> is provided to withstand radial loads on the lower flange bushing <NUM> as it rotates during an operation of the tool <NUM>. An example of a suitable lower radial bearing <NUM> is the Koyo Bearing No. BK1010 manufactured by JTEKT North America Corporation.

Turning now to <FIG>, another exemplary embodiment of the drive assembly (or system) <NUM> according to the present disclosure is shown. As shown in <FIG>, the drive assembly <NUM> includes a drive assembly housing <NUM>, a gear assembly <NUM>, a bearing system <NUM>, a lead drive shaft <NUM>, a motor <NUM> and a jaw drive member that is similar to the jaw drive member <NUM> shown in <FIG> and described above. The drive assembly housing <NUM> holds or encases the gear assembly <NUM>, the bearing system <NUM> and at least a portion of the lead drive shaft <NUM>. More specifically, as shown in <FIG>, the drive assembly housing <NUM> includes a shaft opening <NUM>, a radial bearing compartment <NUM>, a thrust bearing compartment <NUM>, a gear compartment <NUM> ending with an opening <NUM> at a proximal end portion 302b of the drive assembly housing <NUM>. It is noted that the wall of the gear compartment <NUM> may be a flat wall or a stepped wall that aids in securing a ring gear of the gear assembly within the gear compartment <NUM>. Within drive assembly housing <NUM>, the lead drive shaft <NUM> is operatively coupled to the gear assembly <NUM>, seen in <FIG>. Preferably, a distal end portion <NUM> of the lead drive shaft <NUM> extends from a distal end portion 302a of the drive assembly housing <NUM>, seen in <FIG>. The distal end portion 302a of the drive assembly housing <NUM> also includes a pair of mounting apertures <NUM>. The mounting apertures <NUM> are positioned to align with corresponding mounting apertures <NUM> and <NUM> in the first and second jaw plates <NUM> and <NUM> of the first jaw assembly <NUM>, seen in <FIG>. The first and second jaw plates can then be secured to the distal end portion 302a of the drive assembly housing <NUM> using, for example bolts, similar to the bolts <NUM> shown in <FIG>.

In this exemplary embodiment, the lead drive shaft <NUM> includes the distal end portion <NUM>, a proximal end portion <NUM> and an intermediate portion <NUM> between the distal end portion <NUM> and the proximal end portion <NUM>, as shown in <FIG> and <FIG>. The distal end portion <NUM> is threaded with, for example, buttress threads typically used for one-directional loading on the lead drive shaft <NUM>, or acme threads typically used for bi-directional loading on the lead drive shaft <NUM>. The proximal end portion <NUM> of the lead drive shaft <NUM> is a substantially flat plate with, for example, one or more shaft apertures <NUM> used to couple the lead drive shaft <NUM> to the gear assembly <NUM>. In the exemplary embodiment shown, the proximal end portion <NUM> of the lead drive shaft <NUM> is a substantially round flat plate, as shown in <FIG>. The intermediate portion <NUM> of the lead drive shaft <NUM> has a smooth exterior surface with an outside diameter that is substantially the same as the outside diameter of the distal end portion <NUM>. The jaw drive member <NUM>, seen in <FIG>, is movably coupled to the distal end portion <NUM> of the lead drive shaft <NUM>.

Turning now to <FIG>, <FIG> and <FIG>, another exemplary embodiment of a gear assembly according to the present disclosure will be described. The gear assembly <NUM> is positioned with the gear compartment <NUM> of the drive assembly housing <NUM>. In this exemplary embodiment, the gear assembly <NUM> is a multi-stage gear assembly that utilizes a common ring gear. Each stage in the gear assembly is a planetary gear assembly that includes a pinion gear, two or more planetary gears, the common ring gear and a carrier plate. As an example, in the exemplary embodiment shown there are two planetary gear assemblies. A first planetary gear assembly <NUM> is the first stage (or an input stage), and a second planetary gear assembly <NUM> is the second stage (or an output stage). As shown in <FIG> and <FIG>, the first planetary gear assembly <NUM> includes a pinion gear <NUM>, three planetary gears <NUM>, the common ring gear <NUM>, a carrier plate <NUM> and gear shafts <NUM>. The pinion gear <NUM> is attached to the drive shaft <NUM> of the motor <NUM>. The planetary gears <NUM> are attached to gear shafts <NUM> inserted into mounting holes <NUM> of the carrier plate <NUM> and extending from one side of the carrier plate <NUM> so that the planetary gears <NUM> are rotatable relative to their corresponding gear shaft <NUM>. The gear shafts <NUM> are arranged on the carrier plate <NUM> so that the planetary gears <NUM> are spaced apart and independent of each other. As shown in <FIG>, the carrier plate <NUM> is positioned within the bottom portion 406a of the ring gear <NUM> so that the teeth of the planetary gears <NUM> intermesh with the teeth of the ring gear <NUM>. It is noted that the outer diameter of the carrier plate <NUM> is less than the inner diameter of the ring gear <NUM> so that the carrier plate <NUM> does not damage the teeth on the ring gear <NUM>, as seen in <FIG> and <FIG>, as the carrier plate <NUM> rotates within the ring gear. The pinion gear <NUM> passes through a drive housing adapter <NUM>, seen in <FIG>, <FIG> and <FIG>, releasably secured to the drive housing <NUM> so that the pinion gear <NUM> is positioned within the bottom portion 406a of the ring gear <NUM> between the planetary gears <NUM> so that the teeth of the pinion gear <NUM> intermesh with the teeth of the planetary gears <NUM>, as seen in <FIG>. More specifically, the drive housing adapter <NUM> of the drive assembly housing <NUM> is releasably secured to the motor <NUM> using fasteners <NUM>, e.g., cap screws, passing through mounting apertures <NUM> in a lip portion <NUM> of the drive housing adapter <NUM> into engagement with mounting apertures <NUM> in the motor <NUM>, seen in <FIG>, <FIG> and <FIG>. The pinion gear <NUM> passes through aperture <NUM> in the drive housing adapter <NUM> so that the pinion gear <NUM> can intermesh with the teeth of the planetary gears <NUM>, as seen in <FIG> and <FIG>.

Continuing to refer to <FIG> and <FIG>, the second planetary gear assembly <NUM> includes a pinion gear <NUM>, three planetary gears <NUM>, the common ring gear <NUM>, a carrier plate which, in this exemplary embodiment, is the proximal end portion <NUM> of the lead drive shaft <NUM>, and gear shafts <NUM>. The pinion gear <NUM> is attached to a gear shaft <NUM> inserted into mounting hole <NUM> in the carrier plate <NUM> and extending from a side of the carrier plate <NUM> that is opposite the planetary gears <NUM>. The planetary gears <NUM> are attached to gear shafts <NUM> inserted into mounting holes <NUM> in the proximal end portion <NUM> of the lead drive shaft <NUM> and extending from one side of the proximal end portion <NUM> of the lead drive shaft <NUM> so that the planetary gears <NUM> are rotatable relative to their corresponding gear shaft <NUM>. The gear shafts <NUM> are arranged on the proximal end portion <NUM> of the lead drive shaft <NUM> so that the planetary gears <NUM> are spaced apart and independent of each other. The proximal end portion <NUM> of the lead drive shaft <NUM> is positioned adjacent a top portion 406b of the ring gear <NUM> so that the teeth of the planetary gears <NUM> are within the drive assembly housing <NUM> and intermesh with the teeth of the top portion 406b of the ring gear <NUM>, as seen in <FIG> and <FIG>. The pinion gear <NUM> is positioned within the ring gear <NUM> between the planetary gears <NUM> so that the teeth of the pinion gear <NUM> intermesh with the teeth of the planetary gears <NUM>, as seen in <FIG>, <FIG> and <FIG>.

As noted, the proximal end portion <NUM> of the lead drive shaft <NUM> is secured within the drive assembly housing <NUM> by the bearing system <NUM>, the gear assembly <NUM> and the drive housing adapter <NUM> of the drive assembly housing <NUM>, seen in <FIG> and <FIG>. The drive housing adapter <NUM> is secured to a proximal end portion 302b of the drive assembly housing <NUM> by a mechanical connection. In the exemplary embodiment shown, the mechanical connection is a threaded connection, where threading <NUM> on the drive housing adapter <NUM> is screwed into threading <NUM> in the drive assembly housing <NUM>, seen in <FIG>, <FIG> and <FIG>. However, other mechanical connections are contemplated, including snap-fit and press-fit connections where the drive housing adapter <NUM> is snapped or pressed within the drive assembly housing <NUM>. Set screw connections where set screws secures the drive housing adapter <NUM> to the drive assembly housing <NUM> and welds are also contemplated. A first sealing member similar to the sealing member <NUM> shown in <FIG>, may be positioned within the aperture <NUM> in the drive housing adapter <NUM> to seal the connection between motor <NUM> and the drive housing adapter <NUM>. A non-limiting example of a suitable first sealing member is an O-ring. Similarly, a second sealing member (not shown) may be positioned on the lip portion <NUM> adjacent the threading <NUM> of the drive housing adapter <NUM> to further seal the connection between motor <NUM> and the drive housing adapter <NUM>. A non-limiting example of a suitable second sealing member is an O-ring.

Referring now to <FIG>, <FIG>, <FIG> and <FIG>, another exemplary embodiment of a bearing system according to the present disclosure is shown. The bearing system <NUM> is provided so that the drive assembly <NUM> can withstand radial and axial (or thrust) loads as the lead drive shaft <NUM> is rotated during an operation of the tool <NUM>. The bearing system <NUM> is positioned on the intermediate portion <NUM> of the lead drive shaft <NUM> with a portion within the bearing compartment <NUM> of the drive assembly housing <NUM> and a portion in the thrust bearing compartment <NUM> of the drive assembly housing.

In the exemplary embodiment shown, the bearing system <NUM> includes a radial bearing <NUM> and a thrust bearing assembly <NUM>. The radial bearing <NUM> is provided to withstand radial loads on the lead drive shaft <NUM> as it rotates during an operation of the tool <NUM>. An example of a suitable radial bearing <NUM> is the Koyo Bearing No. BK1010 manufactured by JTEKT North America Corporation. The thrust bearing assembly <NUM> includes an upper thrust washer <NUM>, a lower thrust washer <NUM> and a thrust bearing <NUM> between the upper thrust washer <NUM> and lower thrust washer <NUM>. The thrust bearing assembly <NUM> is provided to withstand axial (or thrust) loads on the lead drive shaft <NUM>, in the direction of arrow "A" seen in <FIG>, as the lead drive shaft rotates during an operation of the tool <NUM>. An example of a suitable thrust bearing assembly <NUM> is the Koyo Bearing No. NTA613 manufactured by JTEKT North America Corporation. The upper thrust washer <NUM> is positioned on the thrust bearing <NUM> and the lower thrust washer <NUM> is positioned on the thrust bearing <NUM> and are provided to hold the thrust bearing <NUM> in position within the thrust bearing compartment <NUM> of the drive assembly housing <NUM>. In addition, the upper thrust washer <NUM> and the lower thrust washer <NUM> also resists and transfers thrust loads to the distal end 302a of the drive assembly housing <NUM>.

The radial bearing <NUM> has a central bore <NUM> with a diameter sufficient to receive the intermediate portion <NUM> of the lead drive shaft <NUM>. The thrust bearing assembly <NUM> has a center bore <NUM>, seen in <FIG>, with a diameter sufficient to receive the intermediate portion <NUM> of the lead drive shaft <NUM>. More specifically, the radial bearing <NUM> is press fit into the radial bearing compartment <NUM> of the drive assembly housing <NUM> so that the radial bearing <NUM> can receive the intermediate portion <NUM> of the lead drive shaft <NUM> , as seen in <FIG> and <FIG>. The thrust bearing <NUM> rests on the proximal end portion <NUM> of the lead drive shaft <NUM> within the thrust bearing compartment <NUM> of the drive assembly housing <NUM>, as seen in <FIG> and <FIG>.

It is noted that an additional structure or an additional radial bearing (not shown) may be used to address radial loading or leaning at the distal end portion <NUM> of the lead drive shaft <NUM>, especially under a full load of the jaw drive member <NUM> movably attached to the lead drive shaft <NUM>. For example, such additional structure may be the stabilizing roller <NUM>, seen in <FIG>, that engages the surface <NUM> of the jaw drive member <NUM> described above. The stabilizing roller <NUM> opposes the force applied by the cam roller <NUM> to the jaw drive member <NUM> to provide additional stability to the distal end portion <NUM> of the lead drive shaft <NUM> as the second jaw assembly <NUM> moves toward the first jaw assembly <NUM> when crimping a wire termination positioned between the first and second jaw assemblies during an operation of the tool <NUM>.

Referring to <FIG> and <FIG>, the bearing system <NUM> may include a second thrust bearing assembly <NUM>. The second or upper thrust bearing assembly <NUM> includes an upper thrust washer <NUM>, a lower thrust washer <NUM> and a thrust bearing <NUM> between the upper thrust washer <NUM> and lower thrust washer <NUM>. The thrust bearing assembly <NUM> is provided to withstand axial (or thrust) loads on the lead drive shaft <NUM>, in the direction of arrow "B" seen in <FIG>, as the lead drive shaft rotates during an operation of the tool <NUM>. An example of a suitable second thrust bearing assembly <NUM> is the Koyo Bearing No. NTA613 manufactured by JTEKT North America Corporation. In this exemplary embodiment, the upper thrust washer <NUM> is positioned on the thrust bearing <NUM> and the lower thrust washer <NUM> is positioned on the outer surface 302d of the distal end portion 302a of the drive assembly housing <NUM>. The second thrust bearing <NUM> has a central opening <NUM> configured to receive the intermediate portion <NUM> of the lead drive shaft <NUM> that extends out of the distal end portion 302a of the drive assembly housing <NUM>. The second thrust bearing <NUM> is secured in position on the outer surface 302d of the of the distal end portion 302a of the drive assembly housing <NUM> using a spring washer <NUM> and a retaining ring <NUM> that attaches to a notch <NUM> in the intermediate portion <NUM> of the lead drive shaft <NUM>, as shown.

Referring again to <FIG>, <FIG> and <FIG> and as described above, extending from a proximal end portion 302b of the drive assembly housing <NUM> and operatively coupled to the gear assembly <NUM> is the motor <NUM>. Generally, the motor <NUM> rotates a motor drive shaft <NUM>, seen in <FIG>, that is coupled to the gear assembly <NUM>. The gear assembly <NUM> reduces the rate of rotation of the motor drive shaft <NUM>. The lead drive shaft <NUM> is coupled to the gear assembly <NUM> and rotates at the output rate of the gear assembly. The bearing system <NUM> is provided so that the lead drive shaft <NUM> can withstand radial and axial loads generated during an operation of the jaw assemblies <NUM> and <NUM>. As an example, the motor <NUM> may be configured to rotate the motor drive shaft <NUM> at a rate in the range of about <NUM>,<NUM> rpm and about <NUM>,<NUM> rpm with an output torque in the range of about <NUM> in-lb. and about <NUM> in-lb. In this configuration, the motor current may be in the range of about <NUM> amps and about <NUM> amps, the battery voltage may be in the range of about <NUM> VDC and about <NUM> VDC, and the output motor power may be in the range of about <NUM> watts and about <NUM> watts. The gear assembly <NUM> may reduce the rate of rotation of the motor drive shaft <NUM> to a range of about <NUM> rpm and about <NUM> rpm. As such, the gear ratio of the gear assembly <NUM> may be in the range of about <NUM>:<NUM> and about <NUM>:<NUM>. The output of the gear assembly <NUM> is transferred to the lead drive shaft <NUM>. In this exemplary embodiment, the lead drive shaft <NUM> is a threaded shaft having a diameter in a range of about <NUM> inches and about <NUM> inches, with a lead, e.g., a screw lead, in a range of about <NUM> inches and about <NUM> inches. Under the motor operating configuration described herein above, the efficiency of the gear assembly <NUM> may be in the range of about <NUM> % and about <NUM> %, and the pull force of the lead drive shaft <NUM> may be in the range of about <NUM> lbs. and about <NUM> lbs. Movement of the lead drive shaft <NUM> is transferred to the jaw drive member <NUM>, seen in <FIG>, which as noted above is attached to the lead drive shaft <NUM>. In this exemplary embodiment of the present disclosure, the output of the gear assembly <NUM> is rotational motion which is transferred to the lead drive shaft <NUM>. Rotation of the lead drive shaft <NUM> is translated to linear movement of the jaw drive member <NUM>. With a pull force of the lead drive shaft <NUM> in the exemplary range of about <NUM> lbs. and about <NUM> lbs. , the linear travel distance of the jaw drive member <NUM> may be in the range of about <NUM> inches and about <NUM> inches. Linear movement of the jaw drive member <NUM> moves the second jaw assembly <NUM> toward the first jaw assembly <NUM> when crimping a wire termination positioned between the first and second jaw assemblies. It is noted that with the gear assembly <NUM> reducing the rate of rotation of the motor drive shaft <NUM> to a range of about <NUM> rpm and about <NUM> rpm, the total crimp cycle of the tool <NUM> may be in the range of about <NUM> seconds and about <NUM> seconds.

As another example, the motor <NUM> may be configured to rotate the motor drive shaft <NUM> at a rate in the range of about <NUM>,<NUM> rpm and about <NUM>,<NUM> rpm with an output torque in the range of about <NUM> in-lb. and about <NUM> in-lb. In this exemplary embodiment, the motor current may be in the range of about <NUM> amps and about <NUM> amps, the battery voltage may be in the range of about <NUM> VDC and about <NUM> VDC, and the output motor power may be in the range of about <NUM> watts and about <NUM> watts. The gear assembly <NUM> may reduce the rate of rotation of the motor drive shaft <NUM> to a range of about <NUM> rpm and about <NUM> rpm. As such, the gear ratio of the gear assembly <NUM> may be in the range of about <NUM>:<NUM> and about <NUM>:<NUM>. As noted, the output of the gear assembly <NUM> is transferred to the lead drive shaft <NUM>. In this exemplary embodiment, the lead drive shaft <NUM> is a threaded shaft having a diameter in a range of about <NUM> inches and about <NUM> inches, with a lead, e.g., a screw lead, in a range of about <NUM> inches and about <NUM> inches. Under the motor operating configuration described above the efficiency of the gear assembly <NUM> may be in the range of about <NUM>% and about <NUM>%, and the pull force of the lead drive shaft <NUM> may be in the range of about <NUM> lbs. and about <NUM> lbs. Movement of the lead drive shaft <NUM> is transferred to the jaw drive member <NUM>. In this exemplary embodiment of the present disclosure, the output of the gear assembly <NUM> is rotational motion which is transferred to the lead drive shaft <NUM>. Rotation of the lead drive shaft <NUM> is translated to linear movement of the jaw drive member <NUM>. With a pull force of the lead drive shaft <NUM> in the exemplary range of about <NUM> lbs. and about <NUM> lbs. , the linear travel distance of the jaw drive member <NUM> may be in the range of about <NUM> inches and about <NUM> inches. Linear movement of the jaw drive member <NUM> moves the second jaw assembly <NUM> toward the first jaw assembly <NUM> when crimping a wire termination positioned between the first and second jaw assemblies. It is noted that with the gear assembly <NUM> reducing the rate of rotation of the motor drive shaft <NUM> to a range of about <NUM> rpm and about <NUM> rpm, the total crimp cycle of the tool <NUM> may be in the range of about <NUM> seconds and about <NUM> seconds.

Claim 1:
A drive assembly (<NUM>) for a portable, hand-held tool, the drive assembly comprising:
a drive assembly housing (<NUM>);
a gear assembly (<NUM>) positioned within the drive assembly housing, the gear assembly including a multi-stage planetary gear assembly having at least an input stage and an output stage;
a lead drive shaft (<NUM>) having a distal end portion (130a), a proximal end portion (130b) and an intermediate portion (130c)
between the distal end portion and the proximal end portion, the distal end portion being threaded and substantially outside the drive assembly housing, and the intermediate portion has a smooth exterior surface; and
a bearing system (<NUM>) positioned at least partially within the drive assembly housing, the bearing system being interactive with the lead drive shaft enabling the drive assembly to withstand radial and axial loads as the lead drive shaft is rotated during an operation of the tool.