The present invention relates to an apparatus for attaching safety cables to releasable fasteners and, more particularly, to an adaptable apparatus for tensioning, locking and terminating safety cables.
Various types of machinery are subject to vibration that can loosen nuts and bolts. Safety wire has long been used as protection to resist such loosening. In such use, safety wire secures two or more parts together so that loosening of one part is counteracted by tightening of the wire. Typically, a single wire is passed through an aperture in a nut or bolt, the free ends twisted together up to another part, one of the ends inserted through an aperture in the another part and the ends again twisted. The standards for utilization of safety wire are critical and are set forth in Aerospace Standard AS567, entitled “General Practices for the Use of Lockwire, Key Washers and Cotter Pins,” available from the Society of Automotive Engineers, Inc., 400 Commonwealth Dr., Warrendale, Pa.
Safety wire or lockwire, as it is sometimes known, has several known problems. More recently, there has been developed an improved locking system using safety cable. Safety cable is a stranded cable having a termination on one end allowing the cable to be pulled to a predetermined tension through the aforementioned apertures in nuts and bolts. After tensioning, the free end of the cable must be terminated to hold the tension and cleanly severed to minimize any possibility of snags on loose wires. One such tool to perform this operation is commercially available under the trade name “Safe-T-Cable™” from the assignee of the current application, Daniels Manufacturing Corporation, and is described in U.S. Pat. No. 5,345,663.
Safety cable is utilized on bolts and fasteners that are often located in cramped or minimally accessible locations. Accordingly, it is also desirable to provide a tool which is modular to provide interchangeable tool lengths and is reduced in size to access cramped locations. Further, in typical applications, the installation of safety wire involves a considerable amount of time and manual operation of a tool, resulting in operator fatigue. Accordingly, it is desirable to provide a tool where the required hand force to operate the tool is reduced.
A tool for tensioning safety cable to a mechanically set tension limit and for terminating the cable when the cable has been tensioned to the mechanically set limit is described herein as including a manual actuator for gripping and pulling the cable to the tension limit, and a hydraulically assisted actuator for crimping a ferrule onto the cable when the tension limit has been reached, the hydraulically assisted actuator being operative to sever a free end of the cable concurrently with crimping of the ferrule. The toll may also include a tensioning wheel for retaining cable wrapped around the wheel and allowing tension to be applied to the cable by manual rotation thereof, and a clutch for transferring a rotational force to the wheel, the clutch preventing rotational force from being applied to the wheel when a predetermined cable tension has been reached. The tool may further include a plunger for progressively crimping the ferrule as the hydraulically assisted actuator is operated and a shearing edge, operative in conjunction with a ferrule edge, for severing the free end of the cable as the ferrule edge is forced past the shearing edge by the plunger as the ferrule is being crimped.
The features and advantages of the present invention will become apparent from the following detailed description of the invention when read with the accompanying drawings in which:
The cable tensioner assembly 30 will now be described in further detail with respect to
On the body side 110 of the wheel 82, the surface of the wheel 82 has a flat portion 113 extending radially away from the axle 90, then the surface assumes a sloping profile 114 extending from the flat portion 113 to a rim 81 of the wheel 82. The flat portion 113 is configured to allow attaching a faceplate 86 thereto, with, for example, screws 136. An attachment portion 88 of the faceplate 86 is a raised cylindrical platform having a height perpendicular to a face 87 of the faceplate 86. In an aspect of the invention, the height may be slightly smaller than the diameter of the safety cable 12. When the faceplate 86 is attached to the wheel 82, the face 87 of the faceplate 86 and the sloping profile 114 forms a gripping slot 115 tapering to a relatively smaller width toward the axle 90. Accordingly, the sloping profile 114 acts to wedge a safety cable 12 wrapped circumferentially in the gripping slot 115, thereby retaining the cable 12 so that tension can be applied by rotating the knob 80.
The axle 90 includes an axle bore 92 open on the axle end 102 and intersecting radial passageways 94 extending from the axle bore 92 radially outward and opening at the rim 81 of the wheel 82. The axle bore 92 is partially internally threaded on the axle end 102 to accommodate a threaded adjustment screw 100. Elongated clutch tensioning force pins 116 are slidingly installed in the radial passageways 94 so that an end 121 of the clutch tensioning force pin 116 protrudes from the rim 81 of the wheel 82, and the other end 117 protrudes into the axle bore 92. In an aspect of the invention, the end 121 of the clutch tensioning force pin 116 may be hemispherically shaped. A spring actuator 98, having an angled tip 99, such as a 45 degree chamfer, is positioned in the bore 92 so that the angled tip 99 contacts the ends 117 of the tensioning force pins 116 extending radially into the bore 92. In an aspect of the invention, the ends 117 may be angled, such as with a 45 degree chamfer, to complementarily abut the angled tip 99 of spring actuator 98. A compression spring 96 followed by an adjustment screw 100 (forming an adjustable spring seat) are positioned in the bore 92 to adjustably maintain an axial force on the spring actuator 98 that is transferred, by the angled tip 99 of the spring actuator 98, to a radial force acting radially outward on ends 117 of the clutch tensioning force pins 116.
The clutch ring 84 fits rotatably around the rim 81 of the wheel 82 and, as more clearly shown in
In one form, the spring actuator 98 may have a 45 degree conical tapered end to contact the ends of the tensioning force pins 116 positioned within the axle bore 92. In another aspect, the ends of the tensioning force pins 116 positioned within the axle bore 92 may have a 45 degree conical taper corresponding to the 45 degree conical taper of the spring actuator 98. The longitudinal force applied to the respective ends of the tensioning force pins 116 positioned within the axle bore 92 is then transferred to the indentations 120 in the clutch ring 84, resulting in increased tensioning force required to force the ends of the tensioning force pins 116 from respective indentations 120. Accordingly, the clutch tensioning force pins 116, the spring actuator 98, the compression spring 96, and adjustment screw 100 comprise, with clutch tensioning force wheel 82, the tension setting means for controlling tension in cable 12.
The clutch ring 84 also includes lateral grooves 124 formed in the outside diameter for installing knob mounting pins 118. The clutch ring 84 and wheel 82 fit within a circular recess 122 formed in one side of the knob 80. The knob 80 includes lateral grooves 125 on the inside diameter of the recess 122 corresponding to the lateral grooves 124 on the clutch ring 84 to tangentially fix the clutch ring 84 within the recess 122 by inserting appropriately sized pins 118 into the grooves 124,125 when the clutch ring 84 and wheel 82 are installed. Accordingly, the knob 80 can move coaxially with respect to the elongate axis of the axle 90 as can be seen in
In an aspect of the invention depicted in
When sufficient tension is applied to a cable 12 wrapped around the tensioner assembly 30, the clutch ring 84 and, correspondingly the knob 80, will slip around the rim 81 of wheel 82 by forcing the ends 121 of the clutch tensioning force pins 116 out of the indentations 120 in the clutch ring 84. Accordingly, when the proper tension has been applied to the cable 12, further tensioning of the cable 12 is prevented by allowing the knob 80 and clutch ring 84 to slip tangentially about the clutch tensioning force wheel 82.
The nose 32 of the tool will now be described in further detail with respect to
In one aspect of the invention, the proximal end of the nosepiece 22 has two alignment ears 38 configured to slidably interlock with flat portions 40 of the indenter 34 to align the plunger assembly 33 in a fixed angular orientation with respect to the aperture 21 of the nosepiece 22 for proper crimping of the ferrule 20. The proximal end of the nosepiece 22 is externally threaded to mate with internal threads on a nose extension 52 so that the nosepiece 22 can be screwed into the distal end of the nose extension 52.
Returning now to
The nose extension 52 includes a passageway 53, extending from the distal end to the proximal end, wherein the internal diameter of the passageway 53 is slightly larger than the outside diameter of the pushrod 44 to allow reciprocal movement of the pushrod 44 when the pushrod is assembled within the nose extension 52. As previously described, the distal end of the nose extension 52 is threaded to receive the complementarily threaded proximal end of the nosepiece 22. The proximal end of the nose extension 52 includes a circumferentially enlarged cylindrical head 64 to provide a contact surface 63 for the compression spring 56, and a flange 65 to prevent the nose extension 52 proximal end from being forced out of the tool body 28 when the plunger assembly 33 is activated. In addition, the head 64 is radially bored and tapped to accommodate a setscrew 54 for reciprocally retaining the push rod 44 at the waist 50 when the pushrod 44 is installed in the nose extension 52. The set screw 54 is screwed in so that the end of the set screw 54 is just short of touching the waist 50 of the push rod 44. Accordingly, the plunger assembly 33 is restrained within the nosepiece assembly 62 by the set screw's 54 interference with the waist 50 of the pushrod 44.
The compression spring 56 and spring washer 58 are held in biased engagement against the head 64 of the nose extension 52 by the adjustment barrel 60 and the push rod 44, threaded into the adjustment barrel 60 so that the spring 56 urges the plunger assembly 33 in a direction away from the aperture 21. As a result, the longitudinal position of the plunger assembly 33 with relation to the nosepiece assembly 62 can be adjusted by threading the push rod 44 in and out of the adjustment barrel 60. Accordingly, the depth of a crimp in the ferrule can be controlled by adjusting the effective length of the plunger assembly 33, so the indenter 34 is adjusted to extend further distally to create a deeper crimp, or is adjusted to extend proximally to create a shallower crimp. To facilitate adjustments, the adjustment barrel 60 is radially bored with a series of openings 66 around the circumference of the adjustment barrel 60 near the proximal end to allow insertion of a longitudinal member (not shown). The longitudinal member can be inserted radially into one of the openings 66 to rotate the adjustment barrel 60 (threading the barrel onto or away from the pushrod 44) to perform plunger assembly positioning adjustments, such as to compensate for wear or manufacturing tolerance.
The plunger assembly 33 and the nosepiece assembly 62 are assembled into the nose 32 as described below. The proximal end of the nose 32 is inserted into the body 28 at the nose assembly opening 68 so that the head 64 of the nose extension is entirely inserted within the body 28. A nose collar 72, bored with an aperture 76 to allow the distal end of the nose extension 52 to pass through is installed over the nose extension 52 to slidably retain the proximal end of the nose 32 within the body 28 at the flange 65. The aperture 76 can be circumferentially grooved to allow biased mounting of an appropriately sized o-ring 74 to support the shaft of the nose extension 52 as it passes through the aperture 76. Once the nose collar 72 is installed over the nose extension 52 and the proximal end of the nose 32 is inserted in the body 28, the collar 72 is screwed to the body 28 with screws 78. Accordingly, the nose 32 can be rotated about an elongate axis by depressing the nosepiece 22 in a direction to compress the spring 56 to disengage the flange 65 from frictional contact with the nose collar 72 and allow the nose 32 to be rotatably positioned at a desired orientation. Advantageously, removal and replacement of the nose 32, such as to install a different sized nosepiece 62, can be easily accomplished by removing the nose collar 72 and installing another nose 32.
The body 28 is adapted to be mounted on a hydraulically operated base tool 26 to actuate the plunger assembly 33. Generally, the base tool 26 includes a piston 27, mounting ears 25, a hydraulic reservoir 27A, a pump lever 26A and a release lever 26B. The piston 27 is actuated by repeatedly operating the pump lever 26A, and the hydraulic pressure applied to the piston 27 is released by operating the release lever 26B. The release lever 26B causes hydraulic fluid built up behind the piston 27 during actuation to be drained off, releasing pressure on the piston 27 and allowing the piston 27 to be returned to a retracted position, such as by the spring 56 acting on the adjustment barrel 60 urging the piston 27 to the retracted position after the release lever 26B is activated. In an aspect of the invention, the body 28 is configured to be attached to the mounting ears 25 of the base tool 26 so that the body 28 is held in fixed relation to the base tool, and the piston 27 operates coaxially with the elongate axis of the nose assembly to apply force along the elongate axis of the plunger assembly 33. Accordingly, when the body 28 of the safety cable tool 10 is mounted on the hydraulically operated base tool 26, the crimping of the ferrule 20 and severing of the cable 12 is accomplished by operating the pump lever 26A of the base tool. In another aspect of the invention, the piston 27 travel is limited, for example by a stop within the base tool 26, so that the piston 27 is prevented from pushing the indenter 34 too far into the nose 32 and keeps the spring 56 from being over compressed.
While the invention has been described in what is presently considered to be a preferred embodiment, various modifications and variations will become apparent to those skilled in the art. It is intended therefore that the invention not be limited to the specific disclosed embodiment but be interpreted within the full spirit and scope of the appended claims.