BACKGROUND OF THE INVENTION
The present invention generally relates to crimping machines, and more particularly to their construction and methods for their manufacture and use.
There are various configurations for crimping machines (“crimpers”) and methods for their manufacture. Three such configurations are referred to herein as round head-type, scissor-type, and press-type crimpers, nonlimiting representations of which are depicted in FIGS. 1, 2 and 3, respectively. These types of crimpers have found uses in crimping various hardware, including crimping operations performed to attach fittings on conduits, which as used herein refers to any hose, tube, pipe, or other type of conduit adapted to transport a fluid (liquid or gas) or protect hardware, for example, electrical wiring or other line-like articles susceptible to damage. Because crimpers are often required to apply high forces during crimping, their typical construction typically entails large, high-strength structural components. As examples, the round head-type crimper of FIG. 1 comprises a large one-piece annular-shaped outer frame 12 that surrounds and supports crimping shoes 14 that apply the crimping force, the scissor-type crimper of FIG. 2 comprises a large one-piece outer frame 16 and an inner cradle or block 18 that are each machined from solid steel plates and together apply the crimping force, and the press-type crimper of FIG. 3 comprises upper and lower bases 20 and 22 that are each machined from solid steel plates and support dies (not shown) that apply the crimping force.
The configurations of the outer frame 16 and inner block 18 of the scissor-type crimper of FIG. 2 produced by machining can be better appreciated from the isolated view of these components in FIG. 4. The frame 16 and inner block 18 support a die carrier assembly 24 comprising die carriers 27, and closing of the die carrier assembly 24 is the result of the inner block 18 being actuated upward by an actuator assembly 26, causing intermediate master dies or shoes 28 to collapse toward each other for the purpose of diametrically crimping two components together, such as a fitting onto a conduit. The actuator assembly 26 is located below the block 18 and die carrier assembly 24 and is adapted to raise and lower the block 18 toward the upper end of the frame 16. Actuation is typically with hydraulic power, such as a hydraulic cylinder, though mechanical actuation or some other means of actuation can be used. Those skilled in the art will appreciate that various other types of dies and adapters can be assembled to the die carrier assembly 24 in order to adapt the crimper for crimping different types and sizes of components.
Traditional types of crimpers of the types represented in FIGS. 1-4 may have various shortcomings. As an example, individual steel plates machined to produce the outer frame 16 and inner block 18 of the scissor-type crimper of FIGS. 2 and 4 can be costly to purchase, and machining the plates can be difficult because of their size and weight and the awkward locations of certain machined areas on the frame 16 and block 18, for example, side rails 30 of the outer frame 16 and flanges 32 of the inner block 18 that slidably engage each other. When machining the frame 16 and block 18 of a traditional scissor-type crimper, machining errors may cause either of these components to be unusable, which can be very costly in terms of materials and processing. Similar challenges exist for round head-type and press-type crimpers of the type shown in FIGS. 1 and 3. For example, the outer frame 12 of the round head-type crimper of FIG. 1 can be difficult to manufacture, as the frame 12 must be machined to create cavities in which actuators (not shown) are disposed for actuating the crimping shoes 14.
The crimpers represented in FIGS. 1-4 can also have operational limitations. As an example, the crimping diameter of the scissor-type crimper of FIGS. 2 and 4 is limited by the extent to which the block 18 is able to travel within the outer frame 16. The inner block 18 moves up and down within an interior area 34 formed by machining on opening in the steel plate used to form the outer frame 16. Though a larger interior area 34 provides for a larger opening diameter of the die carrier assembly 24, the size of the interior area 34 also affects the overall strength of the frame 16, and therefore structural limitations of the frame 16 also limit the size and opening diameter of the die carrier assembly 24.
Accordingly, there is a need for crimpers capable of alleviating the above shortcomings, yet are also capable of providing reliable operation to produce commercially acceptable crimped products.
BRIEF DESCRIPTION OF THE INVENTION
The present invention provides crimping machines, including particular constructions thereof and methods for their manufacture and use.
According to one aspect of the invention, a crimping machine includes at least a first load-bearing component that comprises a plurality of load-bearing laminates that are assembled and secured together. The first load-bearing component is installed in the crimping machine so that a crimping load of the crimping machine is imposed on the first load-bearing component during a crimping operation performed by the crimping machine.
According to another aspect of the invention, a method is provided that includes producing at least a first load-bearing component by assembling and securing together a plurality of load-bearing laminates. The first load-bearing component is installed in a crimping machine, and a crimping operation is performed with the crimping machine by applying a crimping load that is imposed on the first load-bearing component.
A technical effect of the invention is the ability to provide a crimping machine that is less expensive than traditional methods requiring the purchase and machining of large plates. Relative complex features can be more readily machined in relative thin load-bearing laminates, and machining errors resulting in scrappage of a laminate are less costly as compared to machining errors that necessitate scrappage of a much larger plate. For embodiments of scissor-type crimpers that include an outer frame and inner block, each of these components can be manufactured as a load-bearing component that includes spacer laminates between or among the load-bearing laminates. In addition, the load-bearing and spacer laminates within the outer frame and inner block can be interdigitated or otherwise arranged in a manner that enables the crimper to have increased opening and closing distances as compared to a traditional scissor-type crimper having an interior area of the same dimensions.
Other aspects and advantages of this invention will be better appreciated from the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1, 2, and 3 schematically represent examples of round head-type, scissor-type, and press-type crimpers known in the art.
FIG. 4 schematically represents an outer frame and inner block of the scissor-type crimper of FIG. 2.
FIGS. 5 and 6 are perspective views schematically representing opposite sides of an inner block subassembly assembled with an outer frame subassembly for use in construction of, respectively, a laminate inner block and a laminate outer frame of a scissor-type crimper.
FIG. 7 is a perspective view schematically representing a laminate outer frame constructed of a plurality of outer frame subassemblies of the type represented in FIGS. 5 and 6, and FIG. 8 is an exploded view of the outer frame of FIG. 7.
FIG. 9 is a perspective view schematically representing a laminate inner block constructed of a plurality of inner block subassemblies of the type represented in FIGS. 5 and 6, and FIG. 10 is an exploded view of the inner block of FIG. 9.
FIG. 11 is a perspective view schematically representing the laminate inner block of FIG. 9 assembled and integrated with the laminate outer frame of FIG. 7 to yield a block and frame assembly, and FIG. 12 is an exploded view of the assembly of FIG. 11.
FIG. 13 is a perspective view schematically representing the block and frame assembly of FIG. 11 further assembled with additional components to yield a scissor-type crimper.
FIG. 14 is a perspective view showing a press-type crimper comprising laminate bases that are each constructed of a plurality of load-bearing laminates, and FIG. 15 is an exploded view of the laminate bases of FIG. 14.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides various types of crimping machines (crimpers) that can be manufactured to have at least one component that is an assembly of individual sheets, plates or plies (hereinafter, laminates) that are assembled and secured together to form a laminate assembly. The invention will be primarily discussed hereinafter in reference to a scissor-type crimper, such as of the type shown in FIGS. 2 and 4. However, it will be appreciated that the teachings of the invention are more generally applicable to various types of crimpers, such as, but not limed to, the round head-type and press-type crimpers of FIGS. 1 and 3. The following discussion will focus primarily on certain aspects of crimpers that differ from the crimpers of FIGS. 1 through 4, and other aspects not discussed in any detail may be, in terms of structure, function, materials, etc., essentially as was described for the crimpers of FIGS. 1 through 4. To facilitate the description of disclosed embodiments of the invention provided below, relative terms, including but not limited to, “vertical,” “horizontal,” “lateral,” “front,” “rear,” “side,” “forward,” “rearward,” “upper,” “lower,” “above,” “below,” “right,” “left,” etc., may be used in reference to the orientation of the various views in FIGS. 5 through 15, and therefore are relative terms and should not be otherwise interpreted as limitations to the construction, installation, operation or use of a crimper.
FIG. 13 schematically represents a scissor-type crimper 40 comprising an outer frame 46 and inner cradle or block 48 assembled with the frame 46 and adapted to cooperate with the frame 46 to apply a crimping force therebetween. As such, the frame 46 and block 48 are both load-bearing components of the crimper 40. The frame 46 and block 48 yield a block and frame assembly 50 (FIG. 11), which is shown in FIG. 13 as further assembled with additional components to yield the scissor-type crimper 40. In particular, the frame 46 and block 48 support a die carrier assembly 42, and closing of the die carrier assembly 42 is the result of the block 48 being actuated by an actuator assembly 44, causing intermediate master dies or shoes of the die carrier assembly 42 to collapse toward each other for the purpose of diametrically crimping two components together, such as a fitting onto a conduit. The actuator assembly 42 can be of any suitable type, including but not limited to a hydraulic cylinder or a mechanical actuator. The crimper 40 is not limited to the type of die carrier assembly 42 depicted in FIG. 13, and various types of dies and adapters can be assembled to the die carrier assembly 42 in order to adapt the crimper 40 for crimping different types and sizes of components.
As evident from FIGS. 11 through 13, the outer frame 46 and inner block 48 of the block and frame assembly 50 are each an assembly of individual laminates, and as such may be referred to as a laminate outer frame 46 and a laminate inner block 48. As represented in FIGS. 7 and 8, the outer frame 46 is preferably constructed of a plurality of outer frame subassemblies 52 and, as represented in FIGS. 9 and 10, the inner block 48 is preferably constructed of a plurality of inner block subassemblies 54. FIGS. 5 and 6 represent a single inner block subassembly 54 assembled with a single outer frame subassembly 52. As evident from FIGS. 5 and 6, each subassembly 52 and 54 is made up of multiple individual laminates 56 and 58 having different functions. The laminates 56 will be referred to herein as load-bearing laminates 56 that are configured to contact or otherwise apply the crimping force to the die carrier assembly 42 and therefore bear the crimping load during a crimping process. The other laminates 58 will be referred to herein as spacer laminates 58 whose function is to appropriately and reliably position and space the load-bearing laminates 56 relative to each other.
In the embodiment of FIGS. 5 and 6, the load-bearing laminate 56 of the inner block subassembly 54 entirely defines the outermost perimeter 60 of the subassembly 54, and is essentially continuous within this perimeter 60, whereas a spacer laminate 58 defines, at most, only portions of the perimeter 60 and is not continuous throughout the extent surrounded by the perimeter 60. Instead, the spacer laminate 58 lies entirely within the perimeter 60 of the block subassembly 54 defined by the load-bearing laminate 56, is entirely superimposed by the load- bearing laminate 56 of the subassembly 54, and is set back (recessed) from at least a portion of the perimeter 60 to define a gap 76 between two immediately-adjacent load-bearing laminates 56 (FIG. 9). Similarly, the load-bearing laminate 56 of the outer frame subassembly 52 entirely defines innermost and outermost perimeters 61 and 62 of the subassembly 52, and is essentially continuous between these perimeters 61 and 62, whereas multiple spacer laminates 58 define, at most, only portions of the perimeters 61 and 62 and are not continuous therebetween. Instead, the multiple spacer laminates 58 lie entirely within the perimeters 61 and 62 of the outer frame subassembly 52 defined by the load-bearing laminate 56, defining an arrangement of spacer laminates 58 that are entirely superimposed by the load-bearing laminate 56 of the subassembly 52, with portions of the spacer laminates 58 being set back (recessed) from at least a portion of each perimeter 61 and 62 to define gaps 74 (FIG. 7) between two immediately-adjacent load-bearing laminates 56.
As a result of the arrangements of the load-bearing and spacer laminates 56 and 58 described above, surfaces 64 of the load-bearing laminate 56 of the outer frame subassembly 52 remain exposed by its corresponding spacer laminates 58, and surfaces 66 of the load-bearing laminate 56 of the inner block subassembly 54 remain exposed by its spacer laminate 58. At least portions of these surfaces 64 and 66 are adapted to contact each other during movement of the inner block 48 within an interior area 68 of the outer frame 46 defined by its innermost perimeter 61. From FIGS. 5 through 12 and the completed block and frame assembly 50 of FIGS. 11 and 13, it can be appreciated that the spacer laminates 58 are interleaved with the load-bearing laminates 56, such that portions of the exposed surfaces 64 and 66 are disposed on frame and block flanges 70 and 72, respectively (FIG. 5), of adjacent pairs of load-bearing laminates 56, and the aforementioned gaps 74 and 76 are defined between the flanges 70 and 72 (FIGS. 7 and 9). By placing the flanges 70 of the frame 46 within the gaps 76 of the block 48 and placing the flanges 72 of the block 48 within the gaps 74 of the frame 46, thus preferably interdigitating the frame and block flanges 70 and 72, the block 48 is slidably secured to the frame 46. In effect, the frame flanges 70 functionally perform the role of the traditional side rails 30 and the block flanges 72 functionally perform the role of the traditional flanges 32 of FIGS. 2 and 4. As evident from FIGS. 11 and 13, crimping forces are applied in a direction parallel to the plane of each load-bearing laminate 56. Because the load-bearing laminates 56 define the perimeters 60, 61 and 62 of the outer frame 46 and inner block 48, the crimping load imposed on a load-bearing laminate 56 is parallel to the plane of the laminate 56 and, at most, may be distributed between load-bearing laminates 56 through contact with shared spacer laminates 58.
As represented in FIGS. 7 through 13, fasteners 78 can be used to secure multiple outer frame subassemblies 52 together to form the outer frame 46 and to secure multiple inner block subassemblies 54 together to form the inner block 48. However, it should be understood that the frame 46 and block 48 could be held together by other means.
As should be evident from FIG. 13, the above-described combinations of load-bearing laminates 56 and spacer laminates 58 used to manufacture the load-bearing outer frame 46 and inner block 48 enable the crimper 40 to have a similar appearance and to essentially function in the same manner as the scissor-type crimper represented in FIG. 2. A laminate construction can be employed to construct other types of crimpers. For example, FIGS. 14 and 15 represent a press-type crimper 80 having load-bearing bases 82 and 84 with a laminate construction. The bases 82 and 84 are not required to be assembled in an interdigitated manner, in which case the spacer laminates 58 of the prior embodiment can be omitted, such that each base 82 and 84 is shown as entirely constructed of load-bearing laminates 56. Because crimping forces are applied in a direction normal to the plane of each base 82 and 84, the laminates 56 primarily promote the ability of the bases 82 and 84 to resist flexing out of their respective planes.
Crimpers manufactured from laminates 56 and (optionally) 58 as described above benefit from the ability to more readily handle and machine the thinner laminates 56 and 58 as compared to a solid plate of a size equivalent to a laminate component (e.g., outer frame 46 or inner block 48) constructed of the laminates 56 and 58. The material for the laminates 56 and 58 can also be less expensive to purchase than an equivalent-sized solid plate. The construction from interleaved laminates 56 and 58 also facilitates machining various features that are more difficult with an equivalent-sized solid plate, for example, the side rails 30 of the outer frame 16 and the flanges 32 of the inner block 18 of the conventional scissor-type crimper of FIGS. 2 and 4.
A round head-style crimper (FIG. 1) can also benefit from being manufactured from laminates 56 and/or 58, as the material costs, machining, and assembly of the laminates 56 and 58 to produce the annular-shaped outer frame 12 can be less extensive than the conventional approach of producing the frame 12 by casting and machining.
Crimpers manufactured from laminates 56 and 58 as described above also benefit from the ability to reduce the costs associated with errors during manufacturing. For example, if an error occurs during the machining of a spacer or load-bearing laminate 56 and 58, only a small subcomponent (e.g., the laminate 56 or 58) of the intended component (e.g., frame 46 or block 48) need be scrapped or remanufactured, avoiding the cost incurred to scrap and replace an entire equivalent-sized solid plate.
In terms of operation, crimpers manufactured from laminates 56 and 58 as described above also benefit from the interdigitated frame and block flanges 70 and 72 replacing the side rails 30 and flanges 32 of the conventional scissor-type crimper of FIGS. 2 and 4. Because the flanges 70 and 72 of the load-bearing laminates 56 of the frame 46 and block 48 are able to slide within the gaps 74 and 76 between the flanges 70/72 of the other, the crimper 40 can have a greater opening and closing distance when compared to a traditional scissor-type crimper of the same dimensions, for example, the same interior area 68 within the inner perimeter 61 of the outer frame 46. This aspect is significant because it can reduce overall size, weight, and cost of material and/or allow a larger crimping die open diameter as compared to a traditional scissor-type crimper.
A variation of the techniques described above could be to manufacture either but not both of the frame 46 and block 48 from the laminates 56 and 58. It should be further noted that, aside from the desire to interdigitate to some extent the load-bearing laminates 56 of the frame 46 and block 48, there are no set number, thicknesses, materials, or arrangements required of the laminates 56 and 58, other that what would be prescribed by conventional engineering principles. Furthermore, it is foreseeable that additional components could be incorporated into a laminate component (for example, the frame 46 and/or block 48) within the scope of the invention, including but not limited to laminates that might not be described as spacer or load-bearing laminates as these terms are used herein.
In view of the above, while the invention has been described in terms of particular embodiments, it is apparent that other forms could be adopted by one skilled in the art. Therefore, the scope of the invention is to be limited only by the following claims.
Patent Application
20140352130
