1. Field of the Invention
The invention relates in general to methods and devices for mounting an electrical contact to an insulated multi-strand or single strand wire and, more particularly, embodiments of the present invention relate to improvements in methods and devices for mounting contacts onto insulated multi-strand and single strand wires by indenting the contact into the multi-strand or solid wire to form an electrical contact, and crimping the contact around the insulation to form an hermetic seal between the insulation and the contact in one crimping cycle.
2. Description of the Prior Art
Multi-strand and single strand aluminum alloy wires have been widely used for various electrical wiring purposes, and recently in aircraft and aerospace applications where a reduction in the weight of the wiring is achieved by such use. Solid or multi-strand aluminum wires typically include a core of aluminum alloy metal strand(s) surrounded by a coating of flexible electrical insulation material. Aluminum and its alloys, for example, are typically susceptible to corrosion if the coating of insulation is broken. The insulation is always broken when the wires are cut to allow joinder to various fittings and contacts. The multi-strand and solid wire core projects beyond the cut insulation to permit direct electrically conductive connection with the contact. Such contacts typically are in the form of a pin that is adapted to plug into a socket to complete a desired circuit. It has been recognized that the connections between wires, particularly aluminum wires, and contacts should be made in such a way that the cut end of the coating is hermetically sealed to the electrical contact. This prevents moisture from entering the cut end and causing corrosion of the metal core. To this end, electric contacts for multi-strand and solid core electrical wires are typically designed so that a dual crimping action is required to mount them. One crimping action seals the contact to the coating of insulation, and another crimping action (indenting) forms the electrical connection between the metal core and the contact. Tools to accomplish this dual crimping action, particularly hand tools, had been previously proposed. See, for example, Kelly et al. US 2004/0072378, Pub. Apr. 15, 2004. Dual crimping of multi-strand electrical wires where hermetic sealing is not expected had been proposed. See, for example, Klemmer et al. U.S. Pat. No. 5,415,015, and Ohsumi et al. U.S. Pat. No. 6,782,608. Previous expedients were generally less than completely satisfactory because the crimp formed seals between the coating and the contact often failed. Also, the previous crimping equipment was generally time consuming to work with because it was difficult and time consuming to change crimping dies to accommodate different gauges of wire, crimper tool malfunctions, or the like. Such previous equipment was generally incapable of accommodating a full range of wire gauges with one tool. “Single wire gauge” crimp tools of various designs had been proposed. See, for example, Fischer U.S. Pat. No. 3,713,322 (four radially opposed dies actuated by a rotatable cam for crimping a contact to a multi-strand wire).
Those concerned with these problems recognize the need for an improved dual crimping tool.
The present invention has been developed in response to the current state of the art, and in particular, in response to these and other problems and needs that have not been fully or completely solved by currently available crimping tools. Thus, it is an overall object of the present invention to effectively resolve at least the problems and shortcomings identified herein. In particular, it is an object of the present invention to provide a crimper tool wherein a crimping die holder is configured for quick and easy insertion and removal in a base unit. It is also an object of the present invention to provide a crimper tool that crimp forms a reliable hermetic seal between a contact and the insulative coating on a single or multi-strand core wire. It is a further object of the present invention to provide a crimper tool with an adjustable crimp depth. It is a further object of the present invention to provide a crimper tool with a sensor system that prevents the performance of a second crimping action on the same contact-wire assembly. Finally, it is an object of the present invention to provide a crimper tool wherein a crimping die holder is configured for quick and easy insertion and removal from a base unit, a sensor system prevents unintentionally performing two crimping cycles on the same contact and monitors the depth of the electrical crimp, and the crimping operation forms a substantially cylindrical hermetic crimp seal between a contact and the insulative coating on a single or multi-strand core wire. Embodiments of the present invention are particularly suitable for use in attaching contacts to single or multi-strand aluminum wire.
A preferred embodiment of the quick disconnect assembly according to the present invention comprises a bench mounted or hand-held crimping tool. A quick-change crimp head crimps a contact to a single or multi-strand core aluminum alloy wire to form both a reliable hermetic seal and good electrical continuity between the contact and the wire. The quick-change crimp head preferably slips axially in and out of a receptacle in a base unit. Between crimp cycles, the quick-change crimp head is generally held in the receptacle by the action of a latching or locking mechanism. The actuating mechanism for the quick-change crimp head is preferably located in the base unit. This placement of the actuating mechanism minimizes the mass, expense, and complexity of the quick-change crimp head. It also allows for very robust and flexible actuating mechanisms that are capable of accurately accommodating a wide range of wire gauges from, for example, 26 gauge or smaller to 12 gauge or larger. Typically, a separate quick-change crimp head is kept available for at least each wire gauge, and, if required, for each style of contact. When a particular wire gauge or contact style is to be crimped, the proper quick-change crimp head is selected and inserted into the receptacle. The mounting of a quick-change crimp head in a base unit by an experienced operator generally requires less than approximately a minute, and preferably, less than approximately 30 seconds. The actuating mechanism engages the quick-change crimp head when it is properly positioned in the receptacle portion of the base unit. A sensor system prevents accidentally applying two crimping cycles to the same contact-wire assembly and verifies continuity-crimp quality. Such sensor systems are conventional in the crimping art. The accidental application of more than one crimping cycle is conveniently prevented by requiring that the system be reset before it will perform another cycle. Crimp continuity is conveniently assured by providing a signal (audible, visual, tactile, or otherwise) to alert the operator if the contact is not indented to a predetermined depth during the cycle.
In an additional preferred embodiment, a base unit for an insulated single or multi-strand aluminum alloy wire crimping system includes a receptacle into which a quick-change crimp head may be slipped and locked. The crimp head includes a set of crimp-seal dies axially spaced from a set of continuity-crimping dies with both sets being mounted in a crimping die holder body. Both sets of dies perform crimping operations on the same contact-wire assembly. The crimp seal dies form the contact into a substantially smooth unbroken generally cylindrical wall hermetically sealed to the outside of the insulation on the core of the wire. The continuity-crimping dies crimp a wall of the contact into electrical contact with the core of the wire by indenting the wall into the wire. The dies are generally driven by ring cams. The ring cams have internal cam profiles, which engage cam followers that are associated with the respective dies. The contact is received in the die holder body in a contact holder. The contact holder is preferably quickly changeable. Preferably, the tool includes a sensor system. The sensor system prevents the crimping tool from unintentionally performing two crimping operations on the same contact-wire assembly, and detects non-compliant continuity-crimping.
The components of the quick-change crimp head typically include, for example, a die holder body in which several individual dies are mounted for reciprocal axial movement, one or more cam surfaces, typically, internal annular cam surfaces, and a contact holder. The contact holder, dies and ring cam(s) are removable and replaceable in the die holder body. Typically, the die holder body is non-rotatably mounted in the base unit and the actuating mechanism rotates the ring cam(s) to drive the dies into crimping engagement with the contact-wire assembly.
In a typical operation, a predetermined length of the end of a single or multi-strand core wire is stripped of its insulation. This stripping is performed in a separate preliminary operation. A contact is selected. Typically, the contact has an open end, and is otherwise completely closed. The exposed end of the core is inserted into the open end of the contact to such a depth that the insulation is located within the open end of the contact, and the exposed core is in a position to be crimped into conductive engagement with the contact. The contact with the wire so positioned within it is inserted into the contact holder in the quick-change crimp head. Sensors detect when the contact is properly positioned in the contact holder, and arm the system for one crimping cycle. The operator initiates the cycle. During the cycle the actuating mechanism rotates the cam ring(s) to cause linear motion of the associated dies in a predetermined sequence into crimping engagement with the contact. The walls of the contact are indented into conductive engagement with the bare wire core. The walls at the open end of the contact are formed into a generally unbroken cylinder clamped in a hermetic seal around a short length of the outside of the insulation. Preferably, a sensor associated with the actuating mechanical linkage detects the position of a particular moving element in the linkage at the end of the crimping stroke, and from this position the depth of the indentation is deduced. The contact wall must be indented to a predetermined depth to assure the desired electrical conductivity through the crimp.
When a crimp sensor detects that the proper depth of electrical crimp indentation has been reached, the actuating mechanism counter-rotates the cam ring(s) to allow the dies to withdraw from crimping engagement with the contact-wire assembly. This completes the cycle. The sensor prevents a second cycle from being inadvertently initiated until the system is armed again. The crimped contact-wire assembly is withdrawn from the contact holder. The sensor will rearm the system for another cycle when it senses a contact in the proper position in the contact holder.
To acquaint persons skilled in the pertinent arts most closely related to the present invention, a preferred embodiment of a crimping tool that illustrates a best mode now contemplated for putting the invention into practice is described herein by, and with reference to, the annexed drawings that form a part of the specification. The exemplary crimping tool is described in detail without attempting to show all of the various forms and modifications in which the invention might be embodied. As such, the embodiments shown and described herein are illustrative, and as will become apparent to those skilled in the arts, can be modified in numerous ways within the scope and spirit of the invention, the invention being measured by the appended claims and not by the details of the specification or drawings.
Other objects, advantages, and novel features of the present invention will become more fully apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings, or may be learned by the practice of the invention as set forth herein.
The present invention provides its benefits across a broad spectrum of crimping applications. While the description which follows hereinafter is meant to be representative of a number of such applications, it is not exhaustive. As those skilled in the art will recognize, the basic apparatus taught herein can be readily adapted to many uses. This specification and the claims appended hereto should be accorded a breadth in keeping with the scope and spirit of the invention being disclosed despite what might appear to be limiting language imposed by the requirements of referring to the specific examples disclosed.
Referring particularly to the drawings for the purposes of illustrating the invention and its presently understood best mode only and not limitation:
Referring now to the drawings wherein like reference numerals designate identical or corresponding parts throughout the several views. It is to be understood that the drawings are diagrammatic and schematic representations of various embodiments of the invention, and are not to be construed as limiting the invention in any way. The use of words and phrases herein with reference to specific embodiments is not intended to limit the meanings of such words and phrases to those specific embodiments. Words and phrases herein are intended to have their ordinary meanings, unless a specific definition is set forth at length herein.
For purposes of illustration, a bench mounted embodiment of the invention has been shown. It will be understood by those skilled in the art that hand held embodiments of the present invention may be used for lighter gauges, for example, smaller than approximately 18 gauge. For heavier gauges, for example, 14 gauge and heavier, it preferable to use a bench mounted embodiment. The force required to crimp, for example, a 12 gauge wire, generally requires driving motors and linkages that are too large and/or heavy to be mounted in a hand held device. A bench mounted unit is more versatile in that it can crimp all gauges from the lightest to the heaviest, whereas a hand held embodiment is generally limited to the lighter gauges.
Referring particularly to the drawings, there is illustrated generally at 10, a base unit with a receptacle in which a quick-change crimp head 12 is mounted. The base unit is adapted to rest on a bench or other surface. Base unit 10 includes crimping stroke adjusting micrometers 14 and 16, and crimp actuating motors 18 and 20. Motors 18 and 20 are typically either electrical or pneumatic motors. Particularly for hand held devices, the activating electricity may be supplied by batteries, if desired. Hand held devices may also be pneumatically activated, if desired. Stroke adjusters 14 and 16 serve to permit very accurate adjustment of the depth of the crimp. This is particularly useful for example, for making prototypes, for short runs, and in adjusting for wear. Stroke adjusters are not necessarily required or even desirable in mass production operations. A crimping cycle is initiated, for example, by pushing a crimp button 24. Crimping cycles may be initiated in other ways, if desired. Actuating motors 18 and 20 drive the crimping dies. The actuating motors should have sufficient capacity to drive the crimping dies regardless of the gauge of the wire or the nature of the material that is deformed in the crimping operation. For purposes of quality control, and the like, a sensor system is preferably provided. Such sensor systems typically serve to prevent the performance of two crimping operations on the same contact-wire assembly, and detect whether the indenter has traveled the full predetermined length of the indenting stroke. Such sensor systems are conventional in the crimping art, and they are not shown here. If it is desired to override the sensor system and manually reset the system, a reset button 15 is provided. Axial bore 22 extends axially through the center of quick-change crimp head 12.
With particular reference to
With particular reference to
There is indicated generally at 38 (
A crimp-seal cam is indicated generally at 42 (
The actuators 40 and 44 are preferably mounted so that when actuated, they cause cams 38 and 42 to counter-rotate relative to one another. Preferably, cam 38 is rotated first to cause the electrical continuity crimping action and the first phase of the crimp sealing operation to be performed. Cam 38 is held in the rotated position and cam 42 is then rotated to cause the performance of the second phase of the crimp sealing operation. Mounting the actuators in the base unit allows the actuators themselves and the drivers for them to be very robust. If, by reason of the use of large sizes or materials that strongly resist deformation, or for any other reason, substantial force is required to perform a crimping operation, that substantial force is available without modification of the base unit. The appropriate quick-change crimp die is inserted into the receptacle, and the equipment is ready for use.
A handle indicated generally at 46 includes a generally cylindrical proximally projecting wall 96, which permits an operator to grasp the quick-change crimp head 12 for easy removal and insertion into a receptacle in base unit 10. Axial bore 94 of handle 46 slips over generally cylindrical surface 56 of body 36. Threaded radially extending holes of which 98 and 104 are typical serve to threadably mount set screws (not shown). These set screws bear against surface 56 to securely but releasably mount handle 46 to body 36 with cams 38 and 42, and actuators 40 and 44 trapped between surface 58 and radially extending face 100 of handle 46.
In the assembled configuration, cams 38 and 42 are rotatably journaled on generally cylindrical surface 54 of body 36. Generally cylindrical internal surfaces 132 and 134 of cam 38, and generally cylindrical internal surfaces 140 and 142 of cam 42 are rotatably journaled on generally cylindrical external surface 54 of body 36. The lands of the respective cams are interengaged so that adjacent axially facing surfaces of cams 38 and 42 are in generally slidable engagement with one another. For example, face 116 of cam 42 slidably engages face 76 of cam 38, and face 110 of cam 42 slidably engages face 72 of cam 38. Surface 90 of cam 42 slidably engages face 100 of handle 46. The lands of the respective cams are of such an arcuate extent that they permit the respective cams to rotate relative to one another without interference through a short arc that is sufficient for crimping purposes. During a crimping cycle, the cams oscillate about the longitudinal axis 102 between open and crimped configurations.
Actuators 40 and 44 are preferably mounted in base unit 10, and the connecting keys, for example, 62 and 92, are preferably mounted in the respective actuators. Thus, a quick change crimp head 12 preferably comprises body 36 with selected crimp dies mounted in associated die bores, for example, 48, 50, and 52, and cams 38 and 42, all held in the assembled configuration by handle 46. Rectangular cut-out 66 in the outer perimeter of cam 38 is proportioned to permit it to slid unobstructed past key 92 in actuator 44 as the head 12 is removed and inserted axially into the receptacle in base unit 10.
The internal surfaces of cams 38 and 42 are shaped to provide cam surfaces. Cam 38 includes six cam surfaces, four of which (122-126 and 120-124) are positioned to camingly engage four radially opposed continuity-crimping dies. The remaining two cam surfaces (128-130) are positioned to camingly engage two of four radially opposed crimp-seal dies. The internal surface of cam 42 includes two cam surfaces (136-138). The two cam surfaces (136-138) in cam 42 are adapted to camingly engage the two remaining radially opposed crimp-seal dies. The cam surfaces 128-130 are formed in an axially projecting face of the most proximally extending lands of cam 38 and project to surfaces 70 and 72, and cam surfaces 136-138 are similarly formed in an axially projecting face of the most distally extending lands of cam 42 and extend to surfaces 88 and 86, respectively. By so positioning these cam surfaces in the faces of these axially overlapping lands, these cam surfaces are positioned to drive radially opposed crimp-seal dies that are mounted in radially opposed die bores in body 36. The axially inter-extending lands on the respective cams accommodate the axial offset between the crimp-seal and continuity-crimping die bores. Six of the dies, two of which are axially offset from the others, are actuated by one cam. The inter-extending lands permit the axially offset dies to be actuated by this one cam. The cam profiles determine the strokes of the dies.
With particular reference to
The movement of actuator 40 through a short arc to the position shown at 144 (
The respective crimp forming dies are driven reciprocally in the crimping die holder body 36 by the interaction between cam followers, of which 148, 152, 156, and 160 are typical. Cam follower 148 is mounted to die shaft 150. Similarly, cam followers 152, 156, and 160 are mounted to die shafts 154, 158, and 162, respectively. Die shafts 164, 166, 168, and 170 are likewise provided with associated cam followers. The length of the stroke through which the die shafts travel during a crimping operation is determined by the profile of the cam surface and the length of the arc through which the associated actuator travels during the crimping cycle. The length of the respective cycle arcs is conveniently adjusted for each actuator by, for example, adjusters 14 and 16, respectively.
In the embodiment chosen for illustration, the cam followers and die shafts are all one piece. This is not a required configuration. The cam followers and die shafts may be separate from one another, if desired, so long as they interact to accomplish the crimping operations.
When actuator 40 is moved arcuately to position 144, the engagement of keys 62 and 64 with the continuity-crimping cam 38 cause it to rotate clockwise about axis 102 to drive, for example, cam surface 120 over cam follower 152. This causes die shaft 154 to move radially towards contact 26. The clockwise rotation of cam 38 also causes, for example, cam surface 130 to camingly engage cam follower 156, which in turn drives die shaft 158 radially towards contact 26. The counterclockwise rotation of actuator 44 to position 146 causes crimp-seal cam 42, acting through cam surfaces 138 and 136 and associated cam followers 148 and 172, respectively, to camingly actuate die shafts 150 and 164, respectively. The actuator 44 acts on cam 42 through the inter-engagement of keys 92 and 106. The crimp-seal die faces of die heads 198 and 196 are generally cylindrically concave. The counterclockwise rotation of the cam that actuates them forces these faces to the fully crimped configuration shown, for example, in
With particular reference to
With particular reference to
In the embodiment chosen for purposes of illustration, the die shafts are received for reciprocal sliding motion in cylindrical bores of which 50 and 51 (
With particular reference to
With particular reference to
With particular reference to
The contact holder may be easily and quickly (generally less than one minute by a skilled operator) removed and replaced. Fitting 268 is rotated to align pins 280 with the release slots (not shown) in mounting ring 266 and is axially withdrawn from engagement with the die holder body. Fitting 268 carries the contact holder with it. Fitting 274 and spring 272 are removed from bore 275 and the contact hold is removed. A new contact holder is inserted and the disassembly process is repeated in reverse. The crimp head may thus be quickly reconfigured for a different contact. Where different dies are necessary, a second quick-change crimp head is preferably provided. Changing out a set of dies generally requires more time and skill than is available in a mass production environment. Such a die change out can be accomplished by skilled workers in a few minutes (generally less than 10 minutes).
The quick-change crimp head is axially slidably mounted in a receptacle in the base unit. This head is preferably held there by a special locking mechanism (not shown), so it may be removed and replaced very quickly (generally less than one minute by a skilled operator). Even if some quick release fastener is used to hold the crimp head in place, the total time to change out a crimp head is generally less than two minutes. The use of a common base unit 10 for use with a plurality of quickly changeable and configurable crimp heads provides the capacity for the efficient performance of a wide variety of crimp forming operations in a mass production environment.
What has been described are preferred embodiments in which modifications and changes may be made without departing from the spirit and scope of the accompanying claims. Many modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.