Method And Tool for Joining Side-Lapped Seams Of Steel Deck Panels And Steel Deck Structure Incorporating Interlocking Side-Lapped Seams

BACKGROUND OF THE INVENTION
1. Field of the Invention

The present invention relates to attachments formed to join adjacent deck panels, methods of forming said attachments, and apparatuses used therefor. More particularly, the present invention is directed to interlocking seam attachments formed in a side-lapped seam between adjacent steel deck panels, methods and apparatuses adapted for forming the interlocking seam attachments, and steel deck structures which incorporate the interlocking seam attachments.

2. Background

Deck panels (also known as “structural panels”) are commonly used in commercial and industrial construction to form load bearing metal roof and/or floor decks. The deck panels are typically rectangular sheet metal panels secured to each other along their longitudinal edges and are connected to load bearing structural support members of a building, such as studs, joists, girders, support beams, or the like. The deck panels are corrugated and include flutes or channels (i.e., fabricated folds or bends in the structural panel that form a repetitive groove or undulation) that extend parallel to the longitudinal edges of the structural panels. The flutes/channels increase the strength and stiffness of the deck panels by resisting bending along the length of the panel. The longitudinal flutes/channels are typically formed via roll forming, break forming, bending, stamping, or other like processes.

One longitudinal edge of each interlocking deck panel typically includes an upwardly extending wall that may be referred to as a male lip. The other longitudinal edge typically includes a downwardly-directed U-shaped portion having a first wall extending upwardly from the panel edge and terminating in a downwardly extending second wall for thereby forming a downwardly-opening U-shaped channel. This U-shaped portion may be referred to as a female channel.

When two interlocking deck panels are placed side-by-side, the female channel is engaged over, and overlapped with, the male lip of the adjacent deck panel for thereby interlocking the edges and forming an “interlocking side-lapped seam.” The deck panels must be properly secured to prevent them from being pulled apart by extreme loading stresses caused by, for example, windstorms, earthquakes, and other high load events. In this regard, it is known that deck panels can be secured together by forming side-lapped seam attachments (otherwise known as a side-lapped seam joints, couplings, or connections) in the side-lapped seams by, for example, shearing, welding, fastening, or otherwise securing the male lip and female channel together.

Examples of side-lapped seam attachments and tools used to form such attachments are shown and described in: Morton, U.S. Pat. No. 8,104,156; Morton, U.S. Pat. No. 7,845,132; Morton, U.S. Pat. No. 7,434,314; Irvin, U.S. Pat. No. 3,641,729; Morton, U.S. Pat. No. 8,667,656; Sundstrom, U.S. Pat. No. 6,990,781; Wiens, U.S. Pat. No. 10,435,890; and, Parker, U.S. Pat. No. 5,878,617. Typically, side-lapped seam attachments are adapted to (1) prevent the deck panels from slipping/sliding longitudinally relative to each other and (2) prevent the female channel of one panel from being pulled vertically upwardly away from the male lip of an adjacent panel.

In some cases, these prior side-lapped seam attachments are formed using a tool adapted to shear and/or bend a portion of the standing side-lapped seam. For example, in Irvin, U.S. Pat. No. 3,641,729, a tool is used to shear an opening through the standing side-lapped seam and bend a portion of the female channel and the male lip through the sheared opening, thereby coupling the male lip to the female channel and securing the deck panels together. By shearing and bending a portion of the female channel and the male lip through the side-lapped seam, opposing sheared edges are formed on either side of the sheared opening. When a load is applied to the structural panels, the opposing sheared edges resist moving or sliding of the deck panels relative to one another.

However, forming these types of side-lapped seam attachments can be challenging and time consuming, and the associated tools can be unwieldly to use. Accordingly, there exists a need for an improved tool and method for forming side-lapped seam attachments and an improved side-lapped seam attachment having increased slip/shear resistance.

SUMMARY OF THE INVENTION

In the present invention, a steel deck structure incorporating an interlocking side-lapped seam can comprise a first steel deck panel including an upturned male lip along one side edge thereof and a second steel deck panel including a downwardly-directed U-shaped female channel along one side edge thereof. The U-shaped female channel can extend over and receive the upturned male lip of the first steel deck panel to form the side-lapped seam. The U-shaped female channel includes first and second walls generally parallel to each other.

An attachment can be formed within the side-lapped seam to attach the first steel deck panel to the second steel deck panel. The attachment can comprise one or more slit openings extending through the male lip and through the first and second walls of the female channel and a pair of semi-conical shaped lobes. Each lobe can bulge in an opposite transverse direction from the longitudinal center of the side-lap seam and can extend longitudinally along the side-lapped seam, in opposite directions from the one or more slit openings, from a base located at the one or more slit openings towards an apex of each semi-conical lobe.

Preferably, the attachment comprises two or more slit openings, wherein each slit opening is formed at an angle relative to adjacent slit openings. Yet more preferably, the two or more slit openings are formed at an angle relative to a vertical direction of the side-lapped seam.

In another embodiment, the present invention can include a method of forming an attachment in an interlocking side-lapped seam of a steel deck structure, wherein the steel deck structure comprises a first steel deck panel, the first steel deck panel including an upturned male lip along one side edge thereof, and a second steel deck panel including a downwardly-directed U-shaped female channel along one side edge thereof, the U-shaped female channel extending over and receiving the upturned male lip of the first steel deck panel to form the side-lapped seam, the U-shaped channel including first and second walls generally parallel to each other.

The method of forming the attachment can comprise the steps of forcing/pushing/punching a first tooth in a first direction through the U-shaped channel first wall and into the side-lapped seam and forcing/pushing/punching a second tooth in a second direction opposite the first direction and adjacent the first tooth through the U-shaped channel second wall and into the side-lapped seam and thereby forming one or more slit openings extending through the male lip and through the first and second walls of the female channel and a pair of semi-conical shaped lobes wherein each lobe bulges in an opposite transverse direction from the longitudinal center of the side-lap seam and extends longitudinally along the side-lapped seam, in opposite directions from the one or more slit openings, from a base located at the one or more slit openings towards an apex of each semi-conical lobe.

Preferably, the first tooth and the second tooth each comprise a semi-conical shape defined by a half-cone shaped leading surface and a generally triangular flat surface, wherein a cutting edge is defined between the half-cone shaped leading surface and the generally triangular flat surface and wherein, during the step of forcing/pushing/punching the first tooth through the U-shaped channel first wall and into the side-lapped seam and the second tooth through the U-shaped channel second wall and into the side-lapped seam, the triangular flat surface of the first punch tooth traverses parallel to, adjacent and past the triangular flat surface of the second tooth.

Preferably, the pair of semi-conical shaped lobes are mirror images of the half-cone shaped leading surfaces.

In another embodiment, the invention includes an apparatus for forming an attachment in an interlocking side-lapped seam of a steel deck structure, wherein the steel deck structure comprises a first steel deck panel, the first steel deck panel including an upturned male lip along one side edge thereof, and a second steel deck panel including a downwardly-directed U-shaped female channel along one side edge thereof, the U-shaped female channel extending over and receiving the upturned male lip of the first steel deck panel to form the side-lapped seam, the U-shaped channel including first and second walls generally parallel to each other.

The apparatus can comprise a die member having one or more die teeth for engaging the first wall of the U-shaped channel, a punch member disposed adjacent to and generally facing the die member, the punch member having one or more punch teeth for engaging the second wall of the U-shaped channel, and a linear actuator connected to the punch member for selectively moving the punch member towards or away from the die member. As the punch member is moved towards the die member, the punch and die teeth of the respective punch and die members traverse into the side-lapped seam and past each other thereby forming one or more slit openings extending through the male lip and through the first and second walls of the female channel and a pair of semi-conical shaped lobes wherein each lobe bulges in an opposite transverse direction from the longitudinal center of the side-lap seam and extends longitudinally along the side-lapped seam, in opposite directions from the one or more slit openings, from a base located at the one or more slit openings towards an apex of each semi-conical lobe.

Preferably, the apparatus can include a sensor for detecting the presence of the side-lapped seam between the die and punch members, wherein the actuator is prevented from selectively moving the punch member when the side-lapped seam is not located between the die and punch members. Yet more preferably, a side-lapped seam receiving gap is provided between the die and punch members and the sensor detects the depth of the side-lapped seam within the receiving gap so that the actuator is prevented from moving the punch member when the side-lapped seam is not positioned sufficiently within the receiving gap.

Preferably, the sensor comprises a first lever disposed between the die and punch members and operably connected to a first stop block member, wherein the first stop block member is disposed between the die and punch members for preventing the punch member from being moved towards the die member, and wherein as the side-lapped seam is received in the side-lapped seam receiving gap between the die and punch members, the first lever engages the side-lapped seam and retracts the first stop block member from between the die and punch members.

In another embodiment, a tool for forming attachments in an interlocking side-lapped seam can comprise a chassis, a crimping assembly operably mounted within the chassis, and a cart assembly mounted to the chassis. The crimping assembly can comprise a die member having one or more die teeth for engaging a first wall of the side-lapped seam, a punch member disposed adjacent to and generally facing the die member and having one or more punch teeth for engaging a second wall of the side-lapped seam, and an actuator connected to the punch member for selectively moving the punch member towards or away from the die member. The cart assembly can comprise a pair of wheels and a handle. The wheels can be rotatably mounted on one or more axles and can be located one on either side of the chassis rotatably mounted on axles located one on either side of the chassis. The handle can be mounted to the chassis between the wheels. The axles can be mounted to the chassis between the crimping assembly and the handle whereby the handle can act as a lever and the axles can act as a fulcrum for tilting/rotating the tool towards or away from the side-lapped seam.

Preferably, the tool includes a pair of sled plates which are secured to the bottom of the chassis. The pair of sled plates rest on top of the first and second deck panels when the tool is engaging the side-lapped seam and, together, locate the punch and die members at a desired height relative to the side-lapped seam.

Preferably, the tool further includes a kick/pivot step which is mounted to the chassis and extends towards the rear of the tool. The kick/pivot step can be used for pushing/driving the tool linearly along a side-lapped seam.

Preferably, the cart assembly further comprises a pump/cart frame which is mounted to the chassis whereby the handle and the kick/pivot step are selectively, releasably mounted to the pump/cart frame.

Preferably, the punch teeth are formed separately from the punch member and the die teeth are formed separately from the die member. Yet more preferably, the punch and die teeth include rear mounting slots and the punch and die members include rail-shaped mounting protrusions, and wherein the punch and die teeth are mounted to the punch and die members by receiving the rear mounting slots over the rail-shaped mounting protrusions.

Preferably, the crimping assembly further comprises dovetail retaining plates and the punch and die members include dovetail slots. In operation, the dovetail retaining plates are received into the dovetail slots and support the punch and die teeth.

In another embodiment, the present invention can include a tool which can be used for forming attachments in a side-lapped seam of a steel deck structure. The tool can include a crimping assembly comprising a die member having one or more die teeth for engaging a first side of the side-lapped seam, a punch member disposed adjacent to and generally facing the die member, the punch member having one or more punch teeth for engaging a second side of the side-lapped seam, and an actuator connected to the punch member for selectively moving the punch member towards or away from the die member. A power supply unit can be operably connected and provides power to the actuator for selectively moving the punch member towards or away from the die member.

The tool can be operated by positioning the tool with the die member and the one or more die teeth adjacent to the first wall of the U-shaped channel and the punch member and the one or more punch teeth adjacent to the second wall of the U-shaped channel. The power supply unit can then be engaged whereby power is supplied to the actuator for moving the punch member towards the die member and thereby forcing/pushing/punching the one or more punch teeth and the one or more die teeth into the side-lapped seam. After the one or more punch teeth and the one or more die teeth have been forced/pushed/punched into the side-lapped seam, the power supply unit can be engaged whereby power is supplied to the actuator for moving the punch member away from the die member.

Preferably, the actuator is a hydraulic cylinder and the power supply unit is a hydraulic pump unit. The hydraulic pump unit can comprise an electric pump motor, a hydraulic pump coupled to the electric pump motor, and a control valve coupled to the hydraulic pump and the hydraulic cylinder.

Preferably, the tool also includes a control system. The control system can include a digital controller that is connected to and controls the power supply unit and a control switch that is connected to the digital controller. The tool can be operated by positioning the tool with the die member and the one or more die teeth adjacent to the first wall of the U-shaped channel and the punch member and the one or more punch teeth adjacent to the second wall of the U-shaped channel and engaging the control switch, wherein the control switch sends a signal to the digital controller to engages the power supply unit for moving the punch member towards the die member and thereby forcing/pushing/punching the one or more punch teeth and the one or more die teeth into the side-lapped seam. After the one or more punch teeth and the one or more die teeth have been forced/pushed/punched into the side-lapped, the digital controller engages the power source whereby power is supplied to the actuator for moving the punch member away from the die member.

Preferably, the control system can be configured to engage the power supply unit for moving the punch member towards the die member for a first time period TP1, and after the first time period TP1, engage the power supply unit for retracting the punch member away from the die member for a second time period TP2.

Preferably, the control system also includes a pressure sensor that is connected to the digital controller and the hydraulic pump and is used to measure the output pressure of the hydraulic pump. In operation, the digital controller can be configured to deactivate the electric pump motor if the output pressure measured by the pressure sensor exceeds a preset maximum pressure.

Preferably, the tool also includes a seam position sensing system. The seam position sensing system can include one or more seam position arms that are configured to engage the side-lapped seam when the punch and die members are positioned one on either side thereof. Preferably, the control system is configured to prevent the power supply unit from activating before the punch and die members are positioned one on either side of the side-lapped seam.

Preferably, the control system also includes an extend limit switch that triggers when the punch member is fully extended towards the die member and a retract limit switch that triggers when the punch member is fully retracted away from the die member. When the control switch is engaged, the digital controller engages the power supply unit for extending the punch member towards the die member until the extend limit switch is triggered. When the extend limit switch is triggered, the digital controller engages the power supply unit for retracting the punch member away from the die member until the retract limit switch is triggered. Thereafter, when the retract limit switch is triggered, the digital controller deactivates the power supply unit.

In another embodiment of the invention, a tool for forming an attachment in an interlocking side-lapped seam of a steel deck structure can comprise a chassis, a crimping assembly operably mounted within the chassis, a control system, and a cart assembly. The crimping assembly can comprise a die member having one or more die teeth for engaging one side of the interlocking side-lapped seam, a punch member disposed adjacent to and generally facing the die member, the punch member having one or more punch teeth for engaging another side of the interlocking side-lapped seam, and a linear actuator connected to the punch member for selectively moving the punch member towards or away from the die member. The cart assembly can comprise one or more pairs of wheels rotatably mounted to the chassis, said wheels engaging the steel deck structure, and one or more handles mounted to the chassis for pushing and pulling the tool across the steel deck structure. The control system can control the linear actuator for automatically moving the punch member towards or away from the die member.

Preferably, the tool further includes one or more motors. The motors can be coupled to one or more of the wheels and provide power thereto for transporting the tool across the steel deck structure. Yet more preferably, the control system controls the motors for thereby automatically advancing the tool a predetermined distance along the interlocking side-lapped seam.

Preferably, the self-contained power supply unit comprises an electric motor powered by one or more replaceable, interchangeable batteries, an internal combustion engine, or an electric motor powered by a generator.

In another embodiment, the invention includes a tool for forming an attachment in an interlocking side-lapped seam of a steel deck structure. The steel deck structure comprises a first steel deck panel having an upturned male lip along one side edge thereof and a second steel deck panel having a downwardly-directed U-shaped female channel along one side edge thereof, the U-shaped female channel extending over and receiving the upturned male lip of the first steel deck panel to form the side-lapped seam. The first and second steel deck panels are corrugated, and each include a plurality longitudinal channels extending generally parallel to the side-lapped seam. The tool can comprise a chassis, a crimping assembly operably mounted within the chassis, and an alignment foot mounted to the chassis. The crimping assembly comprises a die member having one or more die teeth for engaging the first wall of the U-shaped channel, a punch member disposed adjacent to and generally facing the die member, the punch member having one or more punch teeth for engaging the second wall of the U-shaped channel, and an actuator connected to the punch member for selectively moving the punch member towards or away from the die member. During operation of the tool, the die member and the punch member are positioned one on either side of the side-lapped seam and the alignment foot is received into and engages a longitudinal channel adjacent to the side-lapped seam for aligning the die member and the punch member with the side-lapped seam.

In another embodiment, the invention includes a tool for forming an attachment in an interlocking side-lapped seam of a steel deck structure. The steel deck structure comprises a first steel deck panel having an upturned male lip along one side edge thereof and a second steel deck panel having a downwardly-directed U-shaped female channel along one side edge thereof, the U-shaped female channel extending over and receiving the upturned male lip of the first steel deck panel to form the side-lapped seam. The first and second steel deck panels are corrugated, and each include a plurality of longitudinal channels extending generally parallel to the side-lapped seam. The side-lapped seam is formed at the bottom of a longitudinal side-lapped seam channel. The tool can comprise a chassis, a crimping assembly operably mounted within the chassis, and a side-lapped seam guide member mounted to the chassis adjacent to the die member and the punch member. The crimping assembly comprises a die member having one or more die teeth for engaging the first wall of the U-shaped channel, a punch member disposed adjacent to and generally facing the die member, the punch member having one or more punch teeth for engaging the second wall of the U-shaped channel, and an actuator connected to the punch member for selectively moving the punch member towards or away from the die member. A side-lapped seam receiving gap is defined between the die member and the punch member and the side-lapped seam guide member is aligned linearly with the side-lapped seam receiving gap. During operation of the tool, the side-lapped seam is received into the side-lapped seam receiving gap and the guide member is received into and engages the longitudinal side-lapped seam channel for aligning the die member and the punch member with the side-lapped seam.

In another embodiment, the invention includes a tool for forming an attachment in an interlocking side-lapped seam of a steel deck structure comprising a first steel deck panel having a first top surface and a second steel deck panel having a second top surface. The tool can comprise a chassis, a crimping assembly operably mounted within the chassis, and one or more sled plates mounted to the chassis. The crimping assembly comprises a die member having one or more die teeth for engaging the first wall of the U-shaped channel, a punch member disposed adjacent to and generally facing the die member, the punch member having one or more punch teeth for engaging the second wall of the U-shaped channel, and an actuator connected to the punch member for selectively moving the punch member towards or away from the die member. A side-lapped seam receiving gap is defined between the die member and the punch member and the side-lapped seam guide member is aligned linearly with the side-lapped seam receiving gap. During operation of the tool, the side-lapped seam is received into the side-lapped seam receiving gap and the one or more sled plates engage the first and/or second top surfaces for supporting the tool on top of the first and second deck panels and for locating the side-lapped seam vertically within the side-lapped seam receiving gap.

In another embodiment of the invention, a tool for forming an attachment in an interlocking side-lapped seam of a steel deck structure can comprise a die member having one or more die teeth for engaging a first side of the side-lapped seam, a punch member disposed adjacent to and generally facing the die member, the punch member having one or more punch teeth for engaging a second side of the side-lapped seam, a hydraulic pump, a hydraulic fluid reservoir, a hydraulic cylinder connected to the punch member for selectively moving the punch member towards or away from the die member, said hydraulic cylinder having a first hydraulic coupling and a second hydraulic coupling, and a control valve having a first position and a second position, said control valve hydraulically coupled to the hydraulic pump, the hydraulic fluid reservoir, and the hydraulic cylinder. When the control valve is in the first position, the hydraulic pump is connected through the control valve to the first hydraulic coupling for extending the hydraulic cylinder and moving the punch member towards the die member, and, as the hydraulic cylinder extends, hydraulic fluid drains from the second hydraulic coupling through the control valve to the hydraulic fluid reservoir. When the control valve is in the second position, the hydraulic pump is connected through the control valve to the second hydraulic coupling for retracting the hydraulic cylinder and moving the punch member away from the die member, and, as the hydraulic cylinder retracts, hydraulic fluid drains from the first hydraulic coupling through the control valve to the hydraulic fluid reservoir.

In another embodiment of the invention, a tool for forming an attachment in an interlocking side-lapped seam of a steel deck structure can comprise a die member having one or more die teeth for engaging a first side of the side-lapped seam, a punch member disposed adjacent to and generally facing the die member, the punch member having one or more punch teeth for engaging a second side of the side-lapped seam, a hydraulic pump, a hydraulic fluid reservoir, a hydraulic cylinder connected to the punch member for selectively moving the punch member towards the die member, said hydraulic cylinder having a first hydraulic coupling, a return spring connected to the punch member for moving the punch member away from the die member, and a control valve having a first position and a second position, said control valve hydraulically coupled to the hydraulic pump, the hydraulic fluid reservoir, and the hydraulic cylinder. When the control valve is in the first position, the hydraulic pump is connected through the control valve to the first hydraulic coupling for extending the hydraulic cylinder and moving the punch member towards the die member and, as the punch member moves towards the die member, compressing the return spring. When the control valve is in the second position, the hydraulic pump is disconnected from the hydraulic cylinder and the return spring extends for driving the punch member away from the die member and retracting the hydraulic cylinder. As the hydraulic cylinder retracts, hydraulic fluid drains from the hydraulic cylinder through the first hydraulic coupling and the control valve to the hydraulic fluid reservoir.

In another embodiment of the invention, a tool for forming an attachment in an interlocking side-lapped seam of a steel deck structure can comprise a die member having at least two die teeth for engaging a first side of the side-lapped seam and a punch member disposed adjacent to and generally facing the die member, the punch member having at least one punch tooth for engaging a second side of the side-lapped seam. The at least two die teeth can be spaced apart from each other for defining at least one die slot therebetween and the at least one punch tooth can be received into the at least one die slot.

In another embodiment of the invention, a tool for forming an attachment in an interlocking side-lapped seam of a steel deck structure can comprise a die member having at least one die tooth for engaging a first side of the side-lapped seam and a punch member disposed adjacent to and generally facing the die member, the punch member having at least two punch teeth for engaging a second side of the side-lapped seam. The at least two punch teeth can be spaced apart from each other for defining at least one punch slot therebetween and the at least one die tooth is received into the punch slot.

In another embodiment of the invention, a tool for forming an attachment in an interlocking side-lapped seam of a steel deck structure can comprise a die member having two or more die teeth for engaging a first side of the side-lapped seam and a punch member disposed adjacent to and generally facing the die member, the punch member having one or more punch teeth for engaging a second side of the side-lapped seam. The two or more die teeth can be spaced apart from each other and one or more die slots are defined between adjacent die teeth. The one or more punch teeth can be spaced apart from each other and one or more punch slots are defined between adjacent punch teeth. During operation, one or more of the punch teeth can be received into one or more of the die slots and one or more of the die teeth can be received into one or more of the punch slots.

In another embodiment of the invention, a tool for forming an attachment in an interlocking side-lapped seam of a steel deck structure can comprise a die member having a plurality of die teeth for engaging a first side of the side-lapped seam and a punch member disposed adjacent to and generally facing the die member, the punch member having a plurality of punch teeth for engaging a second side of the side-lapped seam. The plurality of die teeth can be spaced apart from each other such that one or more die slots are defined between adjacent pairs of die teeth. Similarly, the plurality of punch teeth can be spaced apart from each other such that one or more punch slots are defined between adjacent pairs of punch teeth. During operation, one or more of the punch teeth can be received into one or more of the die slots and one or more of the die teeth are received into one or more of the punch slots.

In another embodiment of the invention, a tool for forming an attachment in an interlocking side-lapped seam of a steel deck structure can comprise a chassis and a crimping assembly operably mounted within the chassis. The crimping assembly can comprise a die member having one or more die teeth for engaging a first side of the side-lapped seam, a punch member disposed adjacent to and generally facing the die member, the punch member having one or more punch teeth for engaging a second side of the side-lapped seam, a carrier plate coupled to the punch member, one or more rails coupled to the carrier plate, one or more tracks coupled to the chassis, said tracks engaging the one or more rails for slidingly supporting the carrier plate and the punch member within the chassis, and an actuator connected to the punch member for selectively moving the punch member towards or away from the die member. In operation, when the actuator is extended or retracted, the carrier plate and punch member slide towards or away from the die member with the rails sliding along the tracks.

In another embodiment of the invention, a tool for forming an attachment in an interlocking side-lapped seam of a steel deck structure can comprise a chassis and a crimping assembly operably mounted within the chassis. The crimping assembly can comprise a die member having one or more die teeth for engaging a first side of the side-lapped seam, a punch member disposed adjacent to and generally facing the die member, the punch member having one or more punch teeth for engaging a second side of the side-lapped seam, a carrier plate coupled to the punch member, a pair of rails coupled to the carrier plate, a pair of tracks coupled to the chassis, said pair of tracks engaging the pair of rails for slidingly supporting the carrier plate and the punch member within the chassis, and an actuator connected to the punch member for selectively moving the punch member towards or away from the die member. In operation, when the actuator is extended or retracted, the carrier plate and punch member slide towards or away from the die member with the rails sliding along the tracks.

In another embodiment of the invention, a tool for forming an attachment in an interlocking side-lapped seam of a steel deck structure can comprise a die member having a first mounting groove and one or more die teeth for engaging a first side of the side-lapped seam, said one or more die teeth having flared base portions which are slidingly received into the first mounting groove for mounting the one or more die teeth to the die member and a punch member disposed adjacent to and generally facing the die member, the punch member having a second mounting groove and one or more punch teeth for engaging a second side of the side-lapped seam, said one or more punch teeth having flared base portions which are slidingly received into the second mounting groove for mounting the one or more punch teeth to the punch member.

In another embodiment of the invention, a tool for forming an attachment in an interlocking side-lapped seam of a steel deck structure can comprise a chassis, one or more wheels rotatably mounted to the chassis, said wheels engaging the steel deck structure, a crimping assembly operably mounted within the chassis, and a proximity sensor. In operation, the proximity sensor provides an alert notification if the tool approaches an edge of the steel deck structure.

In another embodiment of the invention, a tool for forming attachments in an interlocking side-lapped seam of a steel deck structure can comprise a crimping assembly, a power supply unit, and a pair of limit switches. The crimping assembly can comprise a die member having one or more die teeth for engaging the first wall of the U-shaped channel, a punch member disposed adjacent to and generally facing the die member, the punch member having one or more punch teeth for engaging the second wall of the U-shaped channel, and an actuator connected to the punch member for selectively moving the punch member towards or away from the die member. The power supply unit can be operably connected to and powers the actuator for selectively moving the punch member towards or away from the die member. The tool can be operated by positioning the tool with the die member and the one or more die teeth adjacent to the first wall of the U-shaped channel and the punch member and the one or more punch teeth adjacent to the second wall of the U-shaped channel, engaging the power supply unit which powers the actuator for moving the punch member towards the die member, and thereby forcing/pushing/punching the one or more punch teeth and the one or more die teeth into the side-lapped seam, wherein the power supply unit continues to power the actuator until one of the limit switches is activated, and after one of the limit switches is activated, engaging the power supply unit and powering the actuator for moving the punch member away from the die member, wherein the power supply unit continues to power the actuator until the other limit switch is activated.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned and other features of this invention and the manner of attaining them will become more apparent, and the invention itself will be better understood by reference to the following description of the embodiments of the invention, taken in conjunction with the accompanying drawings, wherein:

FIG. 1 is a perspective view of a deck seam tool on top of a deck structure;

FIGS. 2-4 are perspective views of the deck seam tool shown in FIG. 1 wherein the tool is tilted backwards, rotated, and transported across the deck structure;

FIG. 5A is a top plan view of the deck panel shown in FIG. 1;

FIG. 5B is a front plan view of the deck panel;

FIG. 6 is a perspective view of a deck structure including a pair of panels and a side-lapped seam therebetween;

FIG. 7A is a front plan view of the deck structure shown in FIG. 6;

FIG. 7B is a magnified view of the side-lapped seam shown in FIG. 7A;

FIG. 8 is a perspective view of the deck seam tool;

FIG. 9 is another perspective view of the deck seam tool shown in FIG. 8;

FIG. 10 is a perspective view of the deck seam tool wherein the wheels, handle, and cart frame have been removed for greater clarity;

FIG. 11 is another perspective view of the deck seam tool shown in FIG. 10;

FIG. 12 is a bottom plan view of the deck seam tool shown in FIG. 11;

FIG. 13A is a perspective view of the alignment foot shown in FIG. 12;

FIG. 13B is a side plan view of the alignment foot;

FIG. 13C is an end plan view of the alignment foot;

FIG. 14A is a perspective view of the side-lapped seam guide shown in FIG. 12;

FIG. 14B is a side plan view of the side-lapped seam guide;

FIG. 14C is an end plan view of the side-lapped seam guide;

FIG. 15 is a perspective view of the deck seam tool wherein the wheels have been removed for greater clarity;

FIG. 16 is another perspective view of the deck seam tool shown in FIG. 15;

FIG. 17A is a perspective view of the base plate shown in FIG. 12;

FIG. 17B is a top plan view of the base plate;

FIG. 17C is an end plan view of the base plate;

FIG. 18A is a perspective view of the assembled base plate, the vertical support walls, and the hydraulic cylinder plates;

FIG. 18B is a partially exploded perspective view showing the vertical support walls exploded apart from the base plate;

FIG. 19A is another perspective view of the assembled base plate, the vertical support walls, and the hydraulic cylinder plates;

FIG. 19B is a partially exploded perspective view showing the hydraulic cylinder plates exploded apart from the base plate;

FIG. 20A is a perspective view of the assembled base plate, die plate support wall, and additional vertical support walls;

FIG. 20B is a partially exploded perspective view showing the die plate support wall and the additional vertical support walls exploded apart from the base plate;

FIG. 21A is a perspective view of the support plate shown in FIG. 11;

FIG. 21B is a bottom plan view of the support plate;

FIG. 21C is a side plan view of the support plate;

FIG. 22A is a perspective view of the assembled support plate and frame;

FIG. 22B is a partially exploded perspective view showing the support plate exploded apart from the frame;

FIG. 23 is a partially exploded perspective view showing the support plate exploded apart from the crimping assembly/mechanism and the base plate;

FIG. 24 is a perspective view of the crimping assembly mounted to the base plate with the hydraulic cylinder body secured to the hydraulic cylinder plates;

FIG. 25A is a side plan view of the crimping assembly in the open position with the punch plate separated from the die plate;

FIG. 25B is a side plan view of the crimping assembly in the closed position with the punch plate advanced towards the die plate;

FIG. 26A is a partially exploded perspective view showing the hydraulic ram exploded apart from the cylinder body;

FIG. 26B is a perspective view showing the assembled hydraulic cylinder;

FIG. 27 is a side plan view of the cylinder body shown in FIGS. 26A-B;

FIG. 28 is an exploded perspective view showing the hydraulic cylinder plates exploded apart from the cylinder body;

FIGS. 29A-C are front plan views of the hydraulic cylinder plates shown in FIG. 28;

FIG. 30 is a side plan view of the assembled cylinder body and hydraulic cylinder plates;

FIG. 31 is a partially exploded perspective view showing the annular locking ring exploded apart from the cylinder body;

FIG. 32 is a perspective view showing the assembled annular locking ring, cylinder body, and hydraulic cylinder plates;

FIG. 33 is an exploded perspective view of the carrier assembly, the punch plate, and the die plate;

FIG. 34 is a top plan view of the upper carrier plate, the punch and die plates, and the die plate support wall;

FIG. 35 is a section view of the upper carrier plate, the punch and die plates, and the die plate support wall taken along the line 35-35 shown in FIG. 34;

FIG. 36 is an exploded perspective view of the carrier assembly, the punch plate and the hydraulic cylinder;

FIG. 37A is a perspective view of the lower carrier plate shown in FIG. 36;

FIG. 37B is a top plan view of the lower carrier plate;

FIG. 37C is a side plan view of the lower carrier plate;

FIG. 38A is a perspective view of the upper carrier plate shown in FIG. 36;

FIG. 38B is a top plan view of the upper carrier plate;

FIG. 38C is a side plan view of the upper carrier plate;

FIG. 39 is another perspective view of the upper carrier plate shown in FIGS. 38A-C;

FIG. 40 is an exploded perspective view of the upper and lower carrier plates and the punch plate;

FIG. 41 is an exploded perspective view of the lower carrier plate and the carrier plate locating strip;

FIG. 42A is a perspective view of a sliding rail shown in FIG. 43;

FIG. 42B is an end plan view of the sliding rail;

FIG. 43A is a perspective view of part of the rail carrier/track shown in FIG. 44;

FIG. 43B is an end plan view of the part of the rail carrier/track shown in FIG. 43A;

FIG. 44A is a perspective view of a sliding rail engaging a pair of rail carriers/tracks;

FIG. 44B is an end plan view of the sliding rail engaging the pair of rail carriers/tracks;

FIG. 45 is a partially exploded perspective view showing the sliding rails and the rail carriers/tracks exploded apart from the carrier assembly;

FIG. 46A is a perspective view of the lower carrier plate shown in FIGS. 37A-C and the hydraulic cylinder shown in FIG. 26B;

FIG. 46B is a top plan view of the lower carrier plate and the hydraulic cylinder;

FIG. 46C is a side plan view of the lower carrier plate and the hydraulic cylinder;

FIG. 47A is a perspective view of the upper carrier plate shown in FIGS. 38A-C and the hydraulic cylinder shown in FIG. 26B;

FIG. 47B is a side plan view of the upper carrier plate and the hydraulic cylinder;

FIG. 47C is a bottom plan view of the upper carrier plate and the hydraulic cylinder;

FIG. 48 is an exploded perspective view of the carrier assembly, the punch plate, and the hydraulic cylinder;

FIG. 49 is a side plan view of the punch and die plates;

FIG. 50 is a section view of the punch and die plates taken along the line 50-50 shown in FIG. 49;

FIG. 51A is a perspective view of the punch plate;

FIG. 51B is another perspective view of the punch plate;

FIG. 52A is a front plan view of the punch plate;

FIG. 52B is a top plan view of the punch plate;

FIG. 53A is a perspective view of the die plate;

FIG. 53B is a magnified view of the die plate showing die tooth DT2;

FIG. 54A is a perspective view of die tooth DT2;

FIGS. 54B-D are top, front, and side plan views of die tooth DT2;

FIGS. 54E-H are perspective views of punch tooth PT2 shown in FIG. 51A;

FIG. 55 is a perspective view of the die plate shown in FIG. 53A;

FIG. 56A-C are front, top, and side plan views of the die plate;

FIG. 57 is an exploded perspective view of the die plate, the die teeth, and the tooth fasteners;

FIG. 58A is a perspective view of a die plate wherein the die teeth have been removed;

FIG. 58B is a partially exploded side plan view of the die plate and the tooth fasteners;

FIG. 59 is a perspective view of a deck seam tool having a side-lapped seam insertion sensing system;

FIG. 60 is a perspective view of the side-lapped seam insertion sensing system;

FIG. 61 is another perspective view of the side-lapped seam insertion sensing system;

FIG. 62 is an exploded perspective view of the side-lapped seam insertion sensing system;

FIG. 63 is a top plan view of the deck seam tool;

FIG. 64 is a section view of the side-lapped seam insertion sensing system taken along the line 64-64 shown in FIG. 63 wherein the side-lapped seam insertion sensing system is in the locked position;

FIG. 65 is a section view of the side-lapped seam insertion sensing system taken along the line 64-64 shown in FIG. 63 wherein the deck side-lapped seam has been received in the tool side-lapped seam receiving gap and the side-lapped seam insertion sensing system is in the unlocked position;

FIG. 66 is a front plan view of the deck seam tool engaging a side-lapped seam wherein the crimping assembly is in the open position;

FIG. 67 is a front plan view of the deck seam tool engaging a side-lapped seam wherein the crimping assembly is in the closed position and the punch and die teeth have been advanced into and are embedded in the side-lapped seam;

FIG. 68 is a perspective view of a side-lapped seam having attachments in the form of locking lobes formed in the side-lapped seam;

FIG. 69 is a magnified perspective view of the side-lapped seam shown in FIG. 68;

FIG. 70A is a side plan view of a side-lapped seam having attachments in the form of locking lobes formed in the side-lapped seam;

FIG. 70B is a top plan view of the side-lapped seam shown in FIG. 70A and showing each of the punch and die teeth behind (in their withdrawn position) the attachments and locking lobes which they have formed;

FIG. 71A is a side plan view of a side-lapped seam showing a single attachment including a slit opening and a pair of half-cone shaped locking lobes;

FIG. 71B is a section view of the side-lapped seam taken along the line 71B-71B shown in FIG. 71A and through the slit opening;

FIG. 72A is a section view of the side-lapped seam taken along the line 72A-72A shown in FIG. 71A;

FIG. 72B is a section view of the side-lapped seam taken along the line 72B-72B shown in FIG. 71A;

FIG. 72C is a section view of the side-lapped seam taken along the line 72C-72C shown in FIG. 71A;

FIG. 72D is a section view of the side-lapped seam taken along the line 72D-72D shown in FIG. 71A;

FIG. 72E is a section view of the side-lapped seam taken along the line 72E-72E shown in FIG. 71A;

FIG. 73 is a side plan view of a side-lapped seam showing a single attachment including a slit opening and a pair of half-cone shaped locking lobes;

FIG. 74A is a section view of the side-lapped seam taken along the line 74A-74A shown in FIG. 73;

FIG. 74B is a section view of the side-lapped seam taken along the line 74B-74B shown in FIG. 73;

FIG. 74C is a section view of the side-lapped seam taken along the line 74C-74C shown in FIG. 73;

FIG. 74D is a section view of the side-lapped seam taken along the line 74D-74D shown in FIG. 73;

FIG. 75A is a side plan view of a side-lapped seam showing a pair of attachments;

FIG. 75B is a top plan view of the side-lapped seam shown in FIG. 75A;

FIG. 76A is a side plan view of the punch and die teeth wherein the punch plate has been advanced such that the cutting edges of opposing punch and die teeth are adjacent one another;

FIG. 76B is a section view of the punch and die teeth taken along the line 76B-76B shown in FIG. 76A;

FIG. 76C is a magnified section view of the punch and die teeth shown in FIG. 76B;

FIG. 77A is a side plan view of the punch and die teeth wherein the punch plate has been advanced such that the cutting edges of opposing punch and die teeth extend slightly past one another;

FIG. 77B is a section view of the punch and die teeth taken along the line 77B-77B shown in FIG. 77A;

FIG. 77C is a magnified section view of the punch and die teeth shown in FIG. 77B;

FIG. 78A is a side plan view of the punch and die teeth wherein the punch plate has been advanced such that the cutting edges of each punch and die tooth are adjacent the relief surfaces of the opposing punch and die teeth;

FIG. 78B is a section view of the punch and die teeth taken along the line 78B-78B shown in FIG. 78A;

FIG. 78C is a magnified section view of the punch and die teeth shown in FIG. 78B;

FIG. 79 is a diagrammatic block diagram illustrating a hydraulic circuit of the tool comprising a double acting hydraulic cylinder;

FIG. 80 is a diagrammatic block diagram illustrating a hydraulic circuit of the tool comprising a single acting hydraulic cylinder;

FIG. 81 is a section view of the side-lapped seam insertion sensing system taken along the line 64-64 shown in FIG. 63 wherein the deck side-lapped seam has been received in the tool side-lapped seam receiving gap and the side-lapped seam insertion sensing system is in the locked position;

FIG. 82 is a front plan view of the tool wherein the deck side-lapped seam has been received in the tool side-lapped seam receiving gap;

FIG. 83 is a front plan view of the tool shown in FIG. 82 wherein the side-lapped seam guide has been removed for greater clarity;

FIG. 84 is a section view of the punch and die plates taken along the line 84-84 shown in FIG. 49;

FIG. 85 is section view of the punch and die plates taken along the line 85-85 shown in FIG. 34;

FIG. 86 is a top plan view of a deck side-lapped seam wherein the punch and die teeth are illustratively shown behind (in their withdrawn position) the attachments and locking lobes which they have formed;

FIG. 87 is a perspective view of a deck seam tool on top of a deck structure;

FIGS. 88-90 are perspective views of the deck seam tool shown in FIG. 1 wherein the tool is tilted backwards, rotated, and transported across the deck structure;

FIG. 91 is a perspective view of the deck seam tool;

FIG. 92 is a partially exploded perspective view of the deck seam tool wherein the pump cover has been exploded apart from the pump tray;

FIG. 93 is another perspective view of the deck seam tool shown in FIG. 91;

FIG. 94 is a perspective view of the deck seam tool wherein the pump cover and the hydraulic power source have been removed for greater clarity;

FIG. 95 is another perspective view of the deck seam tool wherein the pump tray has also been removed;

FIG. 96 is an exploded perspective view of the deck seam tool shown in FIG. 95;

FIGS. 97A-B are perspective views of the pump/cart frame shown in FIG. 95;

FIGS. 98A-B are perspective views of the kick/pivot step shown in FIG. 95;

FIGS. 99A-B are side elevation views of the deck seam tool on top of a deck structure;

FIG. 100 is another perspective view of the deck seam tool wherein the pump/cart frame has been removed for greater clarity;

FIG. 101 is a partially exploded perspective view of the deck seam tool wherein a wheel and a wheel brake have been exploded apart from the tool frame;

FIG. 102 is a front elevation view of the deck seam tool on top of a deck structure;

FIG. 103 is a cross-section view of the deck seam tool taken along the line 103-103 shown in FIG. 102;

FIG. 104 is a perspective view of a crimping assembly;

FIG. 105 is a side plan view of the crimping assembly;

FIG. 106 is a perspective view of a punch plate;

FIG. 107 is an exploded view of the punch plate shown in FIG. 106 wherein the punch teeth, dovetail retaining plates, and plate screws have been exploded apart from the punch plate;

FIG. 108 is another exploded view of the punch plate;

FIG. 109A is a front elevation view of the punch plate;

FIG. 109B is a bottom plan view of the punch plate;

FIG. 109C is a magnified detail view of circled Detail 109C shown in FIG. 109A;

FIG. 110A is a perspective view of a dovetail retaining plate;

FIG. 110B is a top plan view of the dovetail retaining plate;

FIG. 110C is a side elevation view of the dovetail retaining plate;

FIGS. 111A-B are perspective views of a punch tooth PT2 having a rear mounting slot;

FIG. 111C is a top plan view of the punch tooth PT2;

FIG. 111D is a rear elevation view of the punch tooth PT2;

FIG. 112 is a perspective view of a die plate;

FIG. 113 is an exploded view of the punch plate shown in FIG. 112 wherein the die teeth, dovetail retaining plates, and plate screws have been exploded apart from the die plate;

FIG. 114 is another exploded view of the die plate;

FIG. 115A is a front elevation view of the die plate;

FIG. 115B is a bottom plan view of the die plate;

FIGS. 116A-B are perspective views of a die tooth DT2 having a rear mounting slot;

FIG. 116C is a top plan view of the die tooth DT2;

FIG. 116D is a rear elevation view of the die tooth DT2;

FIG. 117A is a side elevation view of the punch plate and punch tooth PT2;

FIG. 117B is a magnified detail view of Circled Detail 117B;

FIG. 118A is a side elevation view of the die plate and die tooth DT2;

FIG. 118B is a magnified detail view of Circled Detail 118B;

FIG. 119 is a magnified side plan view of the crimping assembly;

FIG. 120 is a block diagram of a hydraulic power supply unit for powering the deck seam tool;

FIG. 121 is a block diagram of a first control system for controlling the hydraulic power supply unit;

FIG. 122 is a flow chart illustrating the operation of the control system and the hydraulic power supply unit;

FIG. 123 is an exploded perspective view of the crimping assembly wherein the die plate and part of the side-lapped seam insertion sensing system have been exploded apart from the rest of the crimping assembly;

FIG. 124 is an exploded perspective view of the side-lapped seam insertion sensing system;

FIG. 125 is an exploded perspective view showing how the side-lapped seam insertion sensing system is mounted to the die plate;

FIG. 126 is a top plan view of the crimping assembly and the side-lapped seam insertion sensing system;

FIG. 127A-B are cross section views of the crimping assembly and the side-lapped seam insertion sensing system taken along the line 127-127 shown in FIG. 126;

FIG. 128 is a block diagram of a second control system for controlling the hydraulic power supply unit, wherein the control system is connected to the side-lapped seam insertion sensing system;

FIG. 129 is a flow chart illustrating the operation of the control system shown in FIG. 128;

FIG. 130 is a partially exploded perspective view of the crimping assembly wherein the die plate, the return springs, the stop plug, and the upper carrier plate have been exploded apart from the punch plate;

FIGS. 131A-B are cross section views of the crimping assembly and the punch return springs taken along the line 131-131 shown in FIG. 127A;

FIG. 132 is a block diagram of another hydraulic power supply unit having a single-acting hydraulic cylinder;

FIG. 133 is a block diagram of a third control system for the hydraulic power supply unit, wherein the control system also includes retract and extend limit switches for monitoring the position of the crimping assembly;

FIGS. 134A-B are block diagrams illustrating how the retract and extend limit switches are triggered as the crimping assembly cycles between an open position and a closed position;

FIGS. 135A-C are flow charts illustrating the operation of the control system shown in FIG. 133;

FIG. 136 is a block diagram of a fourth control system for the hydraulic power supply unit, wherein the control system is also connected to the electric wheel motors which transport the deck seam tool over the deck structure;

FIG. 137 is a side elevation view of the deck seam tool on top of the deck structure;

FIG. 138 is a flow chart illustrating the operation of the control system shown in FIG. 136;

FIG. 139 is a block diagram of a fifth control system for the hydraulic power supply unit, wherein the hydraulic pump is directly driven by an internal combustion engine;

FIG. 140 is a block diagram of a sixth control system for the hydraulic power supply unit, wherein the hydraulic pump is driven by an electric motor which is powered by a generator connected to an internal combustion engine; and,

FIG. 141 is a side elevation view of the deck seam tool on top of a deck structure illustrating an interchangeable battery being connected to the hydraulic power supply unit.

Corresponding reference characters indicate corresponding parts throughout several views. Although the exemplification set out herein illustrates certain embodiments of the invention, the embodiments disclosed below are not intended to be exhaustive or to be construed as limiting the scope of the invention to the precise form disclosed.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

For ease of reference, the specification has been separated into several sections as follows:

- Section 1 begins at paragraph and includes a brief introduction of the present invention;
- Section 2 begins at paragraph and includes a description of an embodiment of the tool chassis and crimping assembly;
- Section 3 begins at paragraph and includes a description of an embodiment of the punch and die teeth and their respective, corresponding punch slots and die slots;
- Section 4 begins at paragraph and includes a description of an embodiment of the side-lapped seam attachments;
- Section 5 begins at paragraph and includes a description of an embodiment of the side-lapped seam insertion sensing system;
- Section 6 begins at paragraph and includes a description of the operation of the deck seam tool;
- Section 7 begins at paragraph and includes a description of a preferred embodiment of the deck seam tool and tool chassis;
- Section 8 begins at paragraph and includes a description of a preferred embodiment of the crimping assembly; and
- Section 9 begins at paragraph and includes a description of a preferred embodiment of the hydraulic system.

1. Introduction

A deck seam tool constructed in accordance with the principles of the present invention is shown and designated by the numeral 10. Referring initially to FIGS. 1-7, the deck seam tool 10 can be adapted for use with a deck structure 12 comprising a plurality of deck panels 14 supported by and secured to supporting beams/joists 13. The deck panels 14 are formed having a top surface 16t, bottom surface 16b, a pair of parallel, longitudinal side edges 18a, 18b and terminal end edges 19t. The deck panels 14 are longitudinally corrugated as shown, wherein the corrugations are defined by a plurality of parallel, longitudinal channels 21 including troughs or bottom portions 22 spaced between longitudinal peaks or top portions 20, and wherein the bottom portions 22 and top portions 20 are joined/coupled together via web portions 23 operatively extending between adjacent bottom portions 22 and top portions 20.

The deck panels 14 further include upturned male lips 24 extending vertically upwardly along the longitudinal side edges 18a, and downwardly directed U-shaped female channels 26 extending along the longitudinal side edges 18b. The U-shaped female channels 26 comprise female channel walls 28a, 28b extending downwardly from the joinder bend 29. As best seen in FIGS. 6 and 7, when adjacent deck panels 14a, 14b are installed in the deck structure 12, the female channels 26 can extend over and receive the male lip 24 of an adjacent deck panel 14 for thereby forming a side-lapped seam 30 comprising a region of three sheet metal plies/walls 28a, 28b and 24, generally indicated by the dimension line 44. Also, as seen in FIG. 3, the terminal end edges 19t of longitudinally adjacent deck panels 14 are overlapped in a known and customary manner. As more fully described hereinbelow, the deck seam tool 10 is used to join, crimp and otherwise secure the male lip 24 within and to the female channel 26 by forming interlocking side-lap seam attachments 297 along the side-lapped seams 30.

As depicted in FIGS. 8 and 9, the tool 10 comprises a chassis 32 and a side-lapped seam crimping assembly/mechanism 34 operably mounted within the chassis 32. The side-lapped seam crimping assembly 34 comprises a punch plate 36, a die plate 38, and an actuator such as, for example, electric actuators, pneumatic actuators, hydraulic actuators, and other types of linear actuators. In the present exemplary embodiment, the crimping assembly' actuator is preferably a double acting hydraulic cylinder 40. The punch plate 36 is coupled to the double acting hydraulic cylinder 40 and the die plate 38 is secured to the chassis 32. The hydraulic cylinder 40 is powered by an external hydraulic power source, such as, for example, a hydraulic power supply 41, for thereby selectively extending and driving the punch plate 36 (the moving/male plate) towards the die plate 38 (the stationary/female plate), and also selectively retracting the punch plate 36 away from the die plate 38. See, for example, FIG. 79 diagrammatic depiction thereof. The punch plate 36 includes one or more punch teeth (PT1, PT2, PT3 . . . PTX) and, preferably when more than one punch teeth PTX are provided, also one or more punch slots (PS1, PS2, PS3 . . . PSX) defined by the spaces between the punch teeth PTX. Similarly, the die plate 38 includes one or more die teeth (DT1, DT2, DT3 . . . DTX) and, preferably, when more than one die teeth DTX are provided, also one or more die slots (DS1, DS2, DS3 . . . DSX) defined by the spaces between the die teeth.

In operation, the tool 10 is placed on top of the deck structure 12 adjacent to a side-lapped seam 30. The punch and die plates 36, 38 are then positioned one on either side of and sandwiching the side-lapped seam 30 therebetween (FIG. 66). After the punch and die plates 36, 38 are in position, the hydraulic cylinder 40 is actuated and the punch plate 36 is driven towards the die plate 38. As the punch plate 36 approaches the die plate 38, the punch and die teeth PTX, DTX are driven into the sides of the side-lapped seam 30 thereby penetrating, cutting and punching the side-lapped seam and interlocking and joining the male lip 24 and the female channel 26 of the side-lapped seam 30 (by forming interlocking side-lap seam attachments 297), thereby securing the pair of adjacent deck panels 14 together.

As shown in FIGS. 8 and 9, the tool 10 can include a pair of wheels 50 and a handle 52. The wheels 50 are adapted to be secured one on either side of the tool 10 and enable a user to transport the tool 10 along a side-lapped seam 30 and/or transversely over/across the deck panels 14, as shown in FIGS. 1-4. The handle 52 can be mounted between the wheels 50. The wheels 50 are rotatably mounted on an axle 51 which is located between the crimping assembly 34 and the handle 52 (preferably vertically above and on one side or towards the rear of the crimping assembly) whereby the axle serves as a fulcrum and enables a user to tilt and rotate the tool 10 about the wheels 50 for thereby lifting the tool 10 towards and away from the deck panels 14 and the side-lapped seam 30. Accordingly, an operator of the tool 10 can use the handle 52 to easily transport/roll the tool 10 across the top surface of the deck panels 14 when the tool 10 is engaged with a side-lapped seam 30 and, also, lift the tool 10 away from side-lapped seam 30 and/or transport/roll it across the top of the deck panels 14 in a direction perpendicular to the side-lapped seam 30.

2. Tool Chassis & Crimping Assembly

As discussed hereinabove, the tool 10 includes a chassis 32 and a side-lapped seam crimping assembly 34 operably mounted within the chassis 32. As best seen in FIGS. 10-12, the chassis 32 comprises a tool frame 54, a tool alignment foot 56, and a side-lapped seam guide 62. The tool alignment foot 56 can be a trapezoidal prism comprising foot side surfaces 58, 60 extending along a longitudinal length L1 (FIGS. 13A-13C). The tool alignment foot 56 is secured to the bottom of the tool frame 54 and the foot side surfaces 58, 60 are aligned parallel to the punch and die plates 36, 38. Preferably, as shown in FIGS. 82-82, the foot side surfaces 58, 60 are adapted to slidingly engage web portions 23 of a deck longitudinal channel 21 adjacent to the side-lapped seam 30 for thereby helping to align the punch and die plates 36, 38 with the side-lapped seam 30.

Similar to the alignment foot 56, the side-lapped seam guide 62 can comprise a trapezoidal prism shape having guide side surfaces 64, 66 extending parallel to the punch and die plates 36, 38 and along a longitudinal length L2 (FIGS. 14A-14C). Preferably, the guide side surfaces 64, 66 slidingly engage the web portions 23 on either side of the side-lapped seam 30 (FIG. 82). The seam guide 62 can further include a U-shaped seam guide slot 68 opening downwardly toward the deck panels 14 and extending along the longitudinal length L2. The U-shaped seam guide slot 68 is adapted to slidingly receive a side-lapped seam 30 therein. Additionally, the side-lapped seam guide 62 is secured to the bottom of the tool frame 54 adjacent to the punch and die plates 36, 38 such that the U-shaped seam guide slot 68 is longitudinally aligned with the punch and die plates 36, 38 for thereby aligning the punch and die plates 36, 38 with the side-lapped seam 30. The tool alignment foot 56 and side-lapped seam guide 62 are preferably made of a wear-resistant material such as high density polyethylene (“HDPE”).

As shown in FIGS. 1-4 and, more particularly, 15 and 16, the chassis 32 can include a cart frame 116 secured to the tool frame 54 and adapted to support the axle 51, wheels 50 and the handle 52. Preferably, the tool 10 includes a mounting tray 406 mounted to the handle 52 above the wheels 50. The mounting tray 406 is adapted to support a power supply unit 41 which can be, for example, a hydraulic power supply unit, a pneumatic power supply unit, an electrical power supply unit, or other types of power supplies which can be used to selectively operate the tool 10.

Preferably, the power supply unit 41 is a hydraulic power supply unit. As shown in FIGS. 79, 120, 132, 139, and 140, the hydraulic power supply unit 41 includes a hydraulic pump 41p which supplies high pressure hydraulic fluid to the hydraulic cylinder 40 for moving the punch plate 36 towards or away from the die plate 38. The hydraulic power supply 41 can further include a control valve 41cv, a relief valve 41rv and a reservoir 41R hydraulically coupled as shown in FIG. 79. As can be appreciated by one skilled in the art, when the control valve 41cv is in its driving position as shown (connecting the pump 41p to conduit 138 and conduit 140 to the reservoir 41R), the piston of the hydraulic cylinder 40 is actuated for driving the punch plate 36 towards the die plate 38 and, when the control valve 41cv is placed in its retracting position (connecting pump 41p to conduit 140 and conduit 138 to the reservoir 41R), the piston of the hydraulic cylinder 40 is retracted for moving the punch plate 36 away from the die plate 38.

Preferably, the hydraulic pump 41p is powered by a self-contained, portable power source that is mounted to the tool 10. For example, in one embodiment (FIGS. 79, 120, 132, and 141) the hydraulic pump 41p is coupled to and driven by an electric pump motor 41m that is powered by one or more removeable, interchangeable batteries 41b. Preferably, as illustrated in FIG. 141, the interchangeable batteries 41b can be connected to or disconnected from the hydraulic power supply unit 41 to allow the tool operator to replace the batteries 41b once they have been depleted.

In another embodiment (FIGS. 139 and 140), the tool 10 includes an internal combustion engine 41e. The internal combustion engine 41e can be coupled for directly driving the hydraulic pump 41p (FIG. 139) or, alternatively, the internal combustion engine 41e can be coupled a generator 41g which is connected to and powers the pump motor 41m for thereby driving the hydraulic pump 41p (FIG. 140). By using a portable power source, such as the interchangeable batteries 41b or the internal combustion engine 41e, the tool 10 can be used without needing to be connected to an external power source by, for example, electrical cables/power cords which drag behind the tool 10 during use thereof. This, in turn, improves the portability of the tool 10 and eliminates the need for a pre-existing electrical infrastructure.

Returning to FIGS. 17-22, the tool frame 54 comprises a horizontal base plate 70, vertical support walls 86, 88, 90, 92, 94, 96, 98, 100, a support plate 102, a die plate support wall 108, hydraulic cylinder mounting plates 110, 112, 114, and component cover members 118. The horizontal base plate 70 forms the bottom of the tool frame 54. The base plate 70 includes a base plate top surface 72 facing away from the deck panels 14, a base plate bottom surface 74 facing towards the deck panels 14, longitudinal base plate side surfaces 76, 78, and base plate end surfaces 80, 82. As shown in FIG. 17A-C, a crimping assembly window 84 is provided extending through base plate top surface 72 and the base plate 70 between the base plate side surfaces 76, 78 and between the base plate end surfaces 80, 82. The crimping assembly window 84 is configured to allow the punch and die plates 36, 38 to be supported within the tool frame 54 and extend downwardly through the window 84 for thereby engaging the side-lapped seam 30.

In one embodiment, the base plate bottom surface 74 can act as a sled surface that extends perpendicular to and straddles the side-lapped seam 30. Preferably, the base plate bottom surface 74 can rest on and slide across on the deck panel top surface 16t on each side of the side-lapped seam 30 and, together with the wheels 50, locate the punch and die plates 36, 38 at a desired height above the deck panel bottom portions 20.

In a second embodiment, as shown in FIGS. 9, 11 and 12, the tool frame 54 can further include a sled plate 120 adapted to abut the base plate bottom surface 74 and be secured thereto. The sled plate 120 is adapted to rest and slide on the deck panel top surface 16t and, together with the wheels 50, locate the punch and die plates 36, 38 at a desired height above the deck panel bottom portions 20. Preferably, the sled plate 120 is constructed from a high wear-resistant material such as HDPE and is removably secured to the base plate 70 to allow the sled plate 120 to be replaced when it becomes worn-out. Additionally, the tool frame 54 can include a crimping assembly shield plate 400 adapted to be secured to the base plate 70. The crimping assembly shield plate 400 is adapted to cover a portion of the crimping assembly window 84 for thereby shielding the crimping assembly 34 components from impacts during transportation and operation of the tool 10.

As shown in FIGS. 18A-B, the vertical support walls 86, 88, 90, 92, 94, 96, 98, 100 are secured to the base plate 70. Preferably, the vertical support walls 92, 90 are secured to the base plate side surfaces 76, 78, respectively, and the vertical support walls 86, 88 are secured to the base plate top surface 72 adjacent to the base plate end surfaces 80, 82, respectively. Additionally, the vertically extending side edges of adjacent vertical support walls 86, 88, 90, 92, 94, 96, 98, 100 can be secured together by securing means such as, for example, fasteners, welding, brazing or similar securing means, for thereby further strengthening the tool frame 54.

As shown in FIGS. 21A-C, the support plate 102 can comprise support plate top and bottom surfaces 104, 106. The support plate 102 is secured to the vertical support walls 86, 88, 90, 92, 94, 96, 98, 100 and supported above the horizontal base plate 70. Preferably, the support plate bottom surface 106 is aligned generally parallel to and facing the base plate top surface 72. The crimping assembly 34 is adapted to be secured between the support plate 102 bottom surface 106 and the base plate 70 top surface 72. As should now be appreciated, the support plate 102, the vertical support walls 86, 88, 90, 92, 94, 96, 98, 100, and the horizontal base plate 70 form a housing that supports and surrounds the crimping assembly 34.

As shown in FIGS. 20A-B, the die plate support wall 108 is secured between the support plate 102 and the base plate 70 at a position inboard of the base plate end surface 82. The die plate support wall 108 is adapted to rigidly support and hold the die plate 38 in a stationary position during operation of the crimping assembly 34. Additionally, the tool frame 54 can further comprise additional vertical support walls 122, 124 adapted to be secured to the die plate support wall 108, the base plate 70, and the support plate 102 via securing means such as, for example, fasteners, welding, brazing or similar securing means for thereby further supporting and strengthening the die plate support wall 108.

As shown in FIGS. 19A-B, the hydraulic cylinder mounting plates 110, 112, 114 are secured to the base plate 70, with plate 114 being adjacent to the base plate end surface 80. Additionally, the hydraulic cylinder mounting plate 110 can be secured to the support plate 102. The hydraulic cylinder mounting plates 110, 112, 114 include respective hydraulic cylinder mounting bores 126a, 126b, 126c adapted to receive the hydraulic cylinder 40 (FIGS. 28-32) for thereby securing the hydraulic cylinder 40 between the base plate 70 and the support plate 102. Additionally, the vertical support walls 98, 100 can be secured to the base plate 70 extending adjacent and perpendicular to the hydraulic cylinder mounting plates 110, 112, 114. The hydraulic cylinder mounting plates 110, 112, 114 can be secured along their vertical side edges to the vertical support walls 98, 100, thereby supporting the hydraulic cylinder mounting plates 110, 112, 114.

A hydraulic cylinder cover plate 130 can be secured between the vertical support walls 98, 100 above the hydraulic cylinder mounting plates 110, 112, 114. The hydraulic cylinder cover plate 130 and the support plate 102 can include hydraulic conduit receiving bores 132 adapted for receiving hydraulic fluid conduits 138, 140 therethrough (FIGS. 22, 23). More particularly, the hydraulic conduit receiving bores 132 are aligned with hydraulic conduit couplings 150a, 150b of the hydraulic cylinder 40 for thereby allowing the couplings to extend therethrough and engage the respective hydraulic fluid conduits 138, 140 (FIG. 8).

Preferably, as shown in FIGS. 19A-B, the hydraulic cylinder mounting plate 114 can be removably secured to the vertical support walls 98, 100 and the hydraulic cylinder cover plate 130, for example, by using machine screws 114f, for thereby allowing the hydraulic cylinder mounting plate 114 to be removed as desired or needed for maintenance, repair, or replacement of the hydraulic cylinder 40.

As shown in FIG. 10, the component cover members 118 are secured to tool frame 54 to cover exposed portions of the crimping assembly 34 not enclosed within the chassis 32. The component cover members 118 are adapted to protect the exposed portions of the crimping assembly 34 from damage.

Referring now more particularly to FIGS. 23-58, the crimping assembly 34 comprises a punch plate 36, a die plate 38, a double acting hydraulic cylinder 40, and a punch plate carrier assembly 136. The double acting hydraulic cylinder 40 is secured to the tool frame as described hereinabove and can include a hydraulic ram 142 and a cylinder body 148 (FIG. 26A). The punch plate 36 is secured to the punch plate carrier assembly 136 and the carrier assembly 136 is coupled to the hydraulic ram 142 (FIGS. 35-48). As previously mentioned, the die plate 38 is secured to the die plate support wall 108, and hence to the tool frame 54 (FIGS. 20, 24 and 35). The punch plate 36 and the carrier assembly 136 are configured such that, by extending and retracting the hydraulic ram 142, the punch plate 36 can be selectively moved between an open position, wherein the punch teeth PTX of plate 36 are spaced apart from the die teeth DTX of die plate 38 and define a side-lapped seam receiving gap 30G therebetween, as shown in FIGS. 25A, 35 and 50, and a closed position, wherein the punch teeth PTX are received within the die slots DSX and the die teeth DTX are received within the punch slots PSX, as shown in FIGS. 25B and 78B.

As shown in FIGS. 26A-B, the double acting hydraulic cylinder 40 can include a hydraulic ram 142 comprising a piston rod 144 and a ram flange 146 secured adjacent to a terminal end of the piston rod 144, and a cylinder body 148 comprising first and second hydraulic conduit couplings 150a, 150b. The first and second hydraulic fluid conduits 138, 140 can be connected to the respective first and second hydraulic conduit couplings 150a, 150b for connecting the hydraulic cylinder 40 to the hydraulic power supply 41 as diagrammatically shown in FIG. 79.

As shown in FIGS. 27 and 28, the cylinder body 148 comprises a longitudinal axis A1 and cylindrical center, end cap, and head sections 152, 154, 156 each aligned longitudinally along the axis A1. The cylindrical end cap and head sections 154, 156 extend along the axis A1 from respective, opposite terminal ends of the center section 152. The center, end cap, and head sections 152, 154, 156 have respective external diameters D1, D2, D3. Preferably, the end cap and head sections' external diameters D2, D3 are smaller than the center section's diameter D1 for thereby forming annular cylinder shoulders 158a, 158b at opposite terminal ends of the center section 152. The hydraulic cylinder mounting bores 126a, 126b, 126c of respective mounting plates 110, 112, 114 can be adapted to receive the end cap, center, and head sections 154, 152, 156, respectively, and such that the annular cylinder shoulders 158a, 158b abut side surfaces of the respective hydraulic cylinder mounting plates 110, 114. As should now be appreciated, and as shown in FIG. 30, the center section 152 extends through the cylinder mounting bore 126b of mounting plate 112 and is sandwiched between the hydraulic cylinder mounting plates 110, 114 for thereby securing the cylinder body 148 to the tool frame 54.

Preferably, as shown in FIGS. 31 and 32, an annular support ring 160 having a threaded bore 162 is adapted to threadingly receive and be secured to a threaded terminal end of the cap section 154 (threads not shown). The annular support ring 160 is adapted to abut and also be secured to the hydraulic cylinder mounting plate 110 with fasteners (not shown) opposite the annular cylinder shoulder 158a for thereby supporting the end cap section 154 and aligning the axis A1 parallel to the base plate top surface 72. The hydraulic ram 142 extends longitudinally along the cylinder body's longitudinal axis A1 and extends outwardly from the end cap section 154, through the annular ring 160, towards the die plate 38.

As mentioned hereinabove, the hydraulic cylinder 40 is preferably “double acting” whereby the hydraulic cylinder 40 is adapted to drive or pull the hydraulic ram 142 along the cylinder body's longitudinal axis A1 when hydraulic fluid/pressure is provided to one of the hydraulic conduit couplings 150a, 150b. For example, as diagrammatically depicted in FIG. 79, when hydraulic fluid is pumped through, and hydraulic pressure is provided to, the first hydraulic conduit coupling 150a, the hydraulic cylinder 40 is adapted to drive the hydraulic ram 142 towards the die plate 38. Similarly, when hydraulic fluid is pumped through, and hydraulic pressure is provided to the second hydraulic conduit coupling 150b, the hydraulic cylinder 40 is adapted to pull the hydraulic ram 142 away from the die plate 38.

Preferably, as shown in FIGS. 33-35, the crimping assembly 34 can further comprise one or more punch return springs 164 adapted to assist the double acting hydraulic cylinder 40 in returning the punch plate 36 from the closed position to the open position. The punch return springs 164 can be compression coil springs adapted to be secured between the tool frame 54 and the carrier assembly 136. Preferably, the die plate 38 can include punch return spring bores 166 extending through the die plate face surface 264 to the die plate rear surface 266 whereby the punch return springs 164 are received through the punch return spring bores 166 and abut the die plate support wall 108. Additionally, the punch return springs 164 can be adapted to be seated, at their opposite ends, in recessed bores 167 on the upper carrier plate 192 of the carrier assembly 136.

Additionally, as more fully discussed hereinbelow, when the control valve 41cv is placed in its retracting position (connecting the pump 41p to conduit 140 and connecting conduit 138 to the reservoir 41R), the springs 164 provide an additional force to retract and move the punch plate 36 away from the die plate 38 and to push the hydraulic fluid within the hydraulic cylinder 40 out through the conduit 138 to the reservoir 41R.

In another embodiment, as diagrammatically depicted in FIG. 80, the hydraulic cylinder 40 can be “single acting” whereby the hydraulic cylinder 40 is adapted to drive the hydraulic ram 142 only towards the die plate 38. In this embodiment, the hydraulic power supply unit 41 includes a single-acting control valve 41cv′. When the single-acting control valve 41cv′ is in its driving position as shown (connecting the pump 41p to conduit 138 and closing off the return line to the reservoir 41R), the piston of the hydraulic cylinder 40 is actuated for driving the punch plate 36 towards the die plate 38. When the single-acting control valve 41cv′ is placed in its retracting position (closing off the line from the pump 41p and connecting conduit 138 to the reservoir 41R), the springs 164 provide the force to retract and move the punch plate 36 away from the die plate 38 and to push the hydraulic fluid within the hydraulic cylinder 40 out through the same conduit 138 to the reservoir 41R.

As best seen in FIGS. 36-48, the punch plate carrier assembly 136 comprises a lower carrier plate 168, an upper carrier plate 192, a pair of sliding rails 212, and a plurality of rail carriers/tracks 220. The lower carrier plate 168 comprises lower carrier plate top and bottom surfaces 170, 172 and lower carrier plate end surfaces 178, 180. The lower carrier plate 168 is supported adjacent to the base plate 70 and extends generally parallel thereto such that the lower carrier plate bottom surface 172 is generally parallel to and facing the base plate top surface 72.

Preferably, the lower carrier plate 168 further includes a punch plate mounting window 182 and a lower hydraulic cylinder window 184. The punch plate mounting and lower hydraulic cylinder windows 182, 184 are formed as shown extending into the lower carrier plate 168 from respective end surfaces 178, 180. Accordingly, the lower carrier plate 168 is H-shaped having parallel rail legs 186, 188 and a carrier beam 190 extending therebetween. The punch plate mounting window 182 is configured to receive the punch plate 36 therein and whereby the punch plate 36 can be secured to the carrier beam 190. Additionally, the punch plate mounting window 182 can be adapted to receive the die plate 38 whereby the rail legs 186, 188 extend one on either side of the die plate 38. The lower hydraulic cylinder window 184 can be configured to receive a terminal end of the cylinder body 148 for thereby allowing the ram flange 146 to be mounted to the carrier beam 190.

The upper carrier plate 192, as best seen in FIGS. 38A-C, comprises upper carrier plate top and bottom surfaces 194, 196, longitudinal upper carrier plate side surfaces 198, 200, and transverse upper carrier plate end surfaces 202, 204. The upper carrier plate 192 is adapted to be secured to the carrier beam 190 between the rail legs 186, 188 with the upper carrier plate bottom surface 196 abutting the lower carrier plate top surface 170. Additionally, the upper carrier plate 192 can include a die plate receiving window 206 and an upper hydraulic cylinder window 208 extending into the upper carrier plate 192 from respective end surfaces 202, 204. Accordingly, the upper carrier plate 192 is H-shaped. Preferably, the die plate receiving window 206 is aligned with the punch plate mounting window 182 and the upper hydraulic cylinder window 208 is aligned with the lower hydraulic cylinder window 184. The die plate receiving window 206 and the upper hydraulic cylinder window 208 are adapted to receive the die plate 38 and a terminal end of the cylinder body 148, respectively.

As shown in FIGS. 39 and 40, the upper carrier plate 192 can include a punch plate capturing slot 210 extending into the upper carrier plate from the bottom surface 196 and between the upper carrier plate side surfaces 198, 200. The punch plate capturing slot 210 is adapted to receive the punch plate's upper mounting beam 246 (FIG. 51) therein for thereby capturing the punch plate 36 within the punch plate capturing slot 210.

Preferably, lower carrier plate 168 includes an upper carrier plate receiving recess 408 extending into the lower carrier plate from the top surface 170, adjacent the lower hydraulic cylinder window 184 (FIG. 37A-B). The upper carrier plate receiving recess 408 can be adapted to receive a bottom portion of the upper carrier plate 192, for thereby aligning the upper and lower carrier plates 192, 168. The lower carrier plate 168 further includes a carrier plate locating strip 396 and a carrier plate strip slot 398 extending into the lower carrier plate top surface 170 adjacent the upper carrier plate receiving recess 408 and adjacent the punch plate mounting window 182. The carrier plate locating strip 396 is configured to be inserted into the carrier plate strip slot 398 and secured to the lower carrier plate 168. The carrier plate locating strip 396 can be adapted to abut the upper carrier plate 192 when the upper carrier plate 192 is secured within the upper carrier plate receiving recess 408.

As best seen in FIG. 45, the sliding rails 212 are secured to the rail legs 186, 188 of the lower carrier plate 168 one on either side of the upper carrier plate 192. Preferably, the sliding rails 212 are aligned extending parallel to the hydraulic cylinder body 40 longitudinal axis A1. The sliding rails 212 can be I-shaped comprising upper rail heads 214 adapted to engage the rail carriers/tracks 220, lower rail feet 216 adapted to abut the lower carrier plate 168 top surface 170, and rail webs 218 extending therebetween (FIG. 42A-B).

Referring now more particularly to FIGS. 43 and 44, the rail carriers/tracks 220 can be rectangular prisms comprising longitudinal lengths L3, carrier/track bottom surfaces 222, carrier/track end surfaces 224, 226, and rail journal slots 228. The rail carriers/tracks 220 are adapted to be secured to the bottom of the support plate 102 (FIG. 23). Preferably, the rail carriers/tracks 220 and the support plate 102 include a plurality of corresponding rail carrier/track mounting bores 229, 230, respectively, whereby fasteners (not shown) can be extended through the rail carrier/track mounting bores 230 of the support plate 102 for threadingly engaging the rail carrier/track mounting bores 229 of the rail carriers/tracks 220 and securing the rail carriers/tracks 220 to the support plate 102. The rail journal slots 228 extend along the longitudinal lengths L3 between the carrier/track end surfaces 224, 226 and through the carrier/track bottom surfaces 222. The rail journal slots 228 are adapted to capture the rail heads 214 such that the rail carriers/tracks 220 support and longitudinally slidingly suspend the sliding rails 212, and hence the lower and upper carrier plates 168, 192, above the base plate 70. When the hydraulic cylinder 40 is actuated, the sliding rails 212 are adapted to slide longitudinally through the rail journal slots 228, thereby slidingly supporting and aligning the punch plate 36 with the die plate 38 as the crimping assembly 34 is moved between the open and closed positions.

Preferably, the upper and lower carrier plates 192, 168 include a plurality of corresponding carrier plate fastening bores 233, 232, respectively, adapted to receive fasteners such as, for example, bolts (not show) therethrough. The fasteners can be extended through carrier plate fastening bores 232 of the lower carrier plate 168 for thereby threadingly engaging the carrier plate fastening bores 233 of the upper carrier plate 192 and securing the carrier plates 168, 192 together (FIGS. 40 and 48). Additionally, the lower carrier plate 168 and the sliding rails 212 include a plurality of corresponding sliding rail mounting bores 234, 235, respectively, adapted such that fasteners such as bolts (not shown) can be extended through the sliding rail mounting bores 234 of the lower carrier plate 168 for thereby threadingly engaging the sliding rail mounting bores 234 of the sliding rails 212 and securing the sliding rails 212 to the lower carrier plate 168 (FIG. 45).

As shown in FIGS. 46-48, the hydraulic ram 142 flange 146 is coupled to the carrier assembly 136 for thereby allowing the hydraulic cylinder 40 to selectively slidingly drive the carrier assembly 136 along the longitudinal axis A1. As shown in FIG. 26A, the piston rod 144 can be a cylindrical rod extending longitudinally from the cylinder body 148. The ram flange 146 can be secured adjacent to a terminal end of the piston rod 144. Preferably, the ram flange 146 is an annular flange extending radially away from the piston rod 144.

Preferably, upper and lower ram flange receiving pockets 236, 238 are formed extending into the upper carrier plate 192 and the lower carrier plate 136, respectively, and are located adjacent to the upper and lower hydraulic cylinder windows 208, 184, respectively. The upper and lower ram receiving pockets 236, 238 are aligned whereby the ram flange 146 is sandwiched between the upper carrier plate 192 and the lower carrier plate 136 and is captured within the ram receiving pockets 236, 238 for thereby securing the carrier assembly 136 to the hydraulic ram 142.

Preferably, as shown in FIGS. 39 and 46-48, the upper ram receiving pocket 236 can be shaped to extend around and circumscribe more than 180° of the ram flange 146 and so the flange is inserted into the receiving pocket 236 from the rear end of the upper carrier plate, through the upper hydraulic cylinder window 208. Additionally, the carrier assembly 136 can include a ram receiving pocket cover plate 242 adapted to be secured to the upper carrier plate 192 over the upper ram receiving pocket 236 with fasteners (not shown) for thereby covering the upper ram receiving pocket 236 and capturing the ram flange 146 therein (FIG. 48).

As should now be appreciated, when high pressure hydraulic fluid is pumped from hydraulic power supply unit 41 through hydraulic fluid conduit 138 (and hydraulic fluid conduit 140 is connected to the reservoir 41R), the hydraulic ram 142 is extended for thereby driving the carrier assembly 136 and the punch plate 36 towards the die plate 38. Then, when high pressure hydraulic fluid is pumped through hydraulic fluid conduit 140 (and hydraulic conduit 138 is connected to the reservoir 41R), the hydraulic ram 142 is retracted for thereby pulling the carrier assembly 136 and punch plate 36 away from the die plate 38.

As shown in FIGS. 49 and 51-53, the punch plate 36 is preferably integrally formed comprising a vertical punch plate wall 244 and horizontal upper and lower mounting beams 246, 248. The vertical punch plate wall 244 comprises a punch plate face surface 250, a punch plate rear surface 252, and punch plate top and bottom surfaces 258, 260. The horizontal upper and lower mounting beams 246, 248 extend from the punch plate rear surface 252 perpendicularly away from the punch plate wall 244. The upper and lower mounting beams 246, 248 are vertically spaced apart for thereby forming a carrier beam receiving slot 262 therebetween. The carrier beam receiving slot 262 is adapted to receive the lower carrier plate 136 carrier beam 190 therein, and the upper and lower mounting beams 246, 248 are adapted to be secured to the lower carrier plate 168 (FIGS. 33, 40, 48 and 49). Preferably, the upper and lower mounting beams 246, 248 and the carrier beam 190 include a plurality of corresponding punch plate mounting bores 247, 249, respectively, adapted to receive fasteners (not shown) for thereby securing the punch plate 36 to the carrier beam 190 of the lower carrier plate 168.

As shown in FIGS. 55 and 56A-C, the die plate 38 is preferably integrally formed comprising a die plate face surface 264, a die plate rear surface 266, die plate side surfaces 268, 270, and die plate top and bottom surfaces 272, 274. The die plate rear surface 266 is adapted to be placed against/abutting the die plate support wall 108 such that the die plate face surface 264 faces towards the punch plate face surface 250 (FIG. 49). Preferably, the die plate 38 can be received within the lower carrier plate's punch plate mounting window 182 and the sliding rails 212, carriers/tracks 220 and the parallel rail legs 186, 188 of the lower carrier plate 168 can extend one on either side of the die plate 38 (FIG. 24).

As illustrated in FIG. 49, during operation of the tool 10, reaction forces F1, F2 are generated opposing penetration of the punch and die teeth PTX, DTX into the side-lapped seam 30. As shown in FIG. 49, the punch and die teeth PTX, DTX are located adjacent to the punch and die plate bottom surfaces 260, 274, respectively. Accordingly, the reaction forces F1, F2 produce respective reaction torques T1, T2 about the moment centers of the punch and die plates 26, 38. For illustrative purposes, reaction torque T1 is shown as being produced about moment center axis MA1 extending transversely through the punch plate 36, and reaction torque T2 is shown as being produced about moment center axis MA2 extending transversely through the die plate 38.

With respect to the reaction torque T1, as discussed hereinabove, the punch plate 36 is secured to and supported by the lower carrier plate 168, which, in turn, is secured to the chassis 32 with the sliding rails 212 and the rail carriers/tracks 220. Accordingly, the torque T1 is transferred from the punch plate 36 to the carrier beam 190 of the lower carrier plate 168 and then to the chassis 32 through the sliding rails 212 and the rail carriers/tracks 220. The rail carriers/tracks 220 and the chassis 32 resist the torque T1 and prevent the punch teeth PTX and the punch plate 36 from rotating during operation of the tool 10. Preferably, as best seen in FIG. 48, the punch plate 36 is secured to the lower carrier plate 168 carrier beam 190 such that the moment center axis MA1 is located near a midpoint between the lower carrier plate end surfaces 178, 180, for thereby evenly distributing the torque T1 along the lower carrier plate rail legs 186, 188, and, therefore, evenly distributing the torque T1 across the chassis 32 through the sliding rails 212 and the rail carriers/tracks 220.

With respect to the reaction torque T2, as discussed hereinabove, the die plate 38 is secured to and supported by the die plate support wall 108 which, in turn, is secured to the base plate 70. Accordingly, the torque T2 is transferred from the die plate 38 to the die plate support wall 108 and, hence, to the chassis 32, whereby the die plate support wall 108 and the chassis 32 resist the torque T2 and prevent the die teeth DTX and the die plate 38 from rotating during operation of the tool 10. Preferably, as best seen in FIG. 20A-B, the vertical support walls 122, 124, which are secured to the base plate 70 and the die plate support wall 108, further support the die plate support wall 108 and the die plate 38 for thereby resisting and transferring the torque T2 to the base plate 70 and the chassis 32. Yet more preferably, as discussed in greater detail hereinbelow, the tool 10 can include an intermediate beam 320 which is secured to the underside of the support plate 102 (surface 106) and abuts the die plate face surface 264 adjacent the die plate top surface 272. In addition to the vertical support walls 122, 124 and the die plate support wall 108, the torque T2 is counteracted and transferred to the support plate 102 and the chassis 32 by the intermediate beam 320.

Preferably, as shown in FIGS. 51, 52, and 84, the punch plate 36 further includes a plurality of punch plate locating protrusions 276a, 276b, 276c, 276d, 276e extending outwardly from the punch plate face surface 250, and a plurality of punch plate locating pockets 278a, 278b, 278c, 278d extending into punch plate 36 through the punch plate face surface 250 interspersed therebetween. As shown in FIGS. 55 and 56, the die plate 38 similarly includes die plate locating protrusions 280a, 280b, 280c, 280d extending outwardly from the die plate face surface 264, and a plurality of die plate locating pockets 282a, 282b, 282c, 282d, 282e extending into the die plate 38 through the face surface 264 and interspersed therebetween which are, however, a mirror image of the punch plate 36 locating protrusions and pockets 276, 278. As depicted in FIGS. 84 and 85, when the punch plate 36 is driven towards the die plate 38, the punch plate locating protrusions and pockets 276, 278 engage and/or are received in their corresponding die plate locating protrusions and pockets 280, 282 (for example, the punch plate locating protrusion 276a, is received in the die plate locating pocket 282d, the punch plate locating protrusion 276b is received in the die plate locating pocket 282e, the punch plate locating protrusion 276c is received in the die plate locating pocket 282c, the die plate locating protrusion 280a is received in the punch plate locating pocket 278d, the die plate locating protrusion 280b is received in the punch plate locating pocket 278c, the die plate locating protrusion 280c is received in the punch plate locating pocket 278b, etc.) for thereby vertically and horizontally aligning the punch plate 36 with the die plate 38.

As shown in FIGS. 33, 48, and 85, a threaded bore 283 (FIGS. 48 & 85) can be provided extending longitudinally/parallel to axis A1 through the die plate 38, between die plate face surfaces 264 and 266, and aligned with an adjustment window bore 109 extending through the die plate support wall 108. A threaded rod-shaped punch plate stop plug 281 is threadingly received in the threaded bore 283. At one of its terminal ends, stop plug 281 includes a tool engagement and adjustment slot 281as which is accessible through the adjustment window bore 109. The stop plug 281 other/second terminal end extends out of the die plate 38, beyond the die plate surface 264, and is adapted to abut the upper carrier plate 192 face between the recessed bores 167 when the carrier plate 192 is advanced towards the die plate 38. As should now be appreciated, the punch plate stop plug 281 functions to limit and stop the travel of the carrier plate 192 and punch plate 36 mounted thereon and, hence, the penetration depth of the punch and die teeth PTX, DTX into the side-lapped seam 30. Additionally, by inserting a tool such as a flat screwdriver through the adjustment window bore 109 and turning and advancing or retracting the stop plug 281 through the threaded bore 283, the length which the stop plug second terminal end extends beyond the die plate surface 264 can be adjusted, thereby also selectively adjusting the penetration depth of the punch and die teeth PTX, DTX into the side-lapped seam 30.

3. Punch Teeth, Die Teeth and Their Corresponding Respective Receiving Punch Slots and Die Slots

Turning now to FIGS. 50-53, 55, and 56A-C, as also mentioned hereinabove, the punch plate 36 includes one or more punch teeth (PT1, PT2, PT3 . . . PTX) and one or more receiving punch slots (PS1, PS2, PS3 . . . PSX) defined by the spaces between the punch teeth PTX. Similarly, the die plate 38 includes one or more die teeth (DT1, DT2, DT3 . . . DTX) and one or more receiving die slots (DS1, DS2, DS3 . . . DSX) defined by the spaces between the die teeth DTX. The punch and die teeth PTX, DTX can be located adjacent to the punch plate and die plate bottom surfaces 260, 274, respectively. As best seen in FIGS. 50, 76B, 77B and 77B, the punch teeth PTX are spaced horizontally apart from each other at intervals for thereby defining the punch slots PSX therebetween and the die teeth DTX are horizontally spaced apart from each other at intervals for thereby defining the die slots DSX therebetween (e.g., receiving die slot DS1 is located between die teeth DT1 and DT2, receiving punch slot PS2 is located between punch teeth PT1 and PT2, receiving die slot DS2 is located between die teeth DT2 and DT3, etc.). Also, the punch teeth PTX are horizontally shifted relative to the die teeth DTX whereby each of the die slots DSX are adapted to receive a corresponding opposing punch tooth PTX and each of the punch slots PSX are adapted to receive a corresponding opposing die tooth DTX. For example, as the punch plate 36 is advanced towards the die plate 38, punch tooth PT1 is received within die slot DS1, die tooth DT2 is received within punch slot PS2, punch tooth PT2 is received within die slot DS2, etc.

As shown in FIGS. 53B and 54A-54D of a representative die tooth DT2 and FIGS. 54E-54H of a representative punch tooth PT2, each of the punch teeth PT1, PT2, PT3 and the die teeth DT2, DT3 comprise a saddle shape defined by a pommel side end 284p, a cantle side end 286c, and a central seat portion 285s therebetween, wherein the pommel and cantle side ends 284p, 286c of the punch and die teeth PTX, DTX each have a semi-conical configuration (shaped similar to a longitudinally cut-in-half cone). Put another way, each pommel and cantle side end 284p, 286c is defined by a half-cone shaped leading surface 288, a triangular flat surface 290, and a cutting edge 292 therebetween. The cutting edges 292 are shaped with a leading arcuate nose section 294 and lagging triangularly expanding/diverging edges 296a, 296b. The central seat portion 285s is located and extends between the half-cone shaped leading surfaces 288 and defines the depressed “seat” of the saddle-shape. The central seat portion 285s is depressed/recessed from the forward/leading arcuate nose sections 294 a depth defined by the numeral 285d (FIG. 54B). Also, the longitudinal length of each punch and die tooth PTX, DTX (the longitudinal distance between the cantle side end cutting edge 292c and triangular flat surface 290c and the pommel side end cutting edge 292p and triangular flat surface 290p of each tooth) is defined by the numerals PTXL, DTXL (FIGS. 50 and 54B), respectively, and the longitudinal width of each punch and die slot PSX, DSX (the longitudinal distance between the cantle side end cutting edge 292c and triangular flat surface 290c of a punch or die tooth PTX, DTX and the pommel side end cutting edge 292p and triangular flat surface 290p of an adjacent punch or die tooth PTX, DTX) is defined by the numerals PSXL, DSXL, respectively (FIG. 50). As illustrated in FIGS. 50, 76 and 77 and further discussed hereinbelow, the longitudinal width PSXL, DSXL of each receiving punch or die slot PSX, DSX is sized and adjusted to be slightly larger than the longitudinal length PTXL, DTXL of the punch or die tooth PTX, DTX which is received therein.

As mentioned hereinabove, the punch and die teeth PTX, DTX are spaced horizontally apart from each other at intervals for thereby defining the punch and die slots PSX, DSX therebetween. Additionally, the punch teeth PTX are horizontally shifted relative to the die teeth DTX whereby each of the die slots DSX are adapted to receive a corresponding opposing punch tooth PTX and each of the punch slots PSX are adapted to receive a corresponding opposing die tooth DTX. More particularly in this regard, the die teeth DTX are horizontally spaced apart from each other to define die slots DSX having a longitudinal width DSXL slightly larger than and adapted to receive corresponding opposing punch teeth PTX, and the punch teeth PTX are horizontally spaced apart from each other to define punch slots PSX having a longitudinal width PSXL slightly larger than and adapted to receive corresponding opposing die teeth DTX. For example, the die teeth DT1 and DT2 are horizontally spaced apart from each other to define die slot DS1 having a longitudinal width DSXL slightly larger than and adapted to receive corresponding opposing punch tooth PT1 with a longitudinal length PTXL, the punch teeth PT1 and PT2 are horizontally spaced apart from each other to define punch slot PS2 having a longitudinal width PSXL slightly larger than and adapted to receive corresponding opposing die tooth DT2 with a longitudinal length DTXL, the die teeth DT2 and DT3 are horizontally spaced apart from each other to define die slot DS2 having a longitudinal width DSXL slightly larger than and adapted to receive corresponding opposing punch tooth PT2 with a longitudinal length PTXL, etc.

Accordingly, as should now be appreciated, by adjusting the longitudinal lengths PTXL, DTXL of the punch and die teeth PTX, DTX, and hence the corresponding opposing receiving slot DSX, PSX thereof, the number of punch and die teeth PTX, DTX of the crimping system 34 can be increased or decreased as needed or desired and/or for accommodating the width of the punch and die plates 36, 38. Additionally, the longitudinal lengths PTXL, DTXL of each of the punch and die teeth PTX, DTX used within a given crimping system 34 can be varied, hence also varying the corresponding opposing receiving slots DSX, PSX thereof, whereby the longitudinal length of the attachments 297 made by the punch and die teeth PTX, DTX between the slit openings 298 can also be varied.

The end die teeth DT1 and DT4 on the die plate 38 comprise a longitudinal half saddle shape (are shaped essentially the same as one-half of the die teeth DT1, DT3) and define one of either a pommel side end 284p or a cantle side end 286c, each of which similarly include a semi-conical configuration (shaped similar to a longitudinally cut-in-half cone) defined by a half-cone shaped leading surface 288, a triangular flat surface 290, and a cutting edge 292 therebetween. The end die tooth DT1 defines a pommel side end 284p, and the end die tooth DT4 defines a cantle side end 286c.

The punch and die teeth PTX, DTX pommel and cantle side ends 284p, 286c are preferably sloped in opposite directions. For example, as shown in FIGS. 52A and 56A, the triangular flat surfaces 290 of punch teeth PT1, PT2, and PT3 on the punch die 36 are sloped in opposite directions to form an upside-down V-shape as indicated by dash lines PPV, and the triangular flat surfaces 290 of die teeth DT2 and DT3 on the die plate 38 are sloped in opposite directions to form a right-side-up V-shape as indicated by dash lines DPV. As illustrated in FIGS. 50, 52A and 56A, for each punch and die tooth PTX, DTX, the slope of the pommel side end 284p triangular flat surface 290 is a mirror image of the adjacent directly opposing cantle side end 286c triangular flat surface 290 of an opposing punch or die tooth PTX, DTX. The punch and die teeth PTX, DTX triangular flat surfaces 290 can be sloped at between zero and seventy-five degree angles from the vertical, and, for each punch or die tooth PTX, DTX, the pommel side end 284p triangular flat surface 290 is correspondingly sloped at between zero and a one hundred fifty-degree angle from the cantle side end 286c triangular flat surface 290. Preferably, the punch and die teeth PTX, DTX triangular flat surfaces 290 are sloped at approximately thirty-degree angles from the vertical, and, for each punch or die tooth PTX, DTX, the pommel side end 284p triangular flat surface 290 is correspondingly sloped at approximately a sixty-degree angle from the cantle side end 286c triangular flat surface 290.

As illustrated in FIGS. 50, 52A and 56A and should now be appreciated, as each punch or die tooth PTX, DTX is received in its corresponding punch or die slot PSX, DSX, each triangular flat surface 290 on a pommel side end 284p of each punch tooth PTX is coplanar with and advances closely adjacent to a triangular flat surface 290 on a cantle side end 286c of a die tooth DTX, and each triangular flat surface 290 on a pommel side end 284p of each die tooth DTX is coplanar with and advances closely adjacent to a triangular flat surface 290 on the cantle side end 286c of a punch tooth PTX. More particularly, as shown in FIGS. 77C and 78C, when opposing punch and die teeth PTX, DTX traverse past each other (as each punch and die tooth PTX, DTX is received in its corresponding punch or die slot PSX, DSX), there is a narrow planar tolerance space 291 between the triangular flat surface 290 on the pommel side end 284p of each punch tooth PTX and the triangular flat surface 290 on the cantle side end 286c of an opposing die tooth DTX. The size of narrow planar tolerance space 291 is maintained as small as possible and/or is adjusted for optimizing the slicing/shearing action of the cutting edges 292 and minimizing the force required to slice/shear through the side-lapped seam 30.

Preferably, each pommel and cantle side end 284p, 286c of the punch and die teeth PTX, DTX can include a relief surface 293 extending from the triangular flat surfaces 290 opposite the leading arcuate nose sections 294 towards the flared base portion 304. A fillet surface 293f is preferably provided between the relief surface 293 and the flared base portions 304. The relief surfaces 293 taper inwardly toward the seat portions 285s in a direction away from the triangular flat surfaces 290 such that, as the cutting edges 292 and triangular flat surfaces 290 of opposing punch or die teeth PTX, DTX are advanced past each other, as best seen in FIGS. 76C, 77C and 78C, the spaces 291 between the punch and die teeth PTX, DTX widen. The relief surfaces 290 are provided for, as much as possible, preventing the arcuate edges 28ae, 24e and 28be (FIG. 74C), which are formed by the punch and die teeth cutting edges 292 slicing/shearing through the side-lapped seam female wall 28a, male wall 24 and female wall 28b respectively, from contacting and frictionally engaging the punch and die teeth PTX, DTX.

Preferably, the punch and die teeth PTX, DTX are formed separately from the punch and die plates 36, 38 and include flared base portions 304 (FIG. 54). As illustrated in FIGS. 57 and 58, the punch and die plates 36, 38 can include C-shaped mounting grooves 308 extending into the punch and die plates through their face surfaces 250, 264, adjacent the punch and die plate bottom surfaces 260, 274, respectively. The C-shaped mounting grooves 308 are adapted to slidingly receive the flared base portions 304. Preferably, the punch and die teeth PTX, DTX can be removably secured to the punch and die plates 36, 38 with, for example, tooth fasteners 306, for thereby allowing the punch and die teeth PTX, DTX to be replaced when they become worn. The tooth fasteners 306 are adapted to be threadingly received in and engage tooth fastener bores 404 extending through the punch and die plates 36, 38 from the rear surfaces 252, 266 to the C-shaped mounting grooves 308. As the tooth fasteners 306 are threaded into the tooth fastener bores 404, the tooth fasteners 306 engage the punch and die teeth PTX, DTX base portions 304 for thereby securing the punch and die teeth PTX, DTX within the C-shaped mounting grooves 308.

Preferably, as shown in FIGS. 54A-H, the flared base portions 304 can include tooth locating slots 402 adapted to receive tooth fasteners 306. The tooth fasteners 306 are adapted to be captured within the tooth locating slots 402 for thereby aligning and preventing the punch and die teeth PTX, DTX from sliding within the C-shaped mounting grooves 308.

Preferably, as best illustrated in FIG. 54, the punch and die teeth PTX, DTX lagging triangularly expanding/diverging edges 296a, 296b curve horizontally away from their respective triangular flat surfaces 290 towards the central seat portion 285s for thereby forming/defining curved/semi-cylindrical terminal end surfaces 302. For example, as shown in FIGS. 54A-H, the lagging triangularly expanding/diverging edges 296a, 296b of the die tooth DT2 and the punch tooth PT2 curve horizontally away from the triangular flat surfaces 290 towards the central seat portions 285s thereby forming/defining curved/semi cylindrical terminal end surfaces 302 between the relief surfaces 293 and the half-cone shaped leading surfaces 288. The curved/semi cylindrical terminal end surfaces 302, similar to the relief surfaces 290, are provided for, as much as possible, preventing the arcuate edges 28ae, 24e and 28be (which are formed by the punch and die teeth cutting edges 292 slicing/shearing through the side-lapped seam female wall 28a, male wall 24 and female wall 28b respectively) from contacting and frictionally engaging the punch and die teeth PTX, DTX.

4. Side-Lapped Seam Attachments

Turning now to the formation of the attachments 297 in a side-lapped seam 30, during operation of the tool 10, as shown in FIG. 66, a side-lapped seam 30 is first positioned within the gap 30G between the punch and die plates 36, 38. As shown in FIG. 67, the crimping assembly 34 can then be actuated for driving punch plate 36 towards the die plate 38 and advancing the punch and die teeth PTX, DTX into their corresponding punch and die slots PSX, DSX, whereby the cutting edges 292 of adjacent opposing punch and die teeth PTX, DTX traverse past each other, thereby penetrating and shearing through the side-lapped seam 30, and whereby, also, the half-cone shaped leading surfaces 288 simultaneously engage and deform the walls of the side-lapped seam 30 for thereby forming seam attachments 297.

Referring now more particularly to FIGS. 68-75, each seam attachment 297 comprises a slit opening 298 and a pair of half-cone shaped locking lobes 300 formed one on either side of the slit opening 298. The slit openings 298 are defined by and between arcuate edges 28ae, 24e and 28be which have been formed by the punch and die teeth cutting edges 292 slicing/shearing through the side-lapped seam female wall 28a, male wall 24 and female wall 28b respectively. The half-cone shaped locking lobes 300 are formed by the punch and die teeth half-cone shaped leading surfaces 288 being pushed into the side of the side-lapped seam, thereby deforming/shaping the female wall 28a, male wall 24 and female wall 28b into the half-cone shape.

Hence, the arcuate edges 28ae, 24e and 28be are substantially mirror images of the punch and die teeth cutting edges 292, and the locking lobes 300 are substantially mirror images of the half-cone shaped leading surfaces 288. The locking lobes 300 on either side of a respective slit opening 298 bulge in opposite transverse directions from the longitudinal center of the side-lapped seam 30 and extend longitudinally along the side-lapped seam 30, in opposite directions from the slit opening 298, from a base of the half-cone shape defined by the arcuate edges 28ae, 24e and 28be towards an apex 299 (FIG. 70A). The slit openings preferably extend through all three plies/walls 28a, 28b and 24, and the locking lobes 300 are preferably formed in all three plies/walls 28a, 28b and 24.

As should now be appreciated, as diagrammatically illustrated in FIG. 86, by advancing the punch teeth PT1, PT2 and PT3 of the punch plate 36 into side-lapped seam 30 and their respective corresponding opposing die slots DS1, DS2 and DS3 in the die plate 38 and simultaneously advancing the die teeth DT1, DT2, DT3 and DT4 of the die plate 38 into the other side of the side-lapped seam 30 and the die teeth DT2 and DT3 into their respective corresponding opposing punch slots PS2 and PS3 in the punch plate 36, as indicated by arrows A, the following attachments 297 are simultaneously formed:

- Attachment 297a comprising locking lobes 300P0a and 300P1a;
- Attachment 297b comprising locking lobes 300P1b and 300P2b;
- Attachment 297c comprising locking lobes 300P2c and 300P3c;
- Attachment 297d comprising locking lobes 300P3d and 300P4d;
- Attachment 297e comprising locking lobes 300P4e and 300P5e; and,
- Attachment 297f comprising locking lobes 300P5f and 300P6f.

Of course, as mentioned hereinabove, the number of punch and die teeth PTX, DTX of the crimping system 34 can be increased or decreased as needed or desired so that the number of attachments 297 that are simultaneously formed can thereby also be increased or decreased as needed or desired.

Preferably, as best seen in FIGS. 68, 69, 70B and 85, the punch and die teeth PTX, DTX are pushed/forced into the side-lapped seam sufficiently so that, after the attachments 297 and corresponding locking lobes 300 thereof are formed by pushing/forcing the nose sections 294 of the punch and die teeth PTX, DTX a distance 285d into the side of the side-lapped seam, the central seat portions 285s of the punch and die teeth PTX, DTX are also pushed/forced into the side-lapped seam 30 whereby the central seat portions 285s also deform and shape the female wall 28a, male wall 24 and female wall 28b into a substantially half-cylinder shape, as illustrated in FIGS. 74A and 86 and designated by the numeral 295, and wherein the longitudinal ends of the half-cylinder portions 295 are integral with the apex portions 299 of the half-cone shaped locking lobes 300. That is, as each tooth PTX, DTX is pushed into the side-lapped seam 30 and into its corresponding opposing slot PSX, DSX, each tooth PTX, DTX forms a depression PD into the side-lapped seam which is a mirror image thereof and comprises a pair of half-cone shaped lobes 300 joined by a half-cylinder portion 295, wherein the half-cone shaped lobes 300 open in opposite directions from the cylindrical portion 295 towards slit opening 298 on either side of the depression, wherein the depressions are formed longitudinally along the side-lapped seam 30 on alternating opposite sides thereof, except wherein the end die teeth DT1 and DT4 form depressions PDH (FIG. 68) which comprise a single half-cone shaped lobe 300 which opens towards a slit opening 298.

Finally, it is estimated that by providing punch teeth PTX on the punch plate 36 wherein the combined longitudinal lengths PTXL of all the punch teeth PTX thereon is the same as the combined longitudinal lengths DTXL of all the die teeth DTX on the die plate 38, the depressions PD formed on both sides of the side-lapped seam 30 will be roughly the same in depth as, for example, is illustrated in FIG. 86. However, by providing punch or die teeth PTX, DTX on one of the punch or die plates 36, 38 wherein the combined longitudinal lengths PTXL, DTXL of all the punch or die teeth PTX, DTX thereon is smaller or greater than the combined longitudinal lengths PTXL, DTXL of all the punch or die teeth PTX, DTX on the other one of the punch or die plates 36, 38, the depressions PD formed on one side of the side-lapped seam 30 will be different in depth from the other side of the side-lapped seam 30 as, for example, is illustrated in FIG. 70B.

5. Side-Lapped Seam Insertion Sensing System

It is, of course, desirable to prevent actuation of the crimping mechanism unless and until the side-lapped seam 30 has been received in and is properly situated/located within the side-lapped seam receiving gap 30G for both safety purposes and for locating the interlocking side-lap seam attachments 297 being formed thereon at the desired optimum horizontal and vertical location of the side-lap seam. Accordingly, as shown in FIGS. 59-65, the tool 10 can further include a side-lapped seam insertion sensing system/mechanism 312 adapted to prevent the crimping assembly/mechanism 34 from being actuated before the side-lapped seam 30 is properly positioned within the side-lapped seam receiving gap 30G. Particularly, side-lapped seam insertion sensing system 312 is adapted for determining whether the punch and die plates 36, 38 are properly positioned on either side of the side-lapped seam 30 for actuation of the hydraulic cylinder 40. For example, the side-lapped seam insertion sensing system 312 can be adapted for ensuring that the slit openings 298 and locking lobes 300 of the interlocking side-lapped seam attachments 297 are formed at the correct position within the side-lapped seam 30, for thereby maximizing the strength of the attachments 297.

The side-lapped seam insertion sensing system 312 can comprise one or more seam position sensing arms 314, a stop beam 316, and a lever assembly 318. The seam position sensing arms 314 are adapted to extend into the side-lap seam receiving gap 30G and for thereby actuating the stop beam 316 between a locked position wherein the stop beam 316 is in the stop beam pocket 322 and prevents advancement of the punch plate 36 towards the die plate 38, for example, as shown in FIG. 64, and an unlocked position wherein the stop beam 316 is withdrawn from the stop beam pocket 322 and the punch plate 36 can be advanced towards the die plate 38 upon actuation of the hydraulic cylinder 40, for example, as shown in FIG. 65. That is, in the locked position, the stop beam 316 is adapted to prevent the hydraulic cylinder 40 from driving the punch plate 36 towards the die plate 38 and, in the unlocked position, the punch plate 36 can be freely driven towards the die plate 38 upon actuation of the hydraulic cylinder 40.

The side-lapped seam insertion sensing system 312 can also include an intermediate beam 320 secured to the underside of the support plate 102 (surface 106) and abutting the die plate face surface 264 adjacent and extending longitudinally along an edge 263 of the die plate top surface 272. The stop beam 316 can abut the intermediate beam 320 when it is received in the stop beam pocket 322. Preferably, the intermediate beam 320 and the stop beam 316 (as well as the other components and parts of the crimping assembly 34) are manufactured from substantially rigid, incompressible materials such as, for example, steel or aluminum. As shown in FIG. 64, in the locked position, the rigid intermediate and stop beams 320, 316 are sandwiched between the die plate 38 and the upper carrier plate 192, thereby preventing the upper carrier plate 192, and the punch plate 36 mounted thereto and to the lower carrier plate 192, from advancing towards the die plate 38. Accordingly, in the locked position, the rigid intermediate and stop beams 320, 316 resist the driving force applied by the hydraulic cylinder 40 and prevent the punch plate 36 from advancing toward the die plate 38.

As shown in FIGS. 38A-B and mentioned hereinabove, the upper carrier plate 192 can include an upper carrier plate stop beam pocket 322 extending into the upper carrier plate top surface 194 adjacent the die plate receiving window 206. The upper carrier plate stop beam pocket 322 is adapted to receive the intermediate and stop beams 320, 316 as shown in FIGS. 64-65. The support plate 102 can include a support plate beam pocket 324 extending into the support plate bottom surface 106 above and opposite the upper carrier plate stop beam pocket 322. The intermediate beam 320 is secured to the support plate 102 within the support plate beam pocket 324 and the stop beam 316 can be received within the support plate beam pocket 324 when the stop beam 316 is moved to the unlocked position, for example, as shown in FIG. 65. When the stop beam 316 is retracted from the carrier plate stop beam pocket 322 and received within the support plate beam pocket 324, a longitudinally extending gap indicated by the dash line arrows 325 in FIG. 65 is formed within the upper carrier plate stop beam pocket 322, thereby allowing the upper carrier plate 192 to slide towards the die plate 38 beneath the stop beam 316.

Returning to FIGS. 60, 61, 64, and 65, each seam position arm 314 can be a lever having parallel position arm side surfaces 326, 328, a seam engaging bottom surface 330, and a position arm axle bore 332 extending through the seam position arm 314 between the position arm side surfaces 326, 328. The position arm axle bores 332 are adapted to receive a position arm axle 334 therethrough for securing the position sensing arms 314 to the tool 10 and allowing the position sensing arms 314 to rotate about the position arm axle 334. Preferably, the position arm axle 334 extends parallel to the punch and die plate face surfaces 250, 264 and is adapted to secure the position sensing arms 314 adjacent to the punch teeth PX with the seam engaging bottom surfaces 330 facing the deck panels 14. Accordingly, when a side-lapped seam 30 is inserted into the side-lapped seam receiving gap 30G and between the punch and die plates 36, 38, the seam engaging bottom surfaces 330 contact the upper end of the side-lapped seam 30 and the position sensing arms 314 rotate about the position arm axle 334 from the angle shown in FIG. 64 to the angle shown in FIG. 65.

Preferably, the die plate 38 can include one or more die plate position arm slots 336 provided extending through the die plate 38 between the die plate face and rear surfaces 264, 266. The die plate position arm slots 336 extend through the die plate 38 adjacent to the die teeth DTX, and each die plate position arm slot 336 is adapted to slidingly receive a seam position sensing arm 314. Additionally, the die plate 38 can include a die plate axle bore 338 extending horizontally through the die plate between side surfaces 268, 270 and through the die plate position arm slots 336. The position arm axle bores 332 can be aligned with the die plate axle bore 338 such that the position arm axle 334 can be inserted through the die plate bore 332 and position arm axle bores 338, 332 for thereby pivotally securing the seam position sensing arms 314 to the die plate 38.

Yet more preferably, the punch plate 36 can include one or more punch plate position arm slots 340 extending through the punch plate 36 between the punch plate face and rear surfaces 250, 252. The punch plate position arm slots 340 are aligned with the die plate position arm slots 336 and the position sensing arms 314 can be extended through a die plate position arm slot 336 and into a corresponding punch plate position arm slot 340. The punch and die plate position arm slots 336, 340 are adapted to permit the seam position sensing arms 314 to rotate about the position arm axle 334 within the position arm slots 336, 340 and the side-lapped seam receiving gap 30G for thereby actuating the side-lapped seam insertion sensing system 312 between its locked and unlocked positions as shown in FIGS. 64, 65 respectively.

As shown in FIGS. 59-62, the lever assembly 318 can include one or more position arm actuator rods 342, a lever arm 344, a fulcrum member 346, and one or more stop beam actuator rods 348. The lever arm 344 includes opposite lever arm terminal ends 350, 352 and a lever arm axle bore 354 extending transversely through the lever arm 344 between the lever arm terminal ends 350, 352. The fulcrum member 346 is secured to the support plate 102 and includes a fulcrum axle bore 356. The lever arm and fulcrum axle bores 354, 356 are adapted to be aligned with each other for receiving a fulcrum axle 358 whereby the lever arm 344 is adapted to be rotated about the fulcrum axle 358. The position arm actuator rods 342 are adapted to connect the seam position sensing arms 314 to the lever arm terminal end 350, and stop beam actuator rods 348 are adapted to connect the stop beam 316 to the lever arm terminal end 352.

The support plate 102 includes a plurality of support plate actuator rod bores 360 extending through the support plate top surface 104. The support plate actuator rod bores 360 are adapted to receive the position arm and stop beam actuator rods 342, 348 therethrough. The position arm and stop beam actuator rods 342, 348 are secured to the respective lever arm terminal ends 350, 352, and extend downwardly through the support plate actuator rod bores 360 for engaging the position sensing arms 314 and the stop beam 316 respectively. Additionally, the die plate 38 includes vertically extending die plate actuator rod bores 362 extending into the die plate top surface 272 and into the die plate position arm slots 336. The die plate actuator rod bores 362 are adapted in order that the position arm actuator rods 342 can be inserted therethrough and for thereby engaging and being pivotally secured to the seam position sensing arms 314 with pins 315.

Each position arm actuator rod 342 is secured to a terminal end of a position arm 314 such that, as the position sensing arms 314 engage a side-lapped seam 30, the position sensing arms 314 rotate about the position arm axle 334 and pull the position arm actuator rods 342 downward towards the deck panels 14. This, in turn, rotates the lever arm 344 about the fulcrum axle 358 and pulls the stop beam actuator rods 348 upward away from the deck panels 14, thereby pulling the stop beam 316 upward from the locked position to the unlocked position.

As shown in FIGS. 60-62, 64, and 65, the fulcrum member 346 can comprise a fulcrum base 364, a pair of fulcrum axle arms 366, and a lever support platform 368. The fulcrum base 364 includes fulcrum base top and bottom surfaces 370, 372 and fulcrum base ends 374, 376. The fulcrum base 364 can be secured on top of the support plate 102, on the top surface 104 thereof. Fulcrum axle arms 366 extend upwardly from the fulcrum base 364 adjacent the fulcrum base end 374. The fulcrum axle bore 356 extends transversely horizontally through the fulcrum axle arms 366. The lever support platform 368 extends upwardly from the fulcrum base 364 adjacent the fulcrum base end 376. The lever support platform 368 is adapted to abut and support the lever arm terminal end 352 when the stop beam 316 is in the locked position as shown in FIG. 64. Additionally, the fulcrum member 346 can include support platform actuator rod bores 378 extending vertically through the fulcrum base 364 and the lever support platform 368. Preferably, the fulcrum member 346 includes actuator rod bearings 380 inserted into the support platform actuator rod bores 378 and adapted to slidingly receive the stop beam actuator rods 348 for thereby aligning the stop beam actuator rods 348 within the support platform actuator rod bores 378. The fulcrum base 364 can include a pair of lever return spring recesses 382 extending therein through the fulcrum base bottom surface 372 and aligned with the support platform actuator rod bores 378. The lever return spring recesses 382 are adapted to receive lever return springs 384sb and sandwiching the lever return springs 384sb between the fulcrum member 346 and the stop beam 316.

As shown in FIGS. 60-62, the lever arm terminal end 350 is pivotally connected to the upper terminal end of the position actuator arm 342 with ball joints comprising a ball 386 secured to the lever arm and ball sockets 388 secured atop the position actuator arm 342 and adapted to receive the ball 386. The stop beam 316 can include stop beam actuator rod bores 392 adapted to receive the bottom terminal end of the stop beam actuator rods 348. The terminal end of the stop beam actuator rods 348 can be secured to the stop beam 316 within the stop beam actuator rod bores 392 by, for example, welding, brazing, or press-fitting.

The side-lapped seam insertion sensing system 312 can include lever return springs 384pa, 384sb adapted to each receive therethrough one of the position arm actuator rods 342 and stop beam actuator rods 348, respectively. As mentioned hereinabove, the stop beam rods' lever return springs 384sb can be received in the lever return spring recesses 382 between the stop beam 316 and the fulcrum member 346. Each lever return spring 384pa is provided between a stop washer 385 secured to the position arm actuator rod 342 and the support plate 102. The lever return springs 384pa, 384sb are adapted to compress as the seam position sensing arms 314 engage a side-lapped seam 30 and the side-lapped seam insertion sensing system 312 is placed in the unlocked position as shown in FIG. 65. Accordingly, once the seam position sensing arms 314 disengage the side-lapped seam 30, the lever return springs 384pa, 384sb provide the requisite force and expand to return the side-lapped seam insertion sensing system 312 to the locked position as shown in FIG. 64.

Additionally, the lever arm terminal end 352 can include stop beam actuator rod bores 392 adapted to receive the stop beam actuator rods 348 therethrough. The stop beam actuator rods 348 are received through fail safe springs 394 which extend between the lever arm 344 and a stop washer 349 affixed to the top terminal end of the stop beam actuator rods. As shown in FIG. 81, fail safe springs 394 are adapted to compress and allow the lever arm 344 to pivot about the fulcrum axle 358 in the event a side-lapped seam 30 is received in the side-lapped seam receiving gap 30G causing the position sensing arms 314 to pivot about position arm axle 334 and pull down on the position arm actuator rods 342, when the side-lapped seam insertion sensing system 312 is in the locked position and, simultaneously, the crimping assembly 34 has been prematurely actuated and the stop beam 316 has been clamped in the locked position by the hydraulic cylinder 40, thereby preventing damage to the side-lapped seam insertion sensing system 312.

6. Operation of the Deck Seam Tool

In operation, as shown in FIGS. 1-4, the wheels 50 and handle 52 are used to transport the tool 10 over the top of the deck panels 14 and to maneuver the tool 10 for thereby aligning the crimping assembly 34 with a side-lapped seam 30. Once the crimping assembly 34 is aligned with a side-lapped seam 30, the tool 10 is lowered until the side-lapped seam 30 is positioned in the side-lapped seam receiving gap 30G between the punch and die plates 36, 38 and, preferably also, the side-lapped seam 30 is received within the side-lapped seam guide slot 62 and the alignment foot 56 is received in an adjacent deck channel 21 (FIGS. 5B, 82 and 83). As discussed hereinabove, when the tool 10 is lowered and the side-lapped seam 30 is positioned between the punch and die plates 36, 38, the seam position sensing arms 314 contact and engage the upper end of the side-lapped seam 30 for thereby actuating and placing the side-lapped seam insertion sensing system 312 in its unlocked position.

With the punch and die plates 36, 38 properly aligned with the side-lapped seam 30 and the side-lapped seam insertion sensing system 312 in the unlocked position, the hydraulic cylinder 40 of the crimping assembly/mechanism 34 can be actuated, thereby driving the punch plate 36 towards the die plate 38 and driving the punch and die teeth PTX, DTX towards the side-lapped seam 30, and effectively clamping the side-lapped seam 30 between the punch plate 36 and the die plate 38 and driving the punch teeth PTX of the punch plate 36 into one side of the side-lapped seam 30 and the die teeth DTX of the die plate 38 into the other side of the side-lapped seam 30 (FIGS. 66 and 67).

As best seen in FIGS. 66, 67, 77 and 78, as the punch and die teeth PTX, DTX are advanced towards the side-lapped seam 30 and towards their complementary receiving punch and die slots PSX, DSX, the cutting edges 292 of the punch and die teeth PTX, DTX penetrate through the female channel walls 28a, 28b and the male lip 24, and the cutting edges 292 and the triangular flat surfaces 290 of opposing punch and die teeth PTX, DTX travel adjacent each other, thereby cutting slit openings 298 through the side-lapped seam 30.

As the slit openings 298 are formed, the half-cone shaped leading surfaces 288 of the punch and die teeth PTX, DTX also contact and deform the side-lapped seam 30 on both sides of and transversely from the slit openings 298, thereby bending the female channel walls 28a, 28b and the male lip 24 and forming half-cone shaped locking lobes 300 which extend longitudinally along the side-lapped seam 30, in opposite directions from the slit openings 298. As shown in FIGS. 71A-B, the slit openings 298 are a mirror image of the cutting edges 292, and the half-cone shaped locking lobes 300 are a mirror image of the half-cone shaped leading surfaces 288, wherein the locking lobe half-cones extend from a cone base at the slit openings 298 towards an apex.

The shape of the attachments 297 comprising the shape of the slit openings 298 and locking lobes 300 as described and shown have been found to create superior high strength interlocking side-lapped seams. However, it is contemplated that the punch and die teeth PTX, DTX can be shaped differently for producing different shaped attachments 297 as needed or desired.

After the slit openings 298 and the locking lobes 300 have been formed, the hydraulic cylinder 40 can be retracted for thereby retracting the punch plate 36 away from the die plate 38 and also retracting the punch teeth PTX of the punch plate 36 and the die teeth DTX of the die plate 38 from the side-lapped seam 30 and out of the locking lobes 300 that were formed. This disengages the punch and die teeth PTX, DTX from the side-lapped seam 30 thereby freeing the tool 10 to be pushed or pulled longitudinally along deck panels 14 with the side-lapped seam 30 remaining in the side-lapped seam gap 30G and repeating the crimping process for forming additional attachments 297 in the same side-lapped seam 30, or tilting/lifting the tool 10 as described, whereby the side-lapped seam 30 is no longer within the side-lapped seam gap 30G, for moving the tool 10 transversely along the deck panels 14 to another side-lapped seam 30 whereat the crimping process can again be repeated thereon. Of course, when the tool 10 is lifted/tilted and while it is being moved in a manner other than longitudinally along a side-lapped seam 30, the side-lapped seam insertion sensing system 312 will be in its locked position for thereby preventing the actuation of the crimping assembly 34 and the movement of the punch plate 36 and die plate 38.

7. Preferred Tool/Chassis Embodiment

Turning to FIGS. 87-103, in a preferred embodiment, the chassis 32 comprises a tool frame 54, a tool alignment foot 56, a side-lapped seam guide 62, and a pair of sled plates 120a, 120b. The tool alignment foot 56 and the side-lapped seam guide 62 is secured to the tool frame 54 and are adapted to slidingly engage web portions 23 of a deck longitudinal channel 21 for thereby helping to align the punch and die plates 36, 38 with the side-lapped seam 30. The tool alignment foot 56 and side-lapped seam guide 62 are preferably made of a wear-resistant material such as high-density polyethylene (“HDPE”).

The sled plates 120a, 120b are secured to the bottom of the tool frame 54 and extend along the front and rear longitudinal edges 54f, 54r thereof. The sled plates 120a, 120b are adapted to rest on the deck panel top surface 16t and, together, locate the punch and die plates 36, 38 at a desired height above the deck panel bottom portions 20. Preferably, the sled plates 120a, 120b are constructed from a high wear-resistant material such as HDPE and are removably secured to the tool frame 54 to allow the sled plates 120a, 120b to be replaced when they become worn-out.

Preferably, the tool 10 also includes a pair of wheels 50 and a handle 52′ which enable a user to transport the tool 10 along a side-lapped seam 30 and/or transversely over/across the deck panels 14, as shown in FIGS. 87-90. As best seen in FIGS. 93-96, 100, and 101, the wheels 50 are rotatably mounted on axles 51 and are secured one on either side of the tool frame 54. The handle 52′ includes a shaft 524 and a handle grip 525. The handle grip 525 is mounted to the upper terminal end 524U of the shaft 524 and the lower terminal end 524L of the shaft is coupled to the tool frame 54. The axles 51 are located between the crimping assembly 34 and the handle 52′ (preferably vertically above and towards the rear of the tool frame 54) whereby handle 52′ serves as a lever and the axles 51 serve as a fulcrum. By applying a force F1 to the handle grip 525, a user is able to tilt and rotate the tool 10 about the wheels 50 for thereby lifting the tool 10 towards and away from the deck panels 14 and the side-lapped seam 30. Accordingly, an operator of the tool 10 can use the handle 52′ to easily transport/roll the tool 10 across the top surface of the deck panels 14 when the tool 10 is engaged with a side-lapped seam 30 and, also, lift the tool 10 away from side-lapped seam 30 and/or transport/roll it across the top of the deck panels 14 in a direction perpendicular to the side-lapped seam 30.

Preferably, as best seen in FIGS. 102 and 103, when the sled plates 120a, 120b are resting on the deck panel top surface 16t, the wheels 50 are suspended above the deck panel top surface 16t. Suspending the wheels 50 above the deck panel top surface 16t prevents the tool 10 from rolling or sliding along the deck panels 14 during operation of the crimping assembly 34. Additionally, suspending the wheels 50 above the deck panel top surface 16t also prevents the tool 10 rolling or sliding when a user begins to tilt the tool 10 upwardly away from the side-lapped seam 30.

As shown in FIGS. 87-90 and, more particularly, FIGS. 93 and 95-97, the tool 10 further includes a pump/cart frame 510, a hydraulic pump tray 512, and a hydraulic pump cover 514. The pump/cart frame 510 is mounted to the tool frame 54 (preferably vertically above and towards the rear of the tool frame 54) via a pair of L-shaped brackets 516. The hydraulic pump tray 512 is mounted on top of the pump/cart frame 510. The hydraulic power source 41 is supported on top of the hydraulic pump tray 512. The hydraulic pump cover 514 couples to the hydraulic pump tray 512 over top of the hydraulic power source 41 and forms a protective barrier therearound. Preferably, the tool 10 includes a plurality of quick release clasps 518 which secure the pump cover 514 to the pump tray 512. The quick release clasps 518 allow the pump cover 514 to be selectively coupled to or uncoupled from the pump tray 512 to provide access for servicing, repairing, or replacing the hydraulic power source 41.

As best seen in FIGS. 97A-B, the pump/cart frame 510 includes a base plate 511, a pair of box-shaped support arms 513, a coupler plate 515, and a handle receiving tube 520. The base plate 511 is adapted to be secured to the L-shaped brackets 516 for thereby securing the pump/cart frame 510 to the tool frame 54. The box-shaped support arms 513 are mounted on top of the base plate 511 and extend towards the rear of the tool 10. The coupler plate 515 is mounted on top of the box shaped support arms 513 preferably towards the rear of the tool 10. The handle receiving tube 520 is a (preferably, square) tube member which is secured to the coupler plate 515. Preferably, the coupler plate 515 includes a tube mounting bore 515B and the handle receiving tube 520 is secured extending through the tube mounting bore 515B.

In operation, the handle receiving tube 520 is adapted to selectively couple the handle 52′ to the pump/cart frame 510, and, hence, to the tool 10. Specifically, as best seen in FIGS. 97A-B, the handle receiving tube 520 includes a central handle receiving bore 522 which extends longitudinally through the handle receiving tube 520, and one or more receiving tube coupler bores 526 which extend transversely through the handle receiving tube 520 perpendicular to the central handle receiving bore 522. The handle receiving bore 522 is adapted to receive the lower terminal end 524L of the shaft 524. The receiving tube coupler bores 526 are adapted to be aligned with one of more shaft coupler bores 528 which extend transversely through the shaft 524. In operation, the handle 52′ is secured to the pump/cart frame 510 by inserting the shaft lower terminal end 524L into the central handle receiving bore 522, aligning one or more shaft coupler bores 528 with one or more receiving tube coupler bores 526, and inserting a quick release pin 530 through the aligned coupler bores 526, 528 whereby the quick release pin 530 couples the handle 52′ to handle receiving tube 520, and, hence, to the pump/cart frame 510 and the tool 10.

Preferably, the shaft coupler bores 528 are provided at regular intervals along the longitudinal length of the shaft 524 such that the position of the handle 52′ can be selectively adjusted by removing the quick release pin 530, extending or retracting the shaft 524 through the handle receiving bore 522 until the handle 52′ is in the desired position, aligning a pair of coupler bores 526, 528, and inserting the quick release pin 530 through the aligned pair of coupler bore 526, 528.

Preferably, as best seen in FIG. 99, the handle receiving tube 520 is secured to the coupler plate 515 such that the upper end 520U of the handle receiving tube 520 (and, hence, the handle shaft 524 which extends at least partially into/through the handle receiving bore 522 and, therefore, extends generally parallel to the handle receiving tube 520) is tilted slightly away from the tool frame 54.

Preferably, the tool 10 also includes a kick/pivot step 532 which mounts to the pump/cart frame 510 and can be used to provide additional leverage for tilting/rotating the tool 10. The kick/pivot step 532 includes an abutment plate/wall 536, one or more L-shaped hangers 540, and one or more box-shaped platforms 534. The abutment plate/wall 536 is adapted to be placed against/abutting the pump/cart frame 510. The L-shaped hangers 540 are secured to the abutment plate/wall 536 and are adapted to couple to the pump/cart frame 510 for securing the kick/pivot step 532 thereto. The box-shaped platforms 534 are mounted at one end to the abutment plate/wall 536 and extend generally perpendicularly therefrom towards the rear of the tool 10. The other end of the box-shaped platforms 534 (i.e., the end opposite from the abutment plate/wall 536) includes a sloped step panel 535 which slopes towards the abutment plate/wall 536. The sloped step panels 535 form the “step” portion of the kick/pivot step 532 which users step on and press against to help with tilting/rotating the tool 10 and having the sloped step panels 535 slope towards the abutment plate/wall 536 allows a user to push both horizontally towards the tool frame 54 and also vertically downwardly.

In operation, the handle 52′ is used as a lever for tilting/rotating the tool 10 about the axles 51 and the wheels 50 and the kick/pivot step 532 is used to push the tool 10 linearly along the side-lapped seam 30. Specifically, as illustrated in FIG. 99A, a force F1 can be applied to the handle grip 525 and a force F2 can be applied to the sloped step panel 535. The force F1 generates a rotational torque T1 equal to the product of the force F1 multiplied by the distance X between the handle grip 525 and the axles 51. The rotational torque T1 counteracts the weight of the tool frame 54 and the crimping assembly 34 and tilts/rotates the tool 10 upwardly away from a side-lapped seam 30. Once the tool 10 has rotated back onto the wheels 50, the force F2 is applied to assist with driving and linearly advancing the tool 10 along the side-lapped seam 30.

Alternatively, as illustrated in FIG. 99B, the force F2 can be applied in a more vertically downwardly direction which generates a rotational torque T2 equal to the product of the force F2 multiplied by the distance Y between the sloped step panel 535 and the axles 51. This rotational torque T2 supplements the rotational torque T1 generated by applying the force F1 to the handle grip 525 and helps to counteract the weight of the tool frame 54 and the crimping assembly 34 for tilting/rotating the tool 10 upwardly away from a side-lapped seam 30.

Preferably, the kick/pivot step 532 is selectively coupled to the pump/cart frame 510 by a step bracket 544. The step bracket 544 is mounted on top of the coupler plate 515 and includes a horizontal axle bore 546 and a quick release axle 538. The L-shaped hangers 540 include mounting bores 542 which are adapted to be aligned with the axle bore 546. In use, the quick release axle 538 can be inserted through the aligned bores 542, 546 for selectively coupling the kick/pivot step 532 to the pump/cart frame 510.

Preferably, the tool 10 also includes a pair of brake assemblies 548 which can be selectively engaged to prevent the tool 10 from rolling across the deck panels 14. As best seen in FIGS. 93, 100, and 101, the brake assemblies 548 can comprise spring-loaded pins 549, L-shaped support brackets 552, and threaded brake nuts 550. The L-shaped support brackets 552 are mounted to the tool frame 54 adjacent to the wheels 50. The threaded brake nuts 550 are mounted to the L-shaped support brackets 552. The spring-loaded pins 549 include a threaded housing 549h which is adapted to threadingly engage the brake nuts 550 and a ring handle 549r which can be used to retract the spring-loaded pins 549.

In operation, when the spring-loaded pins 549 are in a “locked” position (i.e., when the spring-loaded pins 549 are extended towards the wheels 50), the terminal ends 549te of the spring-loaded pins 549 engage the hubs 50h of the wheels 50. The friction between the terminal ends 549te prevents the wheels 50 from rotating and, hence, prevents the tool 10 from rolling across the deck panels 14. Before moving the tool 10, the spring-loaded pins 549 are moved to an “unlocked” position by pulling the ring handles 549r away from the wheels 50 which causes the terminal ends 549te to retract away from the wheel hubs 50h.

Preferably, the wheel hubs 50h can include one or more radial spokes/fins 50f which extend horizontally outwardly from the wheel hubs 50h. If the wheels 50 rotate after the spring-loaded pins 549 are engaged (i.e., when the spring-loaded pins 549 are in the “locked” position), the radial fins 50f will engage and abut against the pin terminal ends 549te for thereby preventing further rotation of the wheels 50.

8. Preferred Crimping Assembly Embodiment

Turning to FIGS. 104-119, as mentioned above, the side-lapped seam crimping assembly 34 comprises a punch plate 36, a die plate 38, and an actuator such as, for example, a double acting hydraulic cylinder 40. The punch plate 36 is coupled to the double acting hydraulic cylinder 40 and the die plate 38 is secured to the chassis 32. The hydraulic cylinder 40 is powered by an external hydraulic power source 41, such as, for example, a battery-operated hydraulic pump, for thereby selectively extending and driving the punch plate 36 (the moving/male plate) towards the die plate 38 (the stationary/female plate), and also selectively retracting the punch plate 36 away from the die plate 38.

The punch plate 36 includes one or more punch teeth (PT1, PT2, PT3 . . . PTX) and, preferably when more than one punch teeth PTX are provided, also one or more punch slots (PS1, PS2, PS3 . . . PSX) defined by the spaces between the punch teeth PTX. Similarly, the die plate 38 includes one or more die teeth (DT1, DT2, DT3 . . . DTX) and, preferably, when more than one die teeth DTX are provided, also one or more die slots (DS1, DS2, DS3 . . . DSX) defined by the spaces between the die teeth. Also, the punch teeth PTX are horizontally shifted relative to the die teeth DTX whereby each of the die slots DSX are adapted to receive a corresponding opposing punch tooth PTX and each of the punch slots PSX are adapted to receive a corresponding opposing die tooth DTX. For example, as the punch plate 36 is advanced towards the die plate 38, punch tooth PT1 is received within die slot DS1, die tooth DT2 is received within punch slot PS2, punch tooth PT2 is received within die slot DS2, etc.

Preferably, the punch and die teeth PTX, DTX are formed separately from the punch and die plates 36, 38 and include rear mounting slots 554S. The rear mounting slots 554S are adapted to engage rail-shaped mounting protrusions 556P which mirror the shape of the rear mounting slots 554S and protrude from the punch and die plate face surfaces 250, 264 near the punch and die plate bottom surfaces 260, 274. The punch and die teeth PTX, DTX are installed by sliding the rear mounting slots 554S over the rail-shaped mounting protrusions 556P whereby the rail-shaped mounting protrusions 556P are captured within the rear mounting slots 554S, thereby coupling the punch and die teeth PTX, DTX to the punch and die plates 36, 38.

Preferably, as best seen in FIGS. 109A, 111D, 115A, and 116D, the rear mounting slots 554S are tapered and have a wider top end 554St and a narrower bottom end 554Sb. The rail-shaped mounting protrusions 556P mirror the shape of the rear mounting slots 554S, and so, also have a wider top end 556Pt and a narrower bottom end 556Pb. In this regard, tapering the rear mounting slots 554S and the rail-shaped mounting protrusions 556P makes it easier to install the punch and die teeth PTX, DTX because as the punch and die teeth PTX, DTX are installed (FIGS. 107, 108, 113, and 114), the narrower bottom ends 556Pb of the protrusions 556P are received into the wider top ends 554St of the rear mounting slots 554S.

As best seen in FIGS. 107-110 and 113-114, the punch and die plates 36, 38 also include dovetail retaining plates 558 and plate screws 560. The dovetail retaining plates 558 are adapted to be inserted into dovetail slots 562 which extend through the punch and die plate face surfaces 250, 264 and bottom surfaces 260, 274. As best seen in FIGS. 109C and 110A-C, the dovetail retaining plates 558 have wedge shaped terminal ends 558E and the dovetail slots 562 include inwardly tapered corner sections 562C which mirror the shape of the wedge-shaped terminal ends 558E. During installation of the retaining plates 558, the wedge-shaped terminal ends 558E slide into and are captured by the inwardly tapered corner sections 562C which prevents the dovetail retaining plates 558 from falling downwardly out of the dovetail slots 562. The dovetail retaining plates 558 are then secured to the punch and die plates 36, 38 by the plate screws 560 which extend through pass-through bores 564 formed in the dovetail retaining plates 558 and threadingly engage fastener bores 566 which are formed in the dovetail slots 562 and extend upwardly into the punch and die plates 36, 38.

Preferably, the dovetail retaining plates 558 include locating protrusions 568 which are adapted to be received into locating recesses 570 formed in the dovetail slots 562. The locating protrusions 568 and the locating recesses 570 are configured such that, when the locating protrusions 568 are received into and engage the locating recesses 570, the pass-through bores 564, which extend through the locating protrusions 568, are aligned with the dovetail slot fastener bores 566, which are located within the locating recesses 570. Using the locating protrusions 568 and the locating recesses 570 to align the pass-through bores 564 and dovetail slot fastener bores 566 reduces the time and effort required to install the plate screws 560 which, in turn, reduces the time and effort required to install the punch and die teeth PTX, DTX.

As best seen in FIGS. 109, 111, and 115-119, the mounting protrusions 556P preferably include a sloped protrusion face surface 556Pf and the punch and die plates 36, 38 preferably include sloped abutment surfaces 572 located one on either side of each mounting protrusion 556P. The mounting slots 554S include sloped slot face surfaces 554Sf that mirror and are configured to abut and slidingly engage the mounting protrusion sloped face surfaces 556Pf. Similarly, the punch and die teeth PTX, DTX include sloped tooth rear surfaces 574 that mirror and are configured to abut and slidingly engage the sloped abutment surfaces 572. The punch and die plates 36, 38 also include retaining ledges 576 extending along the upper edges of the sloped abutment surfaces 572. The top surfaces 578 of the punch and die teeth PTX, DTX are adapted to engage and abut against the bottom surfaces 576b of the retaining ledges.

As illustrated in FIG. 119, when the crimping assembly 34 is actuated and the punch and die teeth PTX, DTX engage a side-lapped seam 30, the forces F3 experienced by the punch and die teeth PTX, DTX cause the punch and die teeth PTX, DTX to be driven upwardly whereby the tapered mounting slots 554S are jammed onto the tapered mounting protrusions 556P and the punch and die teeth top surfaces 578 are jammed against the retaining ledge bottom surfaces 576b. Specifically, the sloped protrusion face surfaces 556Pf and the sloped abutment surfaces 572 act like ramps whereby the forces F3 drive the punch and die teeth PTX, DTX slightly upwardly with the sloped slot face surfaces 554Sf and sloped tooth rear surfaces 574 sliding along the sloped protrusion face surfaces 556Pf and the sloped abutment surfaces 572, respectively. As the punch and die teeth PTX, DTX are driven upwardly, the tapered mounting slots 554S are driven further onto the tapered mounting protrusions 556P and the punch and die teeth top surfaces 578 are driven against the retaining ledge bottom surfaces 576b. This creates a “jam lock” condition which prevents the teeth PTX, DTX moving or shifting vertically with respect to the punch and die plates 36, 38 and further ensures that the punch and die teeth PTX, DTX remain firmly secured to the punch and die plates 36, 38 during the actuation of the crimping assembly.

Unless otherwise indicated hereinabove, the punch and die teeth PTX, DTX are preferably made of high strength materials such as hardened steel and carbides and most all other components and parts of the tool 10 are made of metal such as steel or aluminum.

9. Preferred Hydraulic System Embodiment

As mentioned above, the punch plate 36 is coupled to a hydraulic cylinder 40 which is powered by an external hydraulic power supply unit 41. As diagrammatically depicted in FIG. 120, in a preferred embodiment, the hydraulic power supply unit 41 includes a hydraulic pump 41p that is coupled to and driven by an electric pump motor 41m. The pump motor 41m is preferably powered by an interchangeable battery 41b or, alternatively, by an internal combustion engine 41e (see ¶[0036] and FIG. 140).

The hydraulic pump 41p is hydraulicly coupled to a control valve 41cv, one or more relief valves 41rv, and a reservoir 41R. The control valve 41cv controls the flow of hydraulic fluid to and from the hydraulic cylinder 40, the relief valves 41rv help to control pressure within the hydraulic system, and the reservoir 41R stores hydraulic fluid for use by the hydraulic pump 41p. The control valve 41cv is preferably a solenoid operated valve that can be switched between an extending position as shown in FIG. 120 (connecting the pump 41p to conduit 138 and conduit 140 to the reservoir 41R) and a retracting position (connecting pump 41p to conduit 140 and conduit 138 to the reservoir 41R). As can be appreciated by one skilled in the art, when the control valve 41cv is in its extending position, the piston of the hydraulic cylinder 40 is extended for driving the punch plate 36 towards the die plate 38. When the control valve 41cv is placed in its retracting position, the piston of the hydraulic cylinder 40 is retracted for moving the punch plate 36 away from the die plate 38.

Preferably, a relief valve 41rv′ is hydraulically coupled between the control valve 41cv and the conduit 140. The relief valve 41rv′ can be configured to limit the pressure supplied to the hydraulic cylinder 40 for retracting the punch plate 36 away from the die plate 38 which can help to prevent damage to the crimping assembly 34 as the punch and die teeth PTX, DTX are pulled free from the side-lapped seam 30.

The hydraulic power supply unit 41 preferably also includes a control system 810 that controls the pump motor 41m and the control valve 41cv and allows an operator to operate the tool 10. The control system 810 can be a mechanical system, a hydraulic system, a pneumatic system, an electrical system, or other types of systems which can be configured to execute a set of predetermined operations. For example, as shown in FIG. 121, the control system 810 can include a digital controller 812, a power switch 814, and a cycle control switch 816. The digital controller 812 connects to the pump motor 41m and the control valve 41cv and can be, for example, a microprocessor, a microcontroller, or another type of digital processor or controller. The power switch 814 is connected between the interchangeable battery 41b and the digital controller 812 and is used to activate or deactivate the hydraulic power supply unit 41 and the control system 810. The cycle control switch 816 is connected to the digital controller 812 and is used by the tool operator to send inputs to the digital controller.

In operation, the digital controller 812 is configured to execute a set of preprogrammed operations for extending and driving the punch plate 36 towards the die plate 38, and thereafter retracting the punch plate 36 away from the die plate 38. For example, as illustrated in FIG. 122, when the power switch 814 is engaged (connecting the digital controller 812 to the battery 41b) and the cycle control switch 816 is engaged, the digital controller 812 activates the pump motor 41m for a first time period TP1. While the pump motor 41m is activated during the first time period TP1, the hydraulic pump 41p supplies high-pressure hydraulic fluid to the hydraulic cylinder 40 through conduit 138 for thereby extending and driving the punch plate 36 towards the die plate 38.

After the first time period TP1 has elapsed, the digital controller 812 switches the control valve 41cv to its retracting position and activates the pump motor 41m for a second time period TP2. While the pump motor 41m is activated during the second time period TP2, the hydraulic pump 41p supplies high-pressure hydraulic fluid to the hydraulic cylinder 40 through conduit 140 for thereby retracting the punch plate 36 away from the die plate 38. After the second time period TP2 has elapsed, the digital controller 812 deactivates the pump motor 41m and switches the control valve 41cv back to its extending position. The cycle control switch 816 can then be re-engaged to restart the process.

Turning momentarily to FIGS. 139 and 140, the internal combustion engine 41e is preferably configured to be controlled by the control system 810. More particularly, the internal combustion engine 41e is preferably configured to activate upon receiving a first signal from the digital controller 812, for example, by engaging a starter motor (not shown) which starts the internal combustion engine 41e, and to deactivate upon receiving a second signal from the digital controller 812, for example, by cutting off fuel to the internal combustion engine 41e.

Returning to FIGS. 123-127, to ensure the crimping assembly 34 is not engaged until the side-lapped seam 42 is properly positioned within the side-lapped seam receiving gap 30G between the punch and die plates 36, 38, the control system 810 is preferably also configured to monitor the position of the side-lapped seam 42. Specifically, the tool 10 preferably includes a side-lapped seam insertion sensing system 312 that is adapted for determining whether the punch and die plates 36, 38 are properly positioned on either side of the side-lapped seam 30. The side-lapped seam insertion sensing system 312 includes one or more seam position sensing arms 314, a stop beam 316, and a lever assembly 318. The seam position arms 314 include position arm axle bores 332 that are adapted to receive a position arm axle 334 therethrough for pivotably securing the position sensing arms 314 to the tool 10.

In operation, the seam position sensing arms 314 extend into the side-lapped seam receiving gap 30G and are configured to engage a side-lapped seam 42 as it enters the side-lapped seam receiving gap 30G (i.e., when the tool 10 is lowered onto the side-lapped seam 42). When the seam position sensing arms 314 engage a side-lapped seam 42, they pivot around the position arm axle 334 and actuate the lever assembly 318 for thereby moving the stop beam 316 between a locked position (wherein the stop beam 316 prevents the punch plate 36 from advancing towards the die plate 38, for example, as shown in FIG. 127A) and an unlocked position (wherein the stop beam 316 is retracted and the punch plate 36 can be advanced towards the die plate 38 upon actuation of the hydraulic cylinder 40, for example, as shown in FIG. 127B).

As best seen in FIGS. 127A-B, the position arm axle 334 is preferably D-shaped and includes a flat cam surface 334C. The position arm axle bores 332 are similarly D-shaped and are configured to engage the flat cam surface 334C such that, when the seam position sensing arms 314 engage a side-lapped seam 42 and pivot upwardly within the side-lapped seam receiving gap 30G, the position arm axle 334 rotates together with the seam position sensing arms 314.

As diagrammatically shown in FIG. 128, the control system 810 preferably also includes a seam position switch 818. The seam position switch 818 is connected to the digital controller 812 and is used to determine whether the tool 10 has been properly positioned relative to the side-lapped seam 42. Particularly, the seam position switch 818 can be coupled to or can otherwise monitor the rotational position of the position arm axle 334 and/or the seam position arms 318 and can be, for example, a rotary switch, a rotary potentiometer, or other types of switches or sensors. By monitoring the rotational position of the position arm axle 334 and/or the seam position arms 318, the seam position switch 818 can be used to determine the position of the seam position sensing arms 314, and, hence, the position of the side-lapped seam 42 within the side-lapped seam receiving gap 30G.

As illustrated in FIG. 129, the digital controller 812 can be configured to check the seam position switch 818 to confirm that the side-lapped seam 42 is properly positioned within the side-lapped seam receiving gap 30G before activating the pump motor 41m. Particularly, the digital controller 812 can be configured to first check whether the seam position switch 818 has been engaged-indicating that the seam position sensing arms 314 have engaged a side-lapped seam 42. If the seam position switch 818 has been engaged, the digital controller 812 then checks whether the cycle control switch 816 has been engaged. If the cycle control switch 816 has also been engaged, the digital controller 812 then activates the pump motor 41m for a first time period TP1 for thereby extending and driving the punch plate 36 towards the die plate 38. After the first time period TP1 has elapsed, the digital controller 812 switches the control valve 41cv to its retracting position and activates the pump motor 41m for a second time period TP2, thereby retracting the punch plate 36 away from the die plate 38.

Additionally, the control system 810 is preferably configured to monitor the hydraulic pressure within the hydraulic power supply unit 41. Specifically, the control system 810 can include a pressure sensor 820, a notification buzzer 822, and a notification light 824. The pressure sensor 820 is connected to the digital controller 812 and is hydraulicly coupled to the pump 41p, for example, as shown in FIG. 120. The pressure sensor 820 can be, for example, a resistive pressure sensor, a capacitive pressure sensor, a piezoelectric pressure sensor, an optical pressure sensor, a micro electro-mechanical pressure sensor, or other types of pressure sensors. The notification light 824 and the notification buzzer 822 are also connected to the digital controller 812 and are used to notify the tool operator of potential issues with the crimping assembly 34 and/or the hydraulic power supply unit 41. The notification light 824 and the notification buzzer 822 can also be used to notify the tool operator that a crimp cycle has been completed.

In operation, the pressure sensor 820 is used to measure the output pressure P1 of the pump 41p. While the pump motor 41m is active, the digital controller 812 monitors the pressure sensor 820 to determine whether the output pressure P1 exceeds a predetermined maximum pressure Pmax. If the output pressure P1 exceeds the predetermined maximum pressure Pmax (which could indicate that the tool 10 has jammed or experienced some other issue), the digital controller 812 deactivates the pump motor 41m (thereby deactivating the pump 41p) and activates the notification light 824 and the notification buzzer 822 to notify the tool operator that the pump motor 41m has been deactivated. By configuring the control system 810 to deactivate the pump motor 41m and activate the notification light 824 and the notification buzzer 822 to notify the tool operator of the deactivation, the control system 810 helps prevent damage to the hydraulic power supply unit 41 and/or the crimping assembly 34 and improves the service life of the tool 10.

The pressure sensor 820 can also be used to ensure that a minimum pressure Pmin has been achieved as the punch plate 36 is extended towards the die plate 38. In this regard, lower than normal pressure may indicate that there is an issue with the side-lapped seam 30 or with the tool 10. For example, a lower than normal output pressure P1 may indicate that the male lip 24 has slipped out from between the female channel walls 28a, 28b which would prevent the attachments 297 from properly forming. A lower than normal output pressure P1 may also indicate that some portion of the tool 10 has failed or broken.

As best seen in FIGS. 130 and 131A-B, the crimping assembly 34 can also include a punch plate stop plug 826 and one or more return springs 164. The stop plug 826 is secured to the die plate 38 and is adapted to abut the upper carrier plate 192 when the punch plate 36 is extended towards the die plate 38 (FIG. 131B). In operation, the stop plug 826 limits and stops the travel of the carrier plate 192 and punch plate 36 mounted thereon and, hence, limits the penetration depth of the punch and die teeth PTX, DTX into the side-lapped seam 30.

The return springs 164 are secured between the support wall 108 (which couples the die plate 38 to the chassis 32) and the upper carrier plate 192 (which couples the punch plate 36 to the hydraulic cylinder 40) and are adapted to assist the hydraulic cylinder 40 in retracting the punch plate 36 away from the die plate 38. When the control valve 41cv is placed in its retracting position, the springs 164 provide an additional force to retract and move the punch plate 36 away from the die plate 38 and to push the hydraulic fluid within the hydraulic cylinder 40 out through the conduit 138 to the reservoir 41R.

The return springs 164 are particularly useful in embodiments of the tool 10 that utilize a single-acting hydraulic cylinder 40′ rather than a double-acting hydraulic cylinder 40. Particularly, as diagrammatically depicted in FIG. 132, the hydraulic cylinder 40′ can be “single acting” whereby the hydraulic cylinder 40′ is adapted to only drive the punch plate 36 towards the die plate 38. In this embodiment, when the control valve 41cv is placed in its retracting position (closing off the line from the pump 41p and connecting conduit 138 to the reservoir 41R), the springs 164 provide the force necessary to retract and move the punch plate 36 away from the die plate 38 and to push the hydraulic fluid within the hydraulic cylinder 40 out through the same conduit 138 and to the reservoir 41R.

Turning to FIGS. 133-135, in addition to monitoring the position of the side-lapped seam 42 and the pressure within the hydraulic power supply unit 41, the control system 810 is preferably also configured to monitor the position of the punch plate 36. Particularly, as diagrammatically shown in FIGS. 133 and 134A-B, the control system 810 preferably includes a retract limit switch 828 and an extend limit switch 830. The retract limit switch 828 is connected to the digital controller 812 and is configured to trigger when the punch plate 36 is fully retracted away from the die plate 38 and the crimping assembly is in the “open” position (FIGS. 127B and 134A). The extend limit switch 830 is also connected to the digital controller 812 and is configured to trigger when the punch plate 36 is fully extended towards the die plate 38 and the crimping assembly is in the “closed” position (FIGS. 131B and 134B). Preferably, the retract and extend limit switches 828, 830 are inductive proximity switches, mechanical switches, or other types of switches or sensors that can be used to determine the position of the punch plate 36.

Preferably, as shown in FIG. 133, the control system 810 also includes a retract override switch 832, an emergency stop switch 834, a pressure input device 836, a display device 838, a tool ready light 840, and a positive crimp light 842. The retract override switch 832, emergency stop switch 834, pressure input device 836, display device 838, tool ready light 840, and positive crimp light 842 are connected to the digital controller 812 and are used to control the tool 10 or to provide information to the tool operator. Particularly, when the retract override switch 832 is engaged, the digital controller 812 is configured to switch the control valve 41cv to its retracting position and activate the pump motor 41m for thereby retracting the punch plate 36 away from the die plate 38. This allows the tool operator to override the normal processes of the digital controller 812 and selectively retract the punch plate 36 as may be necessary or desirable to, for example, unjam the crimping assembly 34.

Similarly, when the emergency stop switch 834 is engaged, the digital controller 812 is configured to immediately deactivate the pump motor 41m and stop the crimping assembly 34 from continuing to actuate. This allows the tool operator to quickly shut off the tool 10 in an emergency.

The pressure input device 836 is configured to be used by the tool operator to set or adjust the maximum pressure Pmax and/or a minimum pressure Pmin, and can be, for example, a set of DIP switches, a digital keypad, or another type of input device. The display device 838 is configured to display information such as, for example, the number of crimping cycles the tool 10 has performed and can be, for example, a digital screen, an analog counter, or other types of digital or analog displays. The tool ready light 840 and the positive crimp light 842 are configured to alert the tool operator when the crimping assembly 34 is ready to be actuated and when the crimping assembly 34 has successfully formed an attachment 297. The tool ready light 840 and the positive crimp light 842 can be, for example, LEDs, incandescent lights, fluorescent lights, or other types of lights or visual indicators.

In operation, as illustrated in FIGS. 135A-C, when the power switch 814 is engaged and the control system 810 is turned on, the digital controller 812 first checks the retract limit switch 828 to determine if the crimping assembly 34 is in the “open” position. If the retract limit switch 828 is engaged (indicating that the crimping assembly 34 is in the open position), the digital controller 812 will proceed to cycle the crimping assembly 34 as illustrated in FIGS. 135B-C. If the retract limit switch 828 is not engaged, the digital controller 812 then checks the extend limit switch 830 to determine if the crimping assembly 34 is in the “closed” position.

If the extend limit switch 830 is engaged (indicating the crimping assembly 34 is in the closed position), the digital controller 812 is configured to switch the control valve 41cv to its retracting position and activate the pump motor 41m for a time period TP2 to begin retracting the punch plate 36 away from the die plate 38. If the extend limit switch 830 is not engaged, the digital controller 812 can be configured to activate the notification buzzer 822 and the notification light 824 to signal to the tool operator that the tool 10 is possibly jammed in a partially open position. Alternatively, the digital controller 812 can be configured to attempt to retract the hydraulic cylinder 40 and reset the crimping assembly 34.

If the digital controller 812 is configured to attempt to retract the hydraulic cylinder 40, the digital controller 812 will first check whether the cycle control switch 816 is engaged. This gives the tool operator an opportunity to examine the crimping assembly 34 before attempting to retract the hydraulic cylinder 40. If the cycle control switch 816 is engaged, the digital controller 812 then switches the control valve 41cv to its retracting position and activates the pump motor 41m for the time period TP2 to begin retracting the punch plate 36 away from the die plate 38. As the punch plate 36 retracts, the digital controller 812 monitors the retract limit switch 828 to determine when the punch plate 36 has fully retracted. When the retract limit switch 828 engages, the punch plate 36 has fully retracted and the digital controller 812 deactivates the pump motor 41m and switches the control valve 41cv to the extending position.

Additionally, while the punch plate 36 is retracting, the digital controller 812 also monitors the pressure sensor 820 to ensure that the output pressure P1 of the hydraulic pump 41p does not exceed the maximum pressure Pmax. As mentioned above, the pressure input device 836 allows the tool operator to adjust the maximum pressure Pmax as may be necessary or desirable for unjamming and/or preventing damage to the crimping assembly 34. If the output pressure P1 exceeds the maximum pressure Pmax before the punch plate 36 has fully retracted, the digital controller 812 is configured to deactivate the pump motor 41m and activate the notification buzzer 822 and the notification light 824 to signal to the tool operator that the tool 10 is possibly jammed. The digital controller 812 is also configured to deactivate the pump motor 41m and activate the notification buzzer 822 and the notification light 824 to signal to the tool operator that the tool 10 is possibly jammed if the retract limit switch 828 is not engaged before the time period TP2 elapses.

As illustrated in FIG. 135B, after the punch plate 36 has been retracted, or if the retract limit switch 828 was engaged at the beginning of the cycle, the digital controller 812 is configured to check the seam position switch 818 to determine whether the side-lapped seam 42 is properly positioned between the punch and die plates 36, 38. If the seam position switch 818 is engaged (indicating that the side-lapped seam 42 is properly positioned in the side-lapped seam receiving gap 30G), the digital controller 812 activates the tool ready light 840 to alert the tool operator that the crimping assembly 34 is ready be actuated and checks the cycle control switch 816. If the cycle control switch 816 is engaged, the digital controller 812 deactivates the tool ready light 840, activates the pump motor 41m for a time period TP1 to extend the punch plate 36 towards the die plate 38, and monitors the pressure sensor 820 to ensure the output pressure P1 exceeds the minimum pressure Pmin (to ensure the tool 10 has successfully formed an attachment 297), but does not exceed the maximum pressure Pmax.

Preferably, the digital controller 812 is configured to keep the pump motor 41m active until either the extend limit switch 830 is engaged (indicating that the punch plate 36 has been fully extended), the output pressure P1 exceeds the maximum pressure Pmax, or the time period TP1 elapses. If the output pressure P1 exceeds the maximum pressure Pmax or the time period TP1 elapses before the extend limit switch 830 is engaged, the digital controller 812 is configured to deactivate the pump motor 41m and activate the notification buzzer 822 and the notification light 824.

If the extend limit switch 830 is engaged before the time period TP1 has elapsed and the output pressure P1 has exceeded the minimum pressure P1 but has not exceeded the maximum pressure Pmax, the digital controller 812 momentarily activates the notification buzzer 822 and the positive crimp light 842, notifying the operator that an attachment 297 has been successfully formed. If the extend limit switch 830 is engaged and the output pressure P1 has not exceeded the minimum pressure P1, the digital controller 812 momentarily activates the notification buzzer 822 and the notification light 824, notifying the operator that an attachment 297 may not have been formed. In either case, as illustrated in FIG. 135C, the digital controller 812 then switches the control valve 41cv to the retracting position and begins retracting the punch plate 36 away from the die plate 38 for a time period TP2.

As the punch plate 36 retracts, the digital controller 812 monitors the retract limit switch 828 to determine when the punch plate 36 has fully retracted and monitors the pressure sensor 820 to ensure the output pressure P1 does not exceed the maximum pressure Pmax. When the retract limit switch 828 is engaged (indicating that the punch plate 36 has been fully retracted), the digital controller 812 deactivates the pump motor 41m, switches the control valve 41cv to the extending position, and increases the number of crimp cycles displayed on the display device 838. The tool 10 can then be repositioned and the process can be restarted in order to form additional attachments 297 in the side-lapped seam 42 or to form attachments 297 in another side-lapped seam 42.

Preferably, as illustrated in FIGS. 136-138, the tool 10 further includes one or more electric wheel motors 844 that are coupled and provide power to the wheels 50 for assisting with transporting the tool 10 over top of the deck structure 12. More particularly, the wheel motors 844 can be, for example, electric hub motors that are connected to the digital controller 812 (FIG. 136) and form the central hubs of the wheels 50 (FIG. 137). Preferably, the wheel motors are powered by the hydraulic power supply unit's interchangeable batteries 41b or, alternatively, directly by other interchangeable batteries or through an electrical cable/power cord (not shown). When the wheel motors 844 are engaged, a torque T1 is applied to one or both of the wheels 50 for transporting the tool 10 over the deck structure 12 (FIG. 137).

Yet more preferably, the control system 810 further includes a transport control switch 856, a crimp distance input device 846, a wheel encoder 848, a proximity sensor 850, and a transport ready light 852. The transport control switch 856, crimp distance input device 846, wheel encoder 848, proximity sensor 850, and transport ready light 852 are connected to the digital controller 812 and are used to alert the tool operator and to control the wheel motors 844 for transporting the tool 10 over the deck structure 12. For example, the control system 810 can include an internal distance counter 854 which can be displayed on the display device 838. The internal distance counter 854 can be a digital program that is programmed into the digital controller 812 or can it be a mechanical or electronic counter device that is connected to the digital controller. In operation, the internal distance counter 854 is used to measure the distance the tool 10 has traveled since the last crimping cycle and can be used by the tool operator to, for example, evenly space the attachments 297 along a side-lapped seam 42.

As illustrated in FIG. 138, after the crimping assembly 34 has completed a crimping cycle (FIGS. 135A-C) and the punch plate 36 has fully retracted away from the die plate 38, the digital controller 812 sets the internal distance counter 854 to zero and activates the transport ready light 852 which alerts the operator that the tool 10 is ready to be transported along the side-lapped seam 42. The digital controller 812 then monitors the transport control switch 856. When the transport control switch 856 is engaged, the digital controller 812 activates the wheel motors 844 for transporting the tool 10 along the side-lapped seam 42. As tool 10 is transported, the wheel encoder 848, which is connected to one or both of the wheels 50, records the rotation of the wheels 50 and sends a signal to the digital controller 812 to incrementally increase the internal distance counter 854.

Preferably, as the internal distance counter 854 incrementally increases, the digital controller 812 compares the value of the internal distance counter 854 against a preset crimp distance D1. The preset crimp distance D1 is set by the tool operator using the crimp distance input device 846 and can be used to have the tool 10 automatically travel a uniform distance between crimping cycles so that the attachments 297 are formed at regular intervals along the side-lapped seam 42. In operation, the digital controller 812 is configured to deactivate the wheel motors 844 once the internal distance counter 854 is equal to the preset crimp distance D1 so that the tool operator can engage the cycle control switch 816 and actuate the crimping assembly 34 for forming attachments 297 in the side-lapped seam 42.

Additionally, the digital controller 812 can also be configured to deactivate the wheel motors 844 if the proximity sensor 850, which is preferably mounted to the front of the tool 10 (see FIG. 137), indicates that the tool 10 is approaching the edge of the deck structure 12. In this regard, the proximity sensor 850 is configured to monitor the deck structure 12 to prevent the tool 10 from rolling or falling off the deck and can be, for example, an optical sensor, a photoelectric sensor, a radar or other electromagnetic wave-based sensor, or other types of mechanical or electrical proximity sensors.

As the tool 10 is transported along the side-lapped seam 42, the digital controller 812 monitors the proximity sensor 850 to determine if the tool 10 is approaching the edge of the deck structure 12. If the proximity sensor 850 indicates that the tool 10 is approaching the edge of the deck structure 12, the digital controller 812 is configured to deactivate the wheel motors 844 and activate the notification buzzer 822 and the notification light 824 to alert the tool operator that the tool 10 is close to the edge of the deck structure 12.

Of course, rolling or falling off of the deck structure 12 could cause significant damage to the tool 10 or to any structures or people that the tool 10 may fall onto. Accordingly, by configuring the control system 810 to monitor the deck structure 12 and deactivate the wheel motors 844 if the tool 10 is approaching the edge of the deck structure 12, the control system 810 helps to prevent damage to the tool 10 or other structures or people.

While this invention has been described as having an exemplary design, the present invention may be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles.

Method And Tool for Joining Side-Lapped Seams Of Steel Deck Panels And Steel Deck Structure Incorporating Interlocking Side-Lapped Seams

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