Patent Grant
11491633
This application claims priority from European Patent Application No. 17306123.5, filed on Aug. 31, 2017, the disclosure of which is incorporated herein by reference.
This specification concerns power tools for crimping or cutting objects and methods of assembling such tools. The specification describes electro-hydraulic versions of such tools, although aspects of the invention could be used in other types of tool.
An example prior art portable electro-hydraulic tool for crimping an object is the Milwaukee® M18™ Force Logic™ 6T crimping tool. It will be appreciated that problems can occur if water, specifically rain, enters the tool when used outside. However, it should be borne in mind that airflow within the tool can assist in reducing the temperature of internal components such as the electric motor, avoiding overheating. In manufacturing portable electro-hydraulic crimping and cutting tools consideration should thus be given to the trade-off between waterproofness and cooling. Also, it is known for portable electro-hydraulic crimping and cutting tools to include a visible indicator on the side of the tool housing to indicate operational information, although users are required to remove their gaze from the operative part of the tool (e.g. the crimping jaws) to look at it and may be required to change which of their hands grips the tool in order to remove their arm from obscuring the view.
According to an aspect of the present invention there is provided a power tool comprising: a pressure generating mechanism including an electric motor and being configured to apply pressure to an object for crimping or cutting the object; a tool housing defining a vent portion to enable airflow within the tool housing for cooling of the electric motor; a frame portion urged against the interior of the tool housing and surrounding the vent portion, the frame portion being urged against the tool housing by cooperating with a component of the tool within the tool housing; and a partition member configured to restrict passage of liquid water while permitting airflow therethrough, wherein the partition member is pinched between the interior of the tool housing and the frame portion such that the partition member extends across the vent portion for restricting ingress of liquid water into contact with electrical components within the tool housing while permitting airflow.
The tool housing may define a plurality of vent portions to enable airflow for cooling of the electric motor and respective partition members may be pinched between the tool housing interior and respective frame portions surrounding the vent portions for restricting ingress of liquid water into contact with electrical components within the tool housing while permitting airflow, the frame portions comprising separate parts of a frame body.
At least one said frame portion may pivot relative to the rest of the frame body prior to being provided within the power tool.
The tool may have a plurality of said frame bodies wedged between the tool housing interior and said component of the tool within the tool housing, a first frame body being provided on one side of the tool inside the housing and a second frame body being provided on the other side of the tool inside the housing such that the partition members pinched thereby cooperate with vent portions on respective sides of the tool.
The or each said frame portion may have an inner profile corresponding in shape to the exterior of the component which wedges the at least one frame portion against the interior of the tool housing, optionally wherein the component may be a housing of the electric motor.
The interior of the tool housing may be provided with at least one feature that forms an interference fit with the or each said frame portion to restrict movement thereof.
According to another aspect of the present invention there is provided a method of assembling a power tool comprising the steps of: providing a first part of a tool housing which defines a vent portion to enable airflow within the tool housing in use; arranging a frame portion supporting a partition member within the first tool housing part such that the partition member extends across the vent portion; providing a pressure generating mechanism including an electric motor and being configured to apply pressure to an object for crimping or cutting the object; and closing the tool housing by causing the first tool housing part to cooperate with another tool housing part, such that when the tool housing is closed the partition member is pinched between the interior of the tool housing and the frame portion for restricting ingress of liquid water into contact with electrical components within the tool housing while permitting airflow.
According to another aspect of the present invention there is provided a power tool comprising: a pressure generating mechanism including an electric motor and being configured to apply pressure to an object for crimping or cutting the object; an actuator that a user can manipulate to influence operation of the pressure generating mechanism; a support on which the actuator is provided, the support having a first part of a two-part sealing mechanism around its periphery; and a tool housing formed by a plurality of tool housing parts which cooperate to form a second part of the two-part sealing mechanism and clamp the support between them such that the first and second parts of the two-part sealing mechanism cooperate to restrict ingress of liquid water into contact with electrical components of the tool within the tool housing.
One of the first and second parts of the two-part sealing mechanism may be a female part configured to receive the other part of the two-part sealing mechanism which may be a male part.
One of the first and second parts of the two-part sealing mechanism may be an overmold feature and the other part of the two-part sealing mechanism may be a channel.
The actuator may be a rocker switch and a sealing feature may be provided around an opening in the support through which a plunger of the rocker switch extends for further restricting the ingress of liquid water into contact with electrical components of the tool within the tool housing.
According to another aspect of the present invention there is provided a method of assembling a power tool comprising the steps of: providing a first part of a tool housing; providing a pressure generating mechanism including an electric motor and being configured to apply pressure to an object for crimping or cutting the object; providing a support carrying an actuator that a user can manipulate to influence operation of the pressure generating mechanism in use, the support having a first part of a two-part sealing mechanism around its periphery; closing the tool housing by causing the first tool housing part to cooperate with at least one other tool housing part such that when the tool housing is closed the housing parts cooperate to form a second part of the two-part sealing mechanism and clamp the support between them such that the first and second parts of the two-part sealing mechanism cooperate to restrict the ingress of liquid water into contact with electrical components of the tool within the housing.
According to another aspect of the present invention there is provided a power tool comprising: a pressure generating mechanism including an electric motor and being configured to apply pressure to an object for crimping or cutting the object; a plurality of light sources for illuminating a working part of the pressure generating mechanism which applies force to an object being crimped or cut in use; at least one sensor for generating output indicative of at least one operational parameter of the tool; and a controller for receiving the output generated by the at least one sensor and based on this output controlling operation of the light sources to give a visible indication of the occurrence of a predetermined condition during tool use, said visible indication being observable by a user gazing at the working part of the pressure generating mechanism which applies force to an object being crimped or cut in use.
The light sources may be distributed in a plane that is orthogonal to a major axis of the tool, optionally wherein the light sources may be circumferentially arranged around said axis.
The controller may be configured to control the light sources to give a visible indication of the occurrence of at least one of: a successful crimping or cutting cycle; an unsuccessful or incomplete crimping or cutting cycle; temperature of the electric motor exceeding a threshold amount; remaining battery power falling below a threshold amount; occurrence of a predetermined number of tool operation cycles; and a malfunction.
The controller may be configured to give a visible indication of the occurrence of a predetermined condition by causing the plurality of light sources to illuminate the working part of the pressure generating mechanism which applies force to an object being crimped or cut in use with light of a colour corresponding to the occurrence of said condition, optionally wherein each of the light sources may be an RGB LED.
The controller may be configured to cause the light sources to illuminate the working part of the pressure generating mechanism which applies force to an object being crimped or cut in use with light of a first colour for a predetermined time frame following a successful crimping or cutting cycle, whereas the controller may be configured to cause the light sources to illuminate the working part of the pressure generating mechanism which applies force to an object being crimped or cut in use with light of a second colour for a predetermined time frame following an unsuccessful or incomplete crimping or cutting cycle.
Various aspects and embodiments of the invention will now be described by way of non-limiting example with reference to the accompanying drawings, in which:
A first such aspect of the present invention is described with reference to
In some power tool embodiments, a plastic frame that supports multiple membrane portions is provided for restricting liquid water ingress through vent portions in the power tool casing while permitting airflow. The frame is retained in place within the power tool by clamping it between an internal component of the power tool (e.g. an electric motor) and an internal surface of the power tool casing. The internal surface of the power tool casing is additionally shaped to cooperate with the frame to further assist in retaining the frame in place, for example by forming an interference fit with the frame. Specific details of example embodiments will now be described.
Partition members supported by a frame are arranged inside the housing 12 adjacent each of the vent portions 14 to restrict the ingress of liquid water into the tool through the vent portions while still permitting airflow for reducing the likelihood of condensation accumulating inside the housing 12.
The fourth frame section 16d is located to the side of the second frame section 16b.
More specifically the fourth frame section 16d has a common edge 24 with the second frame section 16b which couples the two frame sections together. A second notional line 25 perpendicular to the first notional line 22 extends between the second and fourth frame section 16b and 16d. The fourth frame section includes a grid 26 across the opening defined thereby, the purpose of which will be explained later on.
First to third partition members 28a, 28b, 28c are fixed to the first, third and fourth frame sections 16a, 16c, 16d. Moreover, these partition members 28a, 28b, 28c are fixed to a first side of the frame sections 16a, 16c, 16d and extend across the openings defined thereby. That is the first partition member 28a extends across the opening defined by the first frame section 16a, the second partition member 28b extends across the opening defined by the third frame section 16c and the third partition members 28c extends across the opening defined by the fourth frame section 16d. Furthermore, the first to third partition members 28a, 28b, 28c form a water tight seal around the heretofore mentioned frame sections 16a, 16c, 16d to restrict the passage of liquid water through the openings defined by the frame sections 16a, 16c, 16d although the partition members 28a, 28b, 28c allow both air and water vapour to pass through them.
In some embodiments the frame 16 can be formed of plastic such as polypropylene. The frame 16 can thus be formed by an injection moulding technique. Furthermore, the partition members 28a, 28b, 28c can comprise membranes and in some embodiments, can be formed of material such as polypropylene tissue non-woven fabric filter (e.g. material having part number 5100 obtainable from K2 Technologie, France). Various techniques can be used to fix the partition members 28a, 28b, 28c to the frame 16 such as gluing or ultrasonic welding. Using welding for example the peripheries of the partition members 28a, 28b, 28c can be welded to the sections of the frame 16 that delineate the openings defined by the first, third and fourth frame sections 16a, 16c, 16d.
Now with reference to
In more detail, with further reference to
With continued reference to
The aforementioned receiving features 30, which in the embodiment illustrated comprise a series of walls 30, protrude from the inner surface of the first tool housing part 12a. This provides that when the frame 16 is moved into contact with the first tool housing part 12a the frame 16 is received in the space defined by the walls 30, which thereby act to restrict movement of the frame 16 except in a direction extending away from the inner surface of the first tool housing part 12a. With specific reference to
In more detail, looking at
Components of the tool 10 are then arranged within the first tool housing part 12a, such as an electro-hydraulic actuating arrangement that includes an electric motor for actuating a pair of crimping jaws. It will be appreciated that other features necessary for operation of the tool are arranged inside the first tool housing part 12a at this stage.
The grid 26 defined by the fourth frame section 16d restricts components within the tool housing 12 from coming into contact with the partition member 28c and thereby damaging the partition member 28c during use.
A second tool housing part 12b, complementary to the first housing part 12a and also provided with a frame 16 similarly as illustrated in
In other words, due to the complementary shape of the frames 16 and the exterior of the motor housing 32, the frames 16 are clamped between a respective tool housing part 12a, 12b and the motor housing 32. That is the frame 16 on one side of the tool 10 is clamped between the first tool housing part 12a and the motor housing 32, whereas the frame 16 on the other side of the tool is clamped between the second tool housing part 12b and the motor housing 32. Such squeezing of the frames 16 between the motor housing 32 and the tool housing parts 12a, 12b biases the first, third and fourth frame sections 16a, 16c, 16d against the aforementioned edge portions surrounding the vent portions 14a to 14c in the respective tool housing parts 12a, 12b. Looking at
With reference to
It will be appreciated that in addition to providing protection from liquid water ingress, the partition members 28a, 28b, 28c heretofore described provide protection from dust ingress and the ingress of other particulates. In some embodiments the partition members have an IP (Ingress Protection) Rating of IP65.
It will also be appreciated that there is some design freedom in that the features heretofore described do not need to have the exact shape as illustrated in the drawings. For example, the first and third frame sections 16a and 16c may be triangular, the base of each triangle serving as the common edge with the second frame section 16b. In embodiments in which the frame 16 is shaped differently to as shown in the drawings, the arrangement of walls 30 protruding from the inner surface of the tool housing parts 12a, 12b is correspondingly different in order to receive the frame 16 when urged into engagement with the interior of a tool housing part. Furthermore, the motor housing 32 may be shaped differently to that as illustrated, thereby requiring the frame 16 and walls 30 to be correspondingly shaped differently in order to achieve the same effects as heretofore described. More specifically the profile 27 of the bottom-side of the frame 16 and the upper edges of the walls 30 would need to be adapted to correspond with the motor housing exterior.
In some embodiments the component clamped between opposing tool housing parts 12a, 12b and frames 16 need not necessarily be a motor housing 32. For example, another feature, such as a transmission containing a set of selectable gears for example, may be clamped between a pair of frames 16 inside a tool 10 instead.
In some embodiments the frame 16 need not necessarily comprise a plurality of frame portions and may instead comprise just a single frame portion for restricting liquid water ingress through a single vent portion in a tool housing.
A second aspect of the present invention is described with reference to
In some embodiments a rocker switch is provided on a support, wherein the periphery of the support is provided with a rubber overmold. During assembly of a power tool the support is clamped between respective parts of the tool casing, wherein internal surfaces of the respective casing parts cooperate with the rubber overmold to restrict the ingress of liquid water into the power tool. A rubber overmold is also provided around an opening in the support through which a plunger of the switch extends for further restricting the ingress of liquid water into the power tool. Details of example embodiments will now be described.
With reference to
Components of the tool 100 are arranged within the first tool housing part 112a, such as an electro-hydraulic mechanism that includes an electric motor for actuating crimping jaws of the tool. It will be appreciated that other features necessary for operation of the tool are arranged in the first tool housing part 112a.
The switch 102 is also arranged inside the first tool housing part 112a such that it engages an inner wall thereof. A first half of the support 108, in other words a half of the support 108 located on one side of the notional line 107 extending along the central axis of the support 108, is inserted into the first tool housing part 112a as illustrated in
In the arrangement when the support 108 has been inserted in the first tool housing part 112a, the actuation feature 104 is located in a cavity 116a (see
A second tool housing part 112b, complementary to the first housing part 112a and also provided with a channel 113b, similarly as illustrated in
From the foregoing when the first and second tool housing parts 112a, 112b are secured together the channels 113a, 113b cooperate to form a continuous channel extending about the interior of the tool housing 112. The protrusions 114a, 114b of the respective channels 113a, 113b thus cooperate to form a continuous lower edge and the upper surfaces 115a, 115b of the respective channels 113a, 113b cooperate to form a continuous upper edge. As a result, the upper and lower surfaces of the aforementioned continuous channel cooperate with the overmold feature 110 to retain the support 108 in place. Moreover, since the support 108 is clamped between the housing parts 112a, 112b the overmold feature 110 cooperates with the inner wall of the respective housing parts 112a, 112b to form a seal. As a result, if liquid water enters the tool 100 through the space between the rim 118a, 118b of the housing parts 112a, 112b and the actuation feature 104 this water is restricted by the seal mentioned in the previous sentence, from entering the inner chamber 122 of the tool housing 112 where electronic components such as an electric motor are located.
It will be appreciated that there is some design freedom in that the features heretofore described in connection with
In some alternative embodiments the support 108 may have a channel extending around its periphery instead of an overmold feature. In such embodiments the respective tool housing parts 112a, 112b may each be provided with an overmold feature instead of a channel, such that when the two housing parts 112a, 112b are coupled together the two overmold features cooperate to form a continuous overmold feature that extends around the interior of the tool housing 112 formed. More specifically in such embodiments when the support 108 of the switch 102 is clamped between the respective tool housing parts 112a, 112b similarly as heretofore described, the continuous overmold feature protruding from the interior of the tool housing 102 extends into the channel extending around the periphery of the support 108 for forming a seal to restrict the ingress of liquid water into the inner chamber 122 of the tool housing 102.
Furthermore, the overmold feature need not necessarily be formed of rubber but could comprise any other material suitable for fulfilling the purpose of providing a seal for restricting the ingress of liquid water.
Additionally, the switch 102 need not necessarily be of the rocker variety and in some embodiments can merely be some kind of actuator that a user can manipulate to influence tool operation, provided the actuator is provided on a support 108.
Although the second aspect of the present invention has been described in the context of a crimping tool it will be appreciated that it could be applied in the context of an electro-hydraulic cutting tool also.
A third aspect of the present invention is described with reference to
In some embodiments an electro-hydraulic crimping or cutting tool has a series of light emitting units for illuminating the operational part of the power tool (i.e. the crimping jaws or cutting jaws). The light emitting units are arranged next to one another in a manner such that the plurality thereof wraps around the tool housing, wherein they can be caused to change colour for indicating tool usage information to a user. In some embodiments the light emitting units can be a plurality of RGB LEDs. When a tool is initially turned on the light emitting units may emit white light solely for the purpose of illuminating the object to be cut or crimped. Following a good crimping or cutting cycle they may temporarily turn green, whereas following a bad crimping or cutting cycle they may temporarily turn red. Also, if the temperature of the tool becomes too hot the light emitting units may turn yellow or begin to flash. Nevertheless, since the light emitting units illuminate the operational part of the tool while in use, users are not required to remove their gaze from the object being operated on (e.g. the part of an object being crimped or cut) in order to be provided with tool usage information, nor are they required to change which of their hands grips the tool in order to be provided with such information.
In some embodiments the ring of light emitting units 206 is a ring of RGB LEDs e.g. part number P/N RING060 or P/N RING070 obtainable from the company Seko (Hong Kong) Technology Limited, Guangzhou Seko Lighting, 2 floor, No. 98 Tai an Road, shi ji town, panyu District, Guangzhou, China. In such embodiments the colour of light emitted by respective light emitting units (i.e. the respective RGB LEDs) can be selectively controlled by changing the intensity of red, green and blue light emitted from the RGB LEDs.
A highly schematic drawing of components inside the tool 200 is illustrated in
A user input arrangement 218 is connected to the system bus 208 for transmitting user input to the controller 210. This user input arrangement 218 can include a switch, such as a switch of the kind heretofore described in connection with
An electric motor 220 of an electro-hydraulic drive mechanism 222 is connected to the system bus 208 for receiving control signals from the controller 210. The electric motor 220 can be used to drive the crimping jaws 204 via a hydraulic arrangement of the electro-hydraulic drive mechanism 222 in a manner that will be familiar to persons skilled in the art.
A current sensor 224 is connected to the system bus 208 for transmitting information to the controller 210 indicative of the magnitude of current being consumed by the electric motor 220. Based on this information the controller 210 can monitor progress of tool operation and make, for instance, a determination as to whether a crimping cycle is successful, incomplete or unsuccessful. Moreover, when a user indicates to the controller 210 a desire to crimp something via the user input arrangement 218 the controller 210 controls the tool 200 to undergo a crimping cycle by executing instructions pre-stored in the non-volatile memory 212 during manufacture, whereby the controller 210 controls components of the tool 200 accordingly to affect the crimping cycle by monitoring the progress of the crimping cycle based on the amount of current consumed by the electric motor 220. Persons skilled in the art will be familiar with techniques of automatically implementing crimping cycles and determining whether such crimping cycles are successful or not, for example the Neolec™ range of electro-hydraulic crimping tools from Dubuis et Cie, France (e.g. the BPL036 and the BPL055 inline crimping tools) monitor and thereby control the progress of crimping cycles based on differences in the rate of change of current consumed by a driving electric motor.
A ring of light emitting units of the kind heretofore described is referred to hereafter as a halo 206, whereby such a halo 206 is connected to the system bus 208 to enable the controller 210 to control the colour of light emitted thereby for indicting tool usage information to a user.
Additionally, a battery 226 is provided for powering the aforementioned components.
When run, the aforementioned application causes the controller 210 to implement changes in the color of light being emitted by the halo 206 to indicate tool usage information to a user. For example, the controller 210 can be caused to give a visual indication to a user regarding whether an object has been successfully crimped or not. Such a process is illustrated in
In step S2 the controller 210 monitors for signals originating from the user input arrangement 218.
In step S3 the controller 210 responds to a user indication to begin crimping an object by executing crimping cycle control instructions pre-stored in non-volatile memory 212 during manufacture. Control signals are thus caused to be transmitted to the electric motor 220 to start driving the crimping jaws 204 via the hydraulic mechanism 222. Additionally, the controller 210 begins processing information received from the current sensor 224 which is indicative of the amount of current being consumed by the electric motor 220 in order to monitor and control operation of the tool 200 during the crimping cycle being implemented as heretofore described.
In step S4 the controller 210 determines whether the crimping cycle was a success or not, again as heretofore described, for example on the basis of information received from the current sensor 224 during the crimping cycle, or on the basis of whether a user indicated via the input arrangement 218 to stop the crimping process part way through a crimping cycle.
If yes, the crimping cycle is determined to have been a success, then in step S5A the controller 210 causes the halo 206 to emit light of a first predetermined colour (e.g. green light) for a predetermined amount of time, for example two seconds before returning to emit white light. If no, the crimping cycle is determined to have been unsuccessful or incomplete, then in step S5B the controller 210 causes the halo 206 to emit light of a second predetermined colour (e.g. red light) for a predetermined amount of time, for example two seconds before returning to emit white light.
Subsequently in step S6 the controller 210 monitors for further control information from the user input arrangement 218 to determine what to do next, wherein the process in
In some embodiments the sensor 224 may not be a current sensor and may instead be configured to give an output indicative of another parameter (e.g. the voltage consumed by the electric motor 220 or another component of the tool) for enabling the controller 210 to monitor and control the progress of a crimping cycle.
In some embodiments the tool 200 can have other sensors for transmitting to the controller 210 information indicative of the parameter being sensed, whereby the controller 210 can cause the halo 206 to give a visual indication of the occurrence of a pre-determined condition based on such information. In embodiments having multiple sensors the controller 210 can make a determination as to which condition has priority based on information pre-stored in the non-volatile 212.
In some embodiments the power tool 200 can for example additionally include a temperature sensor and the controller 210 can be configured to cause the halo 206 to start emitting light of a predetermined colour (e.g. yellow) when the temperature is determined to exceed a threshold amount. In some embodiments the controller 210 may instead be configured to cause the halo 206 to begin flashing, or give another visual indication, upon determining that the temperature has exceeded the threshold amount.
In some embodiments the tool 200 can include a battery power level sensor arrangement and the controller 210 can be configured to cause the halo 206 to start emitting light of a predetermined colour (e.g. purple) when the battery power level is determined to be below a threshold amount. In some embodiments the controller 210 may instead be configured to cause the halo 206 to begin flashing, or give another visual indication, upon determining that the remaining battery power level is less than the threshold amount.
In some embodiments the tool 200 can be configured to maintain a record of how many operational cycles it undergoes (in other words how many crimping cycles) by updating a flash memory for instance after each operational cycle and the controller 210 can be configured to cause the halo 206 to give a visual indication when a predetermined number of operational cycles is reached (e.g. flash red).
In some embodiments, if the controller 210 determines that a tool malfunction has occurred it controls the halo 206 to emit red light continuously.
In some embodiments the light emitting units 206 may not be circumferentially distributed around the housing 102 as heretofore described in connection with
In some embodiments the light emitting units 206 may not be provided in a continuous arrangement (e.g. a circle) and may instead be provided offset from one another. For example, separate light emitting units may be provided at respective locations corresponding to the corners of a square or a triangle, provided they are arranged to emit light towards the jaws for illuminating an object being crimped.
In some embodiments the tool may not illuminate the jaws with white light as a standard condition, thereafter subsequently changing colour to indicate the occurrence of a predetermined condition. In other words, the jaws may not be illuminated to assist a user in positioning the tool before initiating a crimping or cutting cycle, whereas in some embodiments users have the option to select whether this occurs or not, for example to save battery life if the tool is used outside in good lighting conditions.
Although the embodiments described in connection with
Furthermore, whilst illustrative embodiments have been described in connection with
Although the first, second and third aspects of the present invention have been described separately it will be appreciated that a power tool (such as a portable inline electro-hydraulic crimping or cutting tool as heretofore described, a portable pistol grip type electro-hydraulic crimping or cutting tool or otherwise) could embody one or more of such aspects in any combination thereof.
Although aspects and embodiments of the present invention have primarily been described in the context of portable electro-hydraulic tools for cutting or crimping objects it will be appreciated that such aspects and embodiments could be applied in other types of electric power tool such as battery powered drills or otherwise. For example, an electric drill or other portable electric power tool could have vents in its housing that are closed off by partition members of the type described in connection with
Finally, it will be appreciated that whilst various aspects and embodiments have heretofore been described, the scope of the present invention is not limited thereto and instead extends to encompass all methods and arrangements, and modifications and alterations thereto, which fall within the spirit and scope of the appended claims.
It will be appreciated by persons skilled in the art that the above embodiments have been described by way of example only, and not in any limitative sense, and that various alterations and modifications are possible without departure from the scope of the invention as defined by the appended claims.
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