Abstract
A swage tool comprises a head assembly with a die block holding a lower swage die and a yoke holding an upper swage die. A detachable power unit includes a piston within a cylinder that applies force for vertical movement. The die block, attached to the piston, moves towards the stationary yoke to cause radial compression between the swage dies. The tool includes a mechanism for determining proper swage performance, tool holding mechanisms that improve operator maneuverability, endplates that lock and unlock the swage dies to the tool without themselves being removed from the tool, and a yoke-locking mechanism allowing selective removal of the yoke from the tool.
Claims
1. A swage tool comprising: a head assembly comprising a die block holding a lower swage die and a yoke holding an upper swage die; a power unit detachably coupled to the head assembly, the power unit comprising a piston housed within a cylinder and being configured to apply force that causes vertical movement of the piston, wherein the die block is mounted to the piston and moves vertically with the piston upon application of force by the power unit, and the yoke is fixed to the power unit and does not move vertically with the piston, and as force is applied by the power unit, the piston moves the die block and the lower swage die vertically towards the upper swage die held by the yoke, such that the lower and upper swage dies come into contact and are compressed radially inwardly as force is applied; and a mechanism built into the swage tool for determining whether a swage has been properly performed.
2. The swage tool of claim 1, wherein the mechanism for determining whether the swage has been properly performed comprises at least one sensor for measuring a distance that the die block travels from the power unit.
3. The swage tool of claim 1, wherein the mechanism for determining whether the swage has been properly performed comprises: a first sensor that detects when die block starts moving; and a second sensor that measures the distance that the die block moves.
4. The swage tool of claim 1, wherein the first sensor is a light or photocell sensor, and the second sensor is an ultrasonic sensor.
5. The swage tool of claim 1, further comprising a cycle counter that counts and displays a number of cycles performed by the swage tool, the cycle counter also displaying whether the swage was properly performed.
6. The swage tool of claim 1, further comprising a tool holding mechanism that is configured to allow an operator to hold and maneuver the swage tool.
7. The swage tool of claim 6, wherein the tool holding mechanism is a reduced diameter portion of the cylinder of the power unit that operates as a barbell-shaped grip and maintains a center of gravity near a center of the swage tool.
8. The swage tool of claim 7, wherein the barbell-shaped grip is formed with knurling to provide an enhanced grip.
9. The swage tool of claim 7, wherein the barbell-shaped grip is formed with ribs to provide an enhanced grip.
10. The swage tool of claim 6, wherein the tool holding mechanism is an ergonomic handle that is attached to the power unit by a band wrapped around the cylinder of the power unit, the handle comprising a controller configured to wireless operate a pump attached to the power unit and a button or switch configured to operate the controller.
11. The swage tool of claim 1, further comprising: a lower rotating endplate tab that is rotatable between a locked position that secures the lower swage die to the die block and an unlocked position that allows the lower swage die to be removed from the die block; and an upper rotating endplate tab that is rotatable between a locked position that secures the upper swage die within the yoke and an unlocked position that allows the upper swage die to be removed from the yoke.
12. The swage tool of claim 11, further comprising ball detents mounted in surfaces of the die block and the yoke, wherein the ball detents engage with ball detent sockets formed in the upper and lower rotating endplate tabs to hold the upper and lower rotating endplate tabs in the locked or in the unlocked positions.
13. The swage tool of claim 1, further comprising: slider endplates that are moveable on slider rails between a locked position in which the upper and lower swage dies are secured within the swage tool and an unlocked position in which the upper and lower swage dies can be removed from the tool.
14. The swage tool of claim 13, further comprising ball detents protruding through the slider rails that engage ball detent holes formed in the slider endplates to hold the endplates in the locked position.
15. The swage tool of claim 1, further comprising a yoke-locking mechanism to prevent the yoke from being removed from the tool, the yoke locking mechanism comprising a slider that is moveable on a rail between a locked position in which the slider blocks a groove in which inwardly-projecting ears of the yoke are seated, and an unlocked position in which the slider does not block the groove to allow the yoke to be removed from the tool.
16. The swage tool of claim 15, further comprising a ball detent protruding through the rail that engages ball detent sockets formed in the slider to hold the slider in either the locked or the unlocked position.
17. The swage tool of claim 1, further comprising a yoke-locking mechanism to prevent the yoke from being removed from the tool, the yoke-locking mechanism comprising a rotatable magnetic arm that is secured between the yoke and the power unit.
18. A swage tool comprising: a head assembly comprising a die block holding a lower swage die and a yoke holding an upper swage die; a power unit detachably coupled to the head assembly, the power unit comprising a piston housed within a cylinder and being configured to apply force that causes vertical movement of the piston, wherein the die block is mounted to the piston and moves vertically with the piston upon application of force by the power unit, and the yoke is fixed to the power unit and does not move vertically with the piston, and as force is applied by the power unit, the piston moves the die block and the lower swage die vertically towards the upper swage die held by the yoke, such that the lower and upper swage dies come into contact and are compressed radially inwardly as force is applied; endplates moveable between a locked position that secures the upper and lower swage dies within the tool and an unlocked position that allows the upper and lower swage dies to be removed from the tool, wherein the endplates remain secured to the tool even in the unlocked position.
19. The swage tool of claim 18, further comprising a yoke-locking mechanism that is moveable between a locked position that prevents the yoke from being removed from the swage tool and an unlocked position that allows the yoke to be removed from the swage tool, wherein the yoke-locking mechanism remains secured to the tool even in the unlocked position.
20. A swage tool comprising: a head assembly comprising a die block holding a lower swage die and a yoke holding an upper swage die; a power unit detachably coupled to the head assembly, the power unit comprising a piston housed within a cylinder and being configured to apply force that causes vertical movement of the piston, wherein the die block is mounted to the piston and moves vertically with the piston upon application of force by the power unit, and the yoke is fixed to the power unit and does not move vertically with the piston, and as force is applied by the power unit, the piston moves the die block and the lower swage die vertically towards the upper swage die held by the yoke, such that the lower and upper swage dies come into contact and are compressed radially inwardly as force is applied; a mechanism built into the swage tool for determining whether a swage has been properly performed; a tool holding mechanism that is configured to allow an operator to hold and maneuver the swage tool; endplates moveable between a locked position that secures the upper and lower swage dies within the tool and an unlocked position that allows the upper and lower swage dies to be removed from the tool, wherein the endplates remain secured to the tool even in the unlocked position; and a yoke-locking mechanism that is moveable between a locked position that prevents the yoke from being removed from the swage tool and an unlocked position that allows the yoke to be removed from the swage tool.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] Various features and advantages of this disclosure will be apparent from the following description and accompanying drawings. The drawings are not necessarily to scale; emphasis instead is placed on illustrating the principles of this disclosure. In the drawings, like reference characters may refer to the same parts throughout the different views. The drawings depict only illustrative examples of this disclosure and are not limiting in scope.
[0032] FIG. 1A is an isometric view of a swage tool, in accordance with aspects of this disclosure.
[0033] FIG. 1B is a front view of the swage tool, in accordance with aspects of this disclosure.
[0034] FIG. 2A is a front view of a portion of the swage tool illustrating a recess formed in the power unit to hold a cycle counter and sensors to track die block movement, in accordance with aspects of this disclosure.
[0035] FIG. 2B is a front view of the cycle counter, in accordance with aspects of this disclosure.
[0036] FIG. 2C is a front view of a portion of the swage tool illustrating the cycle counter and die block after movement to a swaging position, in accordance with aspects of this disclosure.
[0037] FIG. 2D is a rear view of a portion of the swage tool illustrating a space to house a battery for the cycle counter of FIGS. 2B-2C, in accordance with aspects of this disclosure.
[0038] FIG. 3 is a flow diagram of a method for counting swage cycles and assessing whether a proper swage has been performed, in accordance with aspects of this disclosure.
[0039] FIG. 4A is an isometric view of a portion of the swage tool with upper and lower rotating endplate tabs installed, in accordance with aspects of this disclosure.
[0040] FIG. 4B is an isometric view of an upper rotating endplate tab, in accordance with aspects of this disclosure.
[0041] FIG. 4C is a front view of the upper rotating endplate tab of FIG. 4B, in accordance with aspects of this disclosure.
[0042] FIG. 4D is a front view of a portion of the swage tool with upper and lower rotating endplate tabs in a locked position before swaging, in accordance with aspects of this disclosure.
[0043] FIG. 4E is a front view of a portion of the swage tool with upper and lower rotating endplate tabs in a locked position during swaging, in accordance with aspects of this disclosure.
[0044] FIG. 4F is a front view of a portion of the swage tool showing the upper endplate tabs after rotation to an unlocked position, in accordance with aspects of this disclosure.
[0045] FIG. 5A is a front view of a portion of the swage tool with slider endplates installed, in accordance with aspects of this disclosure.
[0046] FIG. 5B is a front view of a slider endplate, in accordance with aspects of this disclosure.
[0047] FIG. 5C is a rear view of the slider endplate, in accordance with aspects of this disclosure.
[0048] FIG. 5D is a side view of the slider endplate, in accordance with aspects of this disclosure.
[0049] FIG. 5E is front view of a portion of the swage tool with a slider rail installed, in accordance with aspects of this disclosure.
[0050] FIG. 5F is a front view of a slider endplate, in accordance with aspects of this disclosure.
[0051] FIG. 5G is a side view of the slider endplate, in accordance with aspects of this disclosure.
[0052] FIG. 5H is a front view of a ball detent, in accordance with aspects of this disclosure.
[0053] FIG. 5I is an isometric view of a portion of the swage tool showing the upper slider endplate in an unlocked position and the lower slider endplate in a locked position, in accordance with aspects of this disclosure.
[0054] FIG. 5J is a front view of a portion of the swage tool showing the upper and lower slider endplates in unlocked positions, in accordance with aspects of this disclosure.
[0055] FIG. 5K is an isometric view of the swage tool with the yoke removed and the upper slider endplate in an unlocked position, in accordance with aspects of this disclosure.
[0056] FIG. 5L is an isometric view of the swage tool with the yoke removed, the upper slider endplate in an unlocked position, and the upper swage die removed from the yoke, in accordance with aspects of this disclosure.
[0057] FIG. 5M is an isometric view of the swage tool with the yoke removed, the upper slider endplate in a locked position, and the upper swage die removed from the yoke, in accordance with aspects of this disclosure.
[0058] FIG. 6A is an isometric view of a portion of the swage tool having a yoke-locking mechanism comprising sliders and rails in an unlocked position, in accordance with aspects of this disclosure.
[0059] FIG. 6B is a partial sectional view of the yoke-locking mechanism of FIG. 6A in the unlocked position, in accordance with aspects of this disclosure.
[0060] FIG. 6C is an isometric view of the yoke-locking mechanism of FIG. 6A in a left-locked position, in accordance with aspects of this disclosure.
[0061] FIG. 6D is a partial sectional view of the yoke-locking mechanism of FIG. 6A in the left-locked position, in accordance with aspects of this disclosure.
[0062] FIG. 6E is an isometric view of the yoke-locking mechanism of FIG. 6A in a right-locked position, in accordance with aspects of this disclosure.
[0063] FIG. 6F is a partial sectional view of the yoke-locking mechanism of FIG. 6A in the right-locked position, in accordance with aspects of this disclosure.
[0064] FIG. 6G is a top view of the slider of the yoke-locking mechanism of FIG. 6A, in accordance with aspects of this disclosure.
[0065] FIG. 6H is a bottom view of the slider of the yoke-locking mechanism of FIG. 6A, in accordance with aspects of this disclosure.
[0066] FIG. 6J is a side view of the slider of the yoke-locking mechanism of FIG. 6A, in accordance with aspects of this disclosure.
[0067] FIG. 6I is a sectional view of the slider of the yoke-locking mechanism of FIG. 6A, in accordance with aspects of this disclosure.
[0068] FIG. 6K is a top view of the rail of the yoke-locking mechanism of FIG. 6A, in accordance with aspects of this disclosure.
[0069] FIG. 6L is a side view of the rail of the yoke-locking mechanism of FIG. 6A, in accordance with aspects of this disclosure.
[0070] FIG. 6M is an isometric view of the ball detent mechanism of the yoke-locking mechanism of FIG. 6A, in accordance with aspects of this disclosure.
[0071] FIG. 7A is an isometric front view of the swage locking tool having a yoke-locking mechanism comprising a rotatable and magnetic yoke lock arm in a locked position, in accordance with aspects of this disclosure.
[0072] FIG. 7B is an isometric rear view of the swage locking tool with the yoke lock arm in a locked position, in accordance with aspects of this disclosure.
[0073] FIG. 7C is an isometric rear view of the swage locking tool with the yoke lock arm in an unlocked position, in accordance with aspects of this disclosure.
[0074] FIG. 7D is an isometric view of the yoke lock arm, in accordance with aspects of this disclosure.
[0075] FIG. 7E is a side view of the yoke lock arm showing a magnet attached thereto, in accordance with aspects of this disclosure.
[0076] FIG. 7F is an isometric view of a mechanical linkage for rotatably connecting the yoke lock arm to the power unit of the swage tool, in accordance with aspects of this disclosure.
[0077] FIG. 7G is a side view of the mechanical linkage of FIG. 7F, in accordance with aspects of this disclosure.
[0078] FIG. 8A is an isometric view of an implementation of the swage tool in which the power unit cylinder is formed with a barbell-shaped grip, in accordance with aspects of this disclosure.
[0079] FIG. 8B is an isometric view of the power unit cylinder of FIG. 8A formed with the barbell-shaped grip, in accordance with aspects of this disclosure.
[0080] FIG. 8C is an exploded front view of a knurled barbell-shaped grip, in accordance with aspects of this disclosure.
[0081] FIG. 8D is an exploded front view of a barbell-shaped grip formed with ribs, in accordance with aspects of this disclosure.
[0082] FIG. 9A is a side view of an ergonomic handle for the swage tool with wireless controls, in accordance with aspects of this disclosure.
[0083] FIG. 9B is a cut-away view showing internal parts of the ergonomic handle of FIG. 9A, in accordance with aspects of this disclosure.
DETAILED DESCRIPTION
[0084] The words exemplary and example as used herein mean serving as an example, instance, or illustration. Any embodiment described herein as exemplary or as an example should not be construed as preferred or advantageous over other embodiments.
[0085] The embodiments described herein do not limit the invention to the precise form disclosed, nor are they exhaustive. Rather, various embodiments are presented to provide a description for utilization by others skilled in the art. Technology continues to develop, and elements of the disclosed embodiments may be replaced by improved and enhanced items. This disclosure inherently discloses elements incorporating technology available at the time of this disclosure.
[0086] A swage tool 100 in accordance with aspects of this disclosure is illustrated in FIGS. 1A and 1B. Swage tool 100 applies high pressure to compress or crimp two metal components together to form a strong and durable bond or connection between the two components. Swage tool 100 may be used in various industrial applications including electrical substations, transmission and distribution connections, ground connectors, cell towers, data centers, rail lines, shipyards, and other applications where strong and durable electrical connections are essential. In the electrical utility industry, for example, swage tool 100 may be used to compress clamps and connectors onto electrical cables and grounding rods.
[0087] Swage tool 100 comprises compressive head assembly 110 detachably coupled to power unit 140. Head assembly 110 comprises die block 120, which holds lower swage die 122, and yoke 130, which frames and holds upper swage die 132 in place. Lateral extensions or ears 134 at the lower ends of yoke 130 are firmly seated within grooves or slots 144 formed in power unit 140 to prevent vertical displacement of yoke 130 relative to power unit 140 during application of force (see, e.g., FIGS. 2A and 2C). Upper rotating endplates 430 lock upper swage die 132 within yoke 130, and lower rotating endplates 400 lock lower swage die 122 within die block 120. Rotating endplates 400 and 430 are a novel feature of swage tool 100 and are described in more detail with reference to FIG. 4. In addition, an alternative novel embodiment using sliding endplates 500 and 530 is described with reference to FIG. 5.
[0088] Power unit 140 generates the force required for swaging and includes one or more pistons that are vertically moveable and housed within cylinder 142, and swivel assembly 146 that facilitates connection to a hydraulic pump hose. As can be seen in FIGS. 2A and 2C, for example, die block 120 is vertically moveable via its attachment to piston 145, which extends vertically through piston bore 152 formed though top surface 148 of power unit 140, whereas yoke 130 is not vertically displaced by virtue of yoke ears 134 being seated within grooves 144. Die block 120 may be secured to piston 145, for example, by flat head screws 124 (as shown) or by a push pin or other assembly. As will be described in more detail with reference to FIGS. 2A-2D, power unit 140 also includes cycle counter 200. Handle 900 attaches via clamp 950 to power unit 140 and allows an operator to hold and maneuver swage tool 100 while in use.
[0089] In operation, a first metal component such as a connector or other workpiece is placed around a second metal component such as a cable or other conductor to which it is to be swaged, and the two metal components are placed between swage dies 122, 132. A hydraulic pump is attached via a hydraulic pump hose to swivel assembly 146 of power unit 140 to generate high pressure (force) that drives piston 145 housed within cylinder 142 to move vertically. Die block 120 and lower swage die 122 secured thereto are mounted on piston 145 and are vertically moveable by action of piston 145. Yoke 130 frames and holds upper swage die 132 in a stable and stationary position within its upper end. As hydraulic pressure (force) is applied by power unit 140, piston 145 moves die block 120 and lower swage die 122 vertically towards upper swage die 132 held by yoke 130. As lower swage die 122 moves closer to upper swage die 132, they eventually come into contact and then compress radially inwardly to close around and radially compress or swage the first metal component around the second metal component. Swaging continues in this fashion until a predetermined hydraulic pressure (such as 10,000 psi, for example) is reached, thereby deforming the first metal component (such as a connector) around the second metal component (such as a cable) to form a high-strength permanent mechanical bond (swage) between the two components.
Cycle Counter
[0090] Conventional swage tools generally have a lack of accurate feedback regarding swage performance and maintenance needs and scheduling. While service and maintenance needs of the tool can be gauged by manually counting the number of cycles performed by the tool, automated counting of the number of cycles performed by the tool would be advantageous. Moreover, conventional swage tools are not able to self-check whether a swage is satisfactory. In general, an operator monitors the pressure output from the pump to judge whether a swage has been completed fully and correctly. In one example, a pressure output of 10,000 psi is indicative of a full swage. However, there is substantial room for error in this method. The pump may not always output the full pressure (10,000 psi) that is needed for a full swage. Even where the pump does output the full pressure that is needed, the power unit may not fully convert that pressure into the force needed to fully swage. In addition, the connector being swaged may have a hardness that is too great for the tool to fully close. Aspects of this disclosure automatically track the number of cycles performed by swage tool 100 and assess the quality of the swage performed by tool 100.
[0091] FIGS. 2A-2D depict features (a mechanism) of swage tool 100 that automatically track the number of cycles performed by swage tool 100 and that assess the quality of the swage performed by tool 100 by measuring displacement of die block 120. As will be described in more detail with reference to FIG. 3, cycle counter 200 facilitates service and maintenance of swage tool 100 by counting the number of cycles performed by tool 100 and providing an appropriate indication when service/maintenance of tool 100 is due. Counter 200 is seated within a recess or pocket 210 formed in the upper portion of power unit 140 (FIG. 2A).
[0092] As shown in FIG. 2B, cycle counter 200 includes a screen display 202 that may display the total number of cycles performed by tool 100 during its life, the number of cycles performed since the last service, the date, and the number of cycles performed during the current day. When tool 100 reaches a certain number of cycles needed for maintenance, screen display 202 may display an appropriate message such as Service Due. Screen display 202 may display any additional or alternative information that is relevant to the cycles performed by tool 100. In some examples, counter 200 may include a GPS tracking feature to track the location of tool 100 (such as when tool 100 is a rental tool). As shown in FIG. 2D, a space 216 is provided in the rear of power unit 140 to house a battery or other power source for cycle counter 200.
[0093] In addition to counting cycles performed, swage tool 100 includes a built-in mechanism for determining whether a swage is satisfactory without having to disassemble tool 100 and remove the swaged component. According to aspects of this disclosure, by measuring the distance that die block 120 travels vertically (upwards), it can be determined whether a proper swage was performed as soon as the swage completes. In this regard, as shown in FIG. 2A, first sensor 212 is mounted inside power unit 140 to detect when die block 120 starts moving vertically (upwards) to perform a swage, and second sensor 214 is mounted inside power unit 120 to measure the distance x that die block 120 travels vertically (upwards). Once first sensor 212 has detected movement of die block 120, it may signal to second sensor 214 to start measuring the vertical movement or displacement x of die block 120. In some examples, first sensor 212 is a light or photocell sensor for sensing the start of movement. Alternatively, first sensor 212 may be a proximity or hall effect sensor, or any other type of sensor capable of sensing the start of movement. In some examples, second sensor 214 is an ultrasonic sensor, a laser sensor, or any other type of sensor that is operable to measure the vertical distance x that die block 120 travels upward.
[0094] As depicted in FIG. 2A, in some examples, sensors 212 and 214 are mounted in power unit 140 proximate to the location where top surface 148 of power unit 140 and bottom surface 128 of die block 120 meet, such that they are able to detect movement of die block 120 and measure the vertical distance x that die block 120 travels. That is, x is the distance between top surface 148 of power unit 140 and bottom surface 128 of die block 120 when a swage is performed. In some examples, sensors 212 and 214 are respectively mounted or placed in or adjacent to apertures 222 and 224 that extend from the upper portion of recess 210 that houses cycle counter 200 and through top surface 148 of power unit 140, such that they are able to detect movement of die block 120 and track the vertical distance x that die block 120 travels.
[0095] So long as the distance x is within a predetermined range that is indicative of a proper swage, swage tool 100 provides an indication to the operator that a proper swage has been performed. In some examples, cycle counter 200 may indicate whether a proper swage has been performed. For instance, cycle counter 200 may include a first indicator 204 (such as a green LED, for example) that signals a good or proper swage when the vertical displacement x of die block 120 is within the predetermined range indicating a proper swage, and a second indicator 206 (such as a red LED, for example) that signals a bad or incomplete swage when the vertical displacement x of die block 120 is outside of the predetermined range indicating a proper swage. Alternatively, cycle counter 200 may provide a message on screen display 202 of cycle counter 200 indicating whether the swage was good or bad.
[0096] FIG. 3 is a flow diagram of a method 300 for counting swage cycles and assessing whether a proper (good) swage has been performed. Method 300 may be implemented, for example, by suitable control circuitry or a microprocessor executing instructions stored in a computer-readable medium that cause the microprocessor to perform the flow diagram of FIG. 3. The control circuitry or microprocessor may be integrated or contained in cycle counter 200 or power unit 140, or may be external to those components.
[0097] Method 300 begins with swage tool 100 assembled and powered on at step 302. In step 304, first sensor (photocell or light sensor) 212 monitors for any movement of die block 120. Once first sensor 212 senses movement of die block 120 (304-Y), it signals to second sensor (ultrasonic or laser sensor) 214 to start measuring the vertical distance x that die block 120 travels (step 306). In addition, a timer for measuring the duration t of the swaging process is started in step 306. Once swaging has completed within a specified time range (t.sub.mintt.sub.max) and die block 120 moves back down to its starting position (x=0) (step 308-Y), a signal is sent to cycle counter 200 to increase the cycle count by one (step 312). Alternatively, if movement of die block 120 is sensed but die block 120 does not return to its starting position within the specified time range (step 308-N), this is indicative that die block 120 has been removed from tool 100, and the cycle count is therefore not increased (step 310).
[0098] If second sensor 214 measures that die block 120 travels a vertical distance x that is indicative of a proper swage (x.sub.minxx.sub.max) (step 314-Y), then cycle counter 200 signals that a proper or good swage has been performed (step 318). For instance, cycle counter 200 may illuminate first indicator 204 (a green LED, for example). Alternatively, if second sensor 214 measures that die block 120 travels a vertical distance x that is outside of the range indicative of a proper swage (step 314-N), then cycle counter 200 signals that an improper or bad swage has been performed (step 316). For instance, cycle counter 200 may illuminate second indicator 206 (a red LED, for example).
[0099] Cycle counter 200 also provides an indication, based on the cycle count, of whether swage tool 100 should be serviced or retired. So long as the current cycle count is less than a predetermined count (service count) indicating that tool 100 should be serviced (step 320-Y), then method 300 continues without any service message being displayed. If the cycle count is greater than or equal to the service count (step 320-N), but is still less than a count (tool life) indicating that tool 100 has reached the end of its service life (step 322-Y), then cycle counter 200 displays a message or otherwise indicates that service is due (step 324). Once the cycle count exceeds the service life of tool 100 (step 322-N), tool 100 is retired (step 326).
Endplates
[0100] Swage tool 100 includes endplates that prevent swage dies 122, 132 from escaping or becoming misaligned during a swage cycle. The endplates should be removable or displaceable to allow removal or switching of the dies when necessary. In conventional swage tools, the endplates are screw-locked to the tool to secure the dies during swaging and require a hand tool such as a screwdriver to remove. This can be problematic as hand tools are not commonly found in substation and transmission installation tool kits. Moreover, endplate screws are very small, unwieldy, and easily lost, especially when handled with gloves as is often the case. According to aspects of this disclosure, novel endplate designs and configurations are provided that improve speed of use and handling by dispensing with the need for external hand tools or hardware to remove the endplates. In particular, a rotating endplate tab configuration is illustrated in FIGS. 4A-4F, and a sliding rail endplate configuration is illustrated in FIGS. 5A-5M.
Rotating Endplate System
[0101] Turning first to FIGS. 4A-4F, swage tool 100 with lower rotating endplate tabs 400 and upper rotating endplate tabs 430 installed is depicted. Endplate tabs 400, 430 are made of a material such as aluminum alloy and are shaped to provide stabilizing surfaces against die block 120 and yoke 130 while also having cutouts to receive the positioning tabs on swage dies 122, 132. Upper endplate tabs 430, for example, have stabilizing surfaces 432 that are configured to rest against the surface of yoke 130 and cut-outs or cavities 450 that receive positioning tabs of upper swage die 132 (see, e.g., FIGS. 4B-4E) between surfaces 452 and 454 to hold swage die 132 in place. The positioning tabs of the dies will rest between surfaces 452 and 454, preventing the dies from moving out of place due to the positioning tabs sticking out from the dies. As the tool is swaged and released from swaging, the positioning tabs will move freely between surfaces 452, 454. Likewise, lower endplate tabs 400 have stabilizing surfaces 402 that are configured to rest against the surface of die block 120 and cut-outs that receive positioning tabs of lower swage die 122 to hold swage die 122 in place.
[0102] Eight endplate tabs are used to secure swage dies 122, 132 in place within head assembly 110 of swage tool 100. Two upper endplate tabs 430 are mounted on the front of yoke 130 as shown in FIGS. 4D-4E, and two upper endplate tabs 430 are mounted in a symmetrical configuration on the rear of yoke 130. In this regard, upper endplate tabs 430 are front-back symmetric and can be used on both the front and rear of tool 100. Likewise, two lower endplate tabs 400 are mounted on the front of die block 120 as shown in FIGS. 4D-4E, and two lower endplate tabs 400 are mounted in a symmetrical configuration on the rear of die block 120. Like upper endplate tabs 430, lower endplate tabs 400 are front-back symmetric and can be used on both the front and rear of tool 100. Upper endplate tabs 430 and lower endplate tabs 400 are shaped slightly differently to best fit the respective areas of yoke 130 and die block 120 on which they are mounted. With reference to FIGS. 4D-4E, for example, it can be seen that stabilizing surfaces 432 of upper endplate tabs 430 extend laterally further than do stabilizing surface 402 of lower endplate tabs 400 to accommodate the respective shapes of yoke 130 and die block 120.
[0103] As best shown in FIG. 4A, upper endplate tabs 430 are secured to yoke 130 by fastening screws 438 through endplate tabs 430 and bushings 439 into interference-fit dowel pins in yoke 130. The presence of bushings 439 between tabs 430 and yoke 130 allows for free rotation of upper endplate tabs 430 even while screws 438 are tightened through tabs 430 and yoke 130. Likewise, lower endplate tabs 400 are secured to die block 120 by fastening screws 408 through endplate tabs 400 and bushings into interference-fit dowel pins in die block 120. The presence of bushings between tabs 400 and die block 120 allows for free rotation of lower endplate tabs 400 even while screws 408 are tightened through tabs 400 and die block 120.
[0104] Endplate tabs 400, 430 are rotatable between locked positions in which swage dies 122, 132 are locked into head assembly 110 (FIGS. 4D-4E) and unlocked positions in which swage dies 122, 132 can be removed from head assembly 110 or swapped out for new dies (FIG. 4F). Endplate tabs 400, 430 are formed with cut-outs to facilitate rotation of the tabs. As shown in FIGS. 4B-4C, for example, upper endplate tabs 430 are formed with cut-outs 434 that enable an operator to insert a finger into cut-out 434 to assist in rotating the tabs, rather than having to hold the entire endplate tab 430 with multiple fingers. As can be seen in FIGS. 4D-4E, lower endplate tabs 400 are similarly formed with cut-outs 404 to assist with rotation of the tabs.
[0105] Before swaging is initiated, as shown in FIG. 4D, endplate tabs 400, 430 are rotated to a locked position. Locking is accomplished via ball detents mounted in and protruding slightly above the surfaces of die block 120, 130 (see, for example, FIGS. 4F and 5H), and matching detent sockets formed in endplate tabs 400, 430. Upper endplate tabs 430 are formed with lock sockets 444 and unlock sockets 442. In the locked position of FIGS. 4D-4E, lock sockets 444 (formed on the reverse sides of endplate tabs 430 as shown) are engaged by ball detents 440 (FIG. 4F) protruding from the surface of yoke 130 in alignment with lock sockets 444 to lock or retain upper endplate tabs 430 in the configuration shown. Similarly, lower endplate tabs 400 are formed with lock sockets 414 and unlock sockets 412. In the locked position of FIGS. 4D-4E, lock sockets 414 (formed on the reverse sides of endplate tabs 400 as shown) are engaged by ball detents protruding from the surface of die block 120 in alignment with lock sockets 414 to lock or retain lower endplate tabs 400 in the configuration shown. As can be seen in FIGS. 4B-4C, cavities 450 of endplate tabs 400, 430 retain positioning tabs of swage dies 122, 132 between surfaces 452, 454 to stably retain swage dies 122, 132 in head assembly 110 between yoke 130 and die block 120.
[0106] During swaging, as shown in FIG. 4E, hydraulic pressure is applied to power unit 140 and drives piston 145 vertically upward. Upward movement of die block 120 causes upward movement of die block 120 attached thereto, which in turn brings swage dies 122, 132 into contact and causes them to compress radially inwardly to close around workpiece(s) mounted therebetween. Endplate tabs 400, 430 stay in the locked position and stably secure swage dies 122, 132 within head assembly 110 throughout the swaging process.
[0107] After swaging is complete, as shown in FIG. 4F, the endplate tabs may be rotated to an unlocked position in which they are disengaged from the swage dies to allow die removal and/or swapping. In the unlocked position, ball detents 440 protruding from the surface of yoke 130 in alignment with unlock sockets 442 protrude into unlock sockets 442 to hold upper endplate tabs 430 in the unlocked configuration shown and allow removal of upper swage die 132 from head assembly 100. In this manner, no hand tools or removal of screws or other parts is required to move endplate tabs 430 such that swage die 132 can be removed from tool 100. Similarly, lower endplate tabs 400 are moved to an unlocked position by rotating endplate tabs 400 such that ball detents protruding from the surface of die block 120 protrude into unlock sockets 412 on endplate tabs 400. In the unlocked position, endplate tabs 400 are disengaged from lower swage die 122 such that swage die 122 can be easily removed from tool 100 without needing a hand tool to remove screws or other parts.
[0108] In addition to the features described above, endplate tabs 400, 430 include thin, protruding fins that enhance safety and prevent debris from catching in dies 122, 132 while swaging without interfering with the positioning tabs on dies 122, 132. In particular, lower endplate tabs 400 include fins 416 and upper endplate tabs 430 include fins 446.
Slider Endplate System
[0109] Turning now to FIGS. 5A-5M, swage tool 100 with an alternative slider endplate system comprising slider endplates 500 and slider rails 520 is depicted. Slider endplates 500 and slider rails 520 are front-back and upper-lower symmetric. That is, slider endplates 500 and slider rails 520 are installed on both die block 120 and yoke 130, and on both the front-facing and rear-facing surfaces of die block 120 and yoke 130. As best shown in FIGS. 5B-5D, each slider endplate 500 is shaped to provide a slot or cutout 502 that receives slider rail 520 and allows slider endplate 500 to slide over slider rail 520 between locked and unlocked positions. Slot 502 is shaped to match the shape of slider rail 520. Stabilizing surface 504 is vertically adjacent to slot 502 and is configured to rest against the surface of die block 120 or yoke 130. Recessed surfaces 506 extend over dies 122, 132 to protrusions 508 that receive positioning tabs of dies 122, 132 to hold the swage dies in place.
[0110] Each endplate 500 also has a ball detent hole or socket 510 formed in a central portion of slot 502. Ball detent hole 510 receives ball detent 522 configured in rail 520 to position slider endplate 500 in locked and unlocked positions. Ball detent hole 510 also allows debris to pass through so that hole 510 does not become clogged and stop ball detent 522 from engaging within hole 510.
[0111] As best shown in FIGS. 5E-5H, slider rail 520 has a trapezoidal-shape and includes ball detent 522 mounted in a central portion thereof to slightly protrude over the surface of rail 520. Screw holes 524 are formed in each end of slider rail 520 to receive screws 526. Screws 526 are screwed into threaded dowel pins that are interference-fit into die block 120 and yoke 130. Screws 526, when fully tightened, are flush against the surface of slider rail 520 to facilitate sliding of endplate 500.
[0112] Slider endplate 500 and ball detent hole 510 together with slider rail 520 and ball detent 522 allow movement of slider endplate 500 between a locked position in which swage dies 122, 132 are held in place during swaging, and an unlocked position in which swage dies 122, 132 can be removed and/or swapped without the need for a hand tool to remove screws or other parts. FIG. 5I, for example, shows upper endplate 500 in an unlocked position with ball detent 522 of rail 520 disengaged from ball detent hole 510 of endplate 500 such that upper endplate 500 slides freely along rail 520. Protrusions 508 of upper endplate 500 are disengaged from positioning tabs of upper swage die 132, such that upper swage die 132 can be removed from tool 100. Meanwhile, lower endplate 500 is in a locked position with protrusions 508 engaging positioning tabs of lower swage die 122 such that lower swage die 122 cannot be removed from tool 100.
[0113] FIG. 5J shows both upper and lower endplates 500 in an unlocked position, with ball detents 522 of slider rails 520 disengaged from ball detent holes 510 of slider endplates 500, allowing endplates 500 to slide freely along rails 520 and allowing removal of upper and lower swage dies 122, 132. FIG. 5K shows swage tool 100 with yoke 130 removed and upper slider endplate 500 in an unlocked position with upper swage die 132 removable but not yet removed from tool 100. Lower swage die 122, by contrast, remains locked to die block 120 by lower endplate 500. FIG. 5L shows tool 100 in the same configuration as in FIG. 5K, but with upper swage die 132 now removed from yoke 130. FIG. 5M shows tool 100 in the same configuration as in FIG. 5L, with upper swage die 132 removed from yoke 130 and upper slider endplate 130 moved back to a locked position on rail 520 with ball detent 522 engaged within ball detent hole 510.
Yoke-Locking Mechanisms
[0114] A challenge in connection with conventional swaging tools is positioning and stability of the yoke while using, moving, and maneuvering the swage tool. It is important that the operator to be able to slide the swage tool down a cable line without the yoke falling off and potentially damaging the tool. It is also important to prevent yoke misalignment and the potential for misaligned swaging. As with the endplates, the operator should be able to easily remove and re-attach the yoke from the swage tool without excessive difficulty and without needing additional tools. Aspects of this disclosure provide novel yoke locking mechanisms that allow an operator to slide the assembled tool down a cable line and help to prevent swage die misalignment, yet also allow the yoke to be easily removed from the tool without the need for additional hand tools. In particular, a yoke-locking mechanism 600 using sliders and rails is illustrated in FIGS. 6A-6M, and a yoke-locking magnetic arm configuration is illustrated in FIGS. FIGS. 7A-7G.
Yoke-Locking Sliders and Rails
[0115] FIG. 6A-6M illustrate a yoke-locking mechanism 600 for swage tool 100 comprising sliders 610 and rails 620. Sliders 610 and rails 620 are front-back symmetric and are installed on both the front and rear sides of power unit 140, and are operable to move between locked positions in which yoke 130 is locked to tool 100 and an unlocked position in which yoke 130 can be removed from (slide off of) tool 100. As best shown in FIGS. 6G-6J, each slider 610 has a rounded trapezoidal shape and is formed with a slot or cutout 612 in its underside that receives rail 620 and allows slider 610 to slide over rail 620 between locked and unlocked positions. Slot 612 is trapezoidal-shaped to match the trapezoidal shape of rail 620. Each slider 610 has a socket or recess 614 formed in a central portion of slot 612, which receives ball detent 630 in the unlocked position, and sockets or recesses 616 formed in left and right end portions of slot 612, which receive ball detent 630 in the left-locked and right-locked positions.
[0116] Rail 620 and ball detent 630 are illustrated in FIGS. 6K-6M. Rail 620 has a trapezoidal shape (in the side view of FIG. 6L) and includes ball detent hole 622 in a central portion. When assembled on tool 100, as illustrated in FIGS. 6A-6F, ball detent 630 extends through ball detent hole 622 to slightly protrude over the surface of rail 620. Screw holes 624 are formed in each end of slider rail 620 to receive screws 626. Screws 626 and ball detent 630 are screwed into drilled and tapped holes. Screws 626 are interference-fit into lip 150 of power unit 140 to secure rail 620 on power unit 140 with ball detent 630 protruding through hole 622. Screws 626, when fully tightened, are flush against the surface of slider rail 620 to facilitate sliding of slider 610 along rail 620. As can be seen in FIGS. 6A-6F, yoke-locking mechanism 600 is positioned on front lip 150 of power unit 140 in front of counter 200 and between grooves 144 that receive inwardly-protruding yoke ears 134. As can be seen in FIG. 2D, a yoke-locking mechanism 600 is also configured on rear lip 150 of power unit 140 below cycle counter battery space 216 and between grooves 144 for yoke ears 144.
[0117] Slider 610 and ball detent sockets 614, 616 together with rail 620 and ball detent 630 allow movement of slider 610 between locked positions in which yoke 130 is locked to power tool 140 and tool 100, such as during swaging or between swaging when sliding the assembled tool down a cable line, and an unlocked position in which yoke 130 can be removed from (slid off of) power unit 140 and tool 100 without the need for a hand tool to remove screws or other parts. FIGS. 6A-6B, for example, show slider 610 in an unlocked position in which ball detent 630 is engaged or received in ball detent socket 614 formed in the central part of the undersurface of slider 610 such that slider 610 is retained on rail 620 in a position between and not in front of (not in horizontal alignment with) yoke ears 134. In the unlocked position, slider 610 does not block or interfere with front-to-rear and rear-to-front sliding of yoke ears 134 within grooves 144, such that yoke 130 can be removed from (slid off of) power unit 140 and swage tool 100.
[0118] Yoke 130 is placed in a locked position by positioning both the front and rear sliders 610 in front of one of the grooves 144 within which yoke ears 134 slide, such that yoke 130 cannot be removed from (slid off of) power unit 140 and tool 100. FIGS. 6C-6D show slider 610 in a left-locked position in which ball detent 630 is engaged or received in left ball detent socket 616 formed in the left side of the undersurface of slider 610 such that slider 610 is retained on rail 620 in a position in front of and blocking the left yoke ear groove 134. FIGS. 6E-6F show slider 610 in a right-locked position in which ball detent 630 is engaged or received in right ball detent socket 616 formed in the right side of the undersurface of slider 610 such that slider 610 is retained on rail 620 in a position in front of and blocking the right yoke ear groove 134.
Yoke-Locking Magnetic Arm
[0119] An alternative yoke-locking mechanism 700 for locking yoke 130 to power unit 140 and swage tool 100 to allow an operator to slide the fully assembled swage tool 100 down a cable line without disassembling tool 100, and to prevent misaligned swaging, is illustrated in FIGS. 7A-7G. Yoke-locking mechanism 700 comprises yoke lock arm 710 and mechanical linkage 720. Mechanical linkage 720 is rotatably secured to one side of power unit 140. Yoke lock arm 710 is rotatably attached to linkage 720 such that it can rotate relative to linkage 720 to a locked position where one of the downwardly-extending arms 136 of yoke 130 is retained between protrusions 714 extending from yoke lock portion 712 of arm 710. Magnet 715 mounted in a yoke-facing surface of yoke lock portion 712 contacts yoke arm 136 and secures yoke lock arm 710 to yoke 130.
[0120] Yoke lock arm 710 of yoke-locking mechanism 700 is illustrated in detail in FIGS. 7D-7E. Arm 710 comprises yoke lock portion 712 having protrusions 714 for securing yoke arm 136 therebetween. Magnet 715 is mounted in a yoke-facing surface of yoke lock portion 712 between protrusions 714 and contacts yoke arm 136 to secure yoke lock arm 710 to yoke 130. Yoke lock arm 710 also comprises a connector portion 716 formed with a bore 718 for rotatably connecting arm 710 to mechanical linkage 720.
[0121] Mechanical linkage 720 of yoke-locking mechanism 700 is illustrated in detail in FIGS. 7F-7G. Linkage 720 comprises shaft linkage 722 formed with a bore 724 for rotatably connecting linkage 720 to shaft 732 extending from power unit 140. Shaft linkage 722 is connected to arm linkage 726 by connector 725. Arm linkage 726 includes protrusions 728 formed with bores 729 to facilitate a rotatable connection to arm 710 by a shaft passing through bores 729 and bore 718 of arm 710.
[0122] FIG. 7B illustrates a locked position in which the fully assembled swage tool 100 may be kept intact while being used on a continuous line, for example, with yoke lock arm 710 both securing yoke 130 in place on tool 100 and preventing swage dies 122, 132 from becoming misaligned. In the locked position of FIG. 7B, yoke lock arm 710 is rotated relative to linkage 720 such that one of the downwardly-extending arms 136 of yoke 130 is retained between protrusions 714 extending from yoke lock portion 712 of arm 710. Magnet 715 keeps yoke 130 secured to yoke arm 710 between protrusions 714.
[0123] As can be seen in FIG. 7B, arm 710 is rotatably attached to linkage 720 by shaft 734 passing through protrusions 728 of linkage 720 and connector portion 716 of arm 710. Fastening means such as e-clips may snap into grooves formed in shaft 734 to prevent arm 710 from sliding off linkage 720. Linkage 720, in turn, is rotatably attached to power unit 140 via threaded shaft 732 that is inserted into threaded bore 730 formed in power unit 140. Shaft 732 extends through bore 724 of linkage 720, with linkage 720 being 360 degrees rotatable relative to shaft 732 such that arm 710 can be locked or latched to either of yoke arms 136 of yoke 130. Fastening means such as e-clips may be used to secure the attachment between linkage 720 and power unit shaft 732.
[0124] FIG. 7C illustrates an unlocked position in which yoke lock arm 710 is detached and rotated away from yoke 130. In the unlocked position, yoke 130 can be removed from (slide off of) tool 100.
Barbell Cylinder
[0125] Typical handle designs on conventional swage tools are ergonomically inadequate and not typically in alignment with the center of gravity of the tool, which makes it more difficult manipulate the tool and contributes to operator fatigue, especially in tighter working areas such as trenches. Aspects of this disclosure provide a barbell-shaped grip that addresses these issues.
[0126] FIGS. 8A-8D illustrate an embodiment of power unit 140 in which cylinder 142 is provided with a tool holding mechanism that maintains the center of gravity near the center of tool 100. In particular, rather than attaching a handle to power unit 140, cylinder 142 of power unit 140 is formed with a reduced diameter portion in its midsection that operates as a barbell-shaped grip 160. Barbell-shaped grip 160 maintains the center of gravity near the center of tool 100 and allows an operator to easily manipulate tool 100 without the need for an additional handle such as handle 900. Barbell-shaped grip 160 improves the ergonomics of tool 100 and is better suited for tighter working areas such as trenches where grounding connectors are swaged.
[0127] FIG. 8C illustrates an implementation in which barbell-shaped grip 160 is knurled. Knurling provides a better grip by creating a textured pattern of ridges and grooves on the surface of grip 160. The knurled pattern increases the surface roughness, which enhances friction between the knurled surface and an operator's hand, making tool 100 easier to hold and manipulate. FIG. 8D illustrates an implementation in which barbell-shaped grip 160 is formed with ribs. Forming grip 160 with ribs provides a better grip by creating raised ridges along the surface, which enhances traction and reduces the chance of slipping. Ribs also offer an ergonomic advantage by reducing the amount of force needed to maintain a secure grip.
Ergonomic Handle With Wireless Controls
[0128] Conventional swage tool designs also require operators to manage a separate handheld remote control for the hydraulic pump. Linemen (operators) typically must have one hand holding tool 100 and another hand operating the handheld remote control This not only contributes to operator fatigue but also increases the potential for misplaced or lost remotes. Aspects of this disclosure provided an improved ergonomic handle 900 with a wireless hydraulic pump control.
[0129] FIGS. 9A-9B illustrate a tool holding mechanism in the form of ergonomic handle 900 that eases physical burden while carrying tool 100. Handle 900 comprises grooves 910 that are formed to fit the hand of an average lineman (operator) while wearing a glove. A larger radius groove 912 formed at the top of handle 900 allows handle 900 to sit on a lineman's hand without slipping out. Handle 900 includes a band attachment portion 920 formed with a bore 922 for attachment to a band or clamp 950. As shown in FIGS. 1A-1B, for example, handle 900 is fastened to band 950 via a nut 952 through band attachment portion 920 and bore 922. Band 950 is wrapped around and fits into a slot formed in the outer surface of power unit cylinder 142 such that it does not loosen during operation of tool 100.
[0130] A button or switch 930 is mounted at the top of handle 900 and is coupled to a transponder or wireless controller 940 housed within handle 900 to allow wireless control of the hydraulic pump by pressing button 930. This eliminates the conventional need for a separate handheld remote control and allows tool 100 and the hydraulic pump to be operated by a single operator. With wireless pump control integrated into handle 900, an operator can keep both hands on tool 100 while operating tool 100, which significantly eases fatigue over long periods of work. Additionally, the potential for misplacing or losing the separate handheld remote is eliminated. A hinged cover or cap 932 is provided over button 930 to prevent accidental presses of button 930. Space to house battery 944 to power transponder or controller 940, along with a conduit or cable 942 connecting transponder 940 and battery 944, is also provided within handle 900. Battery cover 946 at the bottom of handle 900 provides access to battery 944.
[0131] While certain embodiments are described herein, these embodiments are presented by way of example only, and do not limit the scope of this disclosure. Various omissions, substitutions and changes may be made without departing from the spirit and scope of this disclosure. The methods and processes described herein are not limited to any particular sequence and may be used independently or combined in various ways. Some method or process steps may be omitted and other steps added in some implementations. Nothing in this description implies that any particular feature, component, characteristic, or step is necessary or indispensable. Many variations, modifications, additions, and improvements are possible and fall within the scope of this disclosure as defined by the following claims.
