Hand crimp tool

Abstract

The invention relates to an hand crimp tool for crimping electrical contact terminals onto electrical cables. This hand crimp tool comprises a crimping frame with two substantially parallel guide rails, and the lever handles configured to be manually operated. The hand crimp tool further comprises a first crimping die and a corresponding second crimping die, at least one of which being mounted to a die carrier. The guide rails are substantially bar-shaped and oriented in a common longitudinal direction. The die carrier is configured to slide in a linear direction parallel to the longitudinal direction of the guide rails, along inner opposite faces of the guide rails, thereby being guided from a cable receiving position to a crimping position.

Claims

1. A hand crimp tool for crimping electrical contact terminals onto electrical cables, comprising: a crimping frame with two substantially parallel guide rails, a first lever handle, and a second lever handle, wherein the first and second lever handles are configured to be manually operated by an operator, thereby being brought from an open configuration to a closed configuration; a first crimping die and a corresponding second crimping die; and a die carrier configured to support the first crimping die or the second crimping die, wherein the die carrier is operatively connected to the first lever handle or the second lever handle and is slideably arranged between the guide rails, wherein the guide rails are substantially bar-shaped and oriented in a common longitudinal direction, wherein the die carrier is configured to slide in a linear direction parallel to the a longitudinal direction of the guide rails along inner opposite faces of the guide rails, thereby being guided from a cable receiving position to a crimping position, wherein the die carrier is configured to support two first crimping dies, wherein the two first crimping dies are crimping anvils and are provided at different anvil heights or wherein surfaces of the two first crimping dies are provided with different radii of curvature, and wherein the two first crimping dies are arranged on the die carrier such that the two first crimping dies can be moved with respect to each other in a direction which corresponds to an orientation of a cable which is received by the hand crimp tool for crimping.

2. The hand crimp tool according to claim 1, wherein the crimping frame has a long side of length and a short side of length, and wherein a ratio of the long side of length to the short side of length is in a range of 1:1 to 5:1.

3. The hand crimp tool according to claim 1, wherein the crimping frame has a long side of length and the guide rails have a substantially rectangular cross-section, and wherein a ratio of the long side of length and a length of one side of the rectangular cross-section is in a range of 5:1 to 20:1.

4. The hand crimp tool according to claim 1, wherein the crimping frame further comprises means for continuously moving the second crimping die substantially parallel to the longitudinal direction of the guide rails.

5. The hand crimp tool according to claim 4, wherein the means for continuously moving the second crimping die comprise two corresponding adjustment members.

6. The hand crimp tool according to claim 1, wherein at least one means for non-continuously moving the second crimping die in a direction substantially parallel to the longitudinal direction is provided for providing a rough adjustment of a distance between the corresponding first and second crimping dies.

7. The hand crimp tool according to claim 1, wherein at least one of the first crimping die and second crimping die is removably mounted to the crimping frame.

8. A hand crimp tool for crimping electrical contact terminals onto electrical cables, comprising: a crimping frame with two substantially parallel guide rails, a first lever handle, and a second lever handle, wherein the first and second lever handles are configured to be manually operated by an operator, thereby being brought from an open configuration to a closed configuration; a first crimping die and a corresponding second crimping die; and a die carrier configured to support the first crimping die or the second crimping die, wherein the die carrier is operatively connected to the first lever handle or the second lever handle and is slideably arranged between the guide rails, wherein the guide rails are substantially bar-shaped and oriented in a common longitudinal direction, wherein the die carrier is configured to slide in a linear direction parallel to the a longitudinal direction of the guide rails along inner opposite faces of the guide rails, thereby being guided from a cable receiving position to a crimping position, wherein the die carrier is configured to support two first crimping dies, wherein the two first crimping dies are crimping anvils and are provided at different anvil heights or wherein surfaces of the two first crimping dies are provided with different radii of curvature, and wherein the hand crimp tool further comprises a spacer which can be inserted in between the two first crimping dies or the two second crimping dies.

9. The hand crimp tool according to claim 8, wherein the crimping frame has a long side of length and a short side of length, and wherein a ratio of the long side of length to the short side of length is in a range of 1:1 to 5:1.

10. The hand crimp tool according to claim 8, wherein the crimping frame has a long side of length and the guide rails have a substantially rectangular cross-section, and wherein a ratio of the long side of length and a length of one side of the rectangular cross-section is in a range of 5:1 to 20:1.

11. The hand crimp tool according to claim 8, wherein the crimping frame further comprises means for continuously moving the second crimping die substantially parallel to the longitudinal direction of the guide rails.

12. The hand crimp tool according to claim 11, wherein the means for continuously moving the second crimping die comprise two corresponding adjustment members.

13. The hand crimp tool according to claim 8, wherein at least one means for non-continuously moving the second crimping die in a direction substantially parallel to the longitudinal direction is provided for providing a rough adjustment of a distance between the corresponding first and second crimping dies.

14. The hand crimp tool according to claim 8, wherein at least one of the first crimping die and second crimping die is removably mounted to the crimping frame.

15. A hand crimp tool for crimping electrical contact terminals onto electrical cables, comprising: a crimping frame with two substantially parallel guide rails, a first lever handle, and a second lever handle, wherein the first and second lever handles are configured to be manually operated by an operator, thereby being brought from an open configuration to a closed configuration; a first crimping die and a corresponding second crimping die; and a die carrier configured to support the first crimping die or the second crimping die, wherein the die carrier is operatively connected to the first lever handle or the second lever handle and is slideably arranged between the guide rails, wherein the guide rails are substantially bar-shaped and oriented in a common longitudinal direction, and wherein the die carrier is configured to slide in a linear direction parallel to the a longitudinal direction of the guide rails along inner opposite faces of the guide rails, thereby being guided from a cable receiving position to a crimping position, wherein the guide rails are mutually connected at respective distal rail ends via a U-shaped support arch, which is configured to support the second crimping die wherein the crimping frame further comprises means for continuously moving the second crimping die substantially parallel to the longitudinal direction of the guide rails, wherein the means for continuously moving the second crimping die comprise two corresponding adjustment members, and wherein at least a first adjustment member of the two corresponding adjustment members is arranged movable in a direction substantially perpendicular to the longitudinal direction of the guide rails, and upon movement of said first adjustment member an inclined abutment surface of the first adjustment member abuts a corresponding surface of a second adjustment member of the two corresponding adjustment members such that the second adjustment member is pressed in another direction substantially parallel to the longitudinal direction of the guide rails.

16. The hand crimp tool according to claim 15, wherein the second crimping die is removably connected to one of the first and second adjustment members.

17. The hand crimp tool according to claim 15, wherein the first adjustment member is provided with a bore with inner screw threads and the crimping frame is provided with a corresponding screw, such that the first adjustment member can be moved in the direction perpendicular to the longitudinal direction of the guide rails by turning the corresponding screw.

18. The hand crimp tool according to claim 15, wherein the crimping frame has a long side of length and a short side of length, and wherein a ratio of the long side of length to the short side of length is in a range of 1:1 to 5:1.

19. The hand crimp tool according to claim 15, wherein the crimping frame has a long side of length and the guide rails have a substantially rectangular cross-section, and wherein a ratio of the long side of length and a length of one side of the rectangular cross-section is in a range of 5:1 to 20:1.

20. The hand crimp tool according to claim 15, wherein at least one means for non-continuously moving the second crimping die in a direction substantially parallel to the longitudinal direction is provided for providing a rough adjustment of a distance between the corresponding first and second crimping dies.

21. The hand crimp tool according to claim 15, wherein at least one of the first crimping die and second crimping die is removably mounted to the crimping frame.

22. A hand crimp tool for crimping electrical contact terminals onto electrical cables, comprising: a crimping frame with two substantially parallel guide rails, a first lever handle, and a second lever handle, wherein the first and second lever handles are configured to be manually operated by an operator, thereby being brought from an open configuration to a closed configuration; a first crimping die and a corresponding second crimping die; and a die carrier configured to support the first crimping die or the second crimping die, wherein the die carrier is operatively connected to the first lever handle or the second lever handle and is slideably arranged between the guide rails, wherein the guide rails are substantially bar-shaped and oriented in a common longitudinal direction, wherein the die carrier is configured to slide in a linear direction parallel to the a longitudinal direction of the guide rails along inner opposite faces of the guide rails, thereby being guided from a cable receiving position to a crimping position, wherein the guide rails are mutually connected at respective distal rail ends via a U-shaped support arch, which is configured to support the second crimping die, wherein the crimping frame further comprises means for continuously moving the second crimping die substantially parallel to the longitudinal direction of the guide rails, and wherein the means for continuously moving the second crimping die comprise at least one screw which is configured to be screwed into a corresponding bore hole with inner threads which is provided in the U-shaped support arch.

23. The hand crimp tool according to claim 22, wherein the crimping frame has a long side of length and a short side of length, and wherein a ratio of the long side of length to the short side of length is in a range of 1:1 to 5:1.

24. The hand crimp tool according to claim 22, wherein the crimping frame has a long side of length and the guide rails have a substantially rectangular cross-section, and wherein a ratio of the long side of length and a length of one side of the rectangular cross-section is in a range of 5:1 to 20:1.

25. The hand crimp tool according to claim 22, wherein the means for continuously moving the second crimping die comprise two corresponding adjustment members.

26. The hand crimp tool according to claim 22, wherein at least one means for non-continuously moving the second crimping die in a direction substantially parallel to the longitudinal direction is provided for providing a rough adjustment of a distance between the corresponding first and second crimping dies.

27. The hand crimp tool according to claim 22, wherein at least one of the first crimping die and second crimping die is removably mounted to the crimping frame.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

(1) The present invention will now be described, by way of example with reference to the accompanying drawings, in which:

(2) FIG. 1 shows a schematic three-dimensional view of the hand crimp tool;

(3) FIG. 2 shows a schematic exploded view of the crimping dies; and

(4) FIGS. 3 to 5 schematically illustrate means for moving crimping dies for the provision of a pre-adjustment.

DETAILED DESCRIPTION OF THE INVENTION

(5) FIG. 1 shows a hand crimp tool 10 which can be used for crimping contact terminals to electrical cables, wires or similar electrical conductors. As shown, the hand crimp tool 10 comprises first and second lever handles 11, 13 which can be manually operated by a person, for instance pressed together in the shown example, for performing a crimping action.

(6) In the FIG. 1, the first and second lever handles 11, 13 are shown in an open configuration and upon operation the handles 11, 13 can be brought from the open configuration to a closed configuration.

(7) As depicted, the hand crimp tool 10 is further provided with a crimping frame 20, which, forms substantially a closed rectangle. Thereby, the closed shape of the crimping frame 20 as it is shown provides for optimal stability of the hand crimp tool 10 and allows a compact construction. Necessary openings, such as an opening for crimping die, can be advantageously incorporated into the compact frame construction.

(8) As further depicted in FIG. 1, the hand crimp tool 10 comprises a first crimping die 31, 33 and a corresponding second crimping die 35, 37. The first crimping dies 31, 33 and the second crimping die 35, 37 are arranged substantially within the crimping frame 20 between two guide rails 21, 23 of the crimping frame 20.

(9) The first crimping die 31, 33 is supported by a die carrier 25, which is operatively connected to at least one of the first and second lever handles 11, 13 and slidably arranged between the guide rails 21, 23. The first and second lever handles 11, 13 are mutually connected by a joint element 12. At least one of the first and second lever handles 11, 13 is connected to the die carrier 25 by means of a suitable hinge mechanism.

(10) Advantageously, the guide rails 21, 23 are substantially bar-shaped and are oriented in a common longitudinal direction 61. In other words, the guide rails 21, 23 are elongated members, which, in different embodiments, can be provided with different cross-sections such as round or irregular cross-sections. These elongated members are substantially mutually parallel to be optimally suited for guiding the die carrier 25.

(11) In the shown embodiment, at least the length of one side of the shown cross-section of the guide rails r.sub.gr, a rectangular cross-section of the guide rails r.sub.gr, may be on the order of a few millimeters, 2 mm to 10 mm.

(12) The crimping frame 20 has a long side of length l.sub.l, which is within the range of about 90 mm to 150 mm.

(13) The ratio l.sub.l/r.sub.gr may be from 5 to 20, 6 to 18, or 7 to 16. Alternatively, the ratio l.sub.l/r.sub.gr may be from 5 to 20, 5 to 14, or 11 to 13. For example, if the long side of length l.sub.l of the crimping frame 20 is 100 mm and the length of one side of the cross-section r.sub.gr is 10 mm, the ratio l.sub.l/r.sub.gr is 10.

(14) As shown in FIG. 1, the guide rails 21, 23 are mounted with respective proximal rail ends 26, 26′ to a frame base 28. The frame base 28, is advantageously arranged substantially perpendicular to the longitudinal direction 61 of the guide rails 21, 23. Moreover, the frame base 28 surrounds at least partially the first crimping die 31, 33 when the die carrier 25 is in a cable receiving position as shown in FIG. 1. As particularly shown in FIG. 1, the frame base 28 is formed by a plate which is screwed to both guide rails 21, 23, thereby firmly connecting the guide rails 21, 23.

(15) On the opposite side, not visible in FIG. 1 due to the perspective view, a similar plate is provided such that the frame base 28 surrounds corresponding portions of the die carrier 25 and the first crimping die 31, 33.

(16) Further, the guide rails 21, 23 are mutually connected at respective distal rail ends 27, 27′, via an substantially U-shaped support arch 29, which is configured to support the second crimping die 35, 37.

(17) By the provision of frame base 28 to support the guide rails 21, 23, a compact and stable construction is provided which is further improved by the provision of the support arch 29.

(18) According to the invention, upon operation of the first and second lever handles 11, 13, the die carrier 25 slides in a linear direction, parallel to the longitudinal direction 61 of the guide rails 21, 23, along inner opposite faces 22, only one of which is visible due to the perspective view of the FIG. 1, of the guide rails 21, 23. Thereby the die carrier 25 is guided from the cable receiving position to a crimping position.

(19) When the die carrier 25 is placed in the cable receiving position, an operator can place a contact terminal with an inserted cable between the first crimping dies 31, 33 and the second crimping dies 35, 37. Upon moving the die carrier 25 from the cable receiving position towards the crimping position, i.e. in a upward direction in the FIG. 1, corresponding crimping wings of the contact terminal are bent and the contact terminal is crimped to the cable.

(20) The crimping frame 20 is constructed such that upon movement of the die carrier 25, the die carrier 25 is supported and surrounded by the crimping frame 20 such that its movement is guided and determined by the crimping frame 20.

(21) Thereby, the movement of the die carrier 25 from the cable receiving position to the crimping position does substantially not involve a rotational component.

(22) As compared to lever-pivot based constructions as known from the prior art, with the crimping frame 20, the present construction provides the advantage that, for example, an unwanted tilting of the die carrier 25 and/or the first crimping die 31, 33 is prevented. Thus, due to the crimping frame 20, a higher crimping precision can be achieved and the construction is less susceptible to misalignment. As a result, the hand crimp tool 10 requires less maintenance.

(23) As shown in FIG. 1, the crimping frame 20 essentially consists of the frame base 28, the guide rails 21, 23 and the support arch 29. In this form, with only the minimum of necessary elements, the frame base 28 provides for a high stability of the hand crimp tool 10 and allows for a stable guidance of the die carrier 25 within the crimping frame 20.

(24) The crimping frame 20 has a short side of length l.sub.s, as shown in FIG. 1, and a corresponding ratio of the long side length l.sub.l to the length of a short side l.sub.s, i.e., the ratio l.sub.l/l.sub.s may be from 1 to 5, 2 to 4, 2.5 to 3.5, or 2.8 to 3.2. For example, if the length of the long side l.sub.l is 100 mm and the length of the short side is 40 mm, the resulting ratio l.sub.l/l.sub.s is 2.5.

(25) The second crimping die 35, 37 is removably mounted to the support arch 29. The die carrier 25 is configured to support two first crimping dies 31, 33. Moreover, the two first crimping dies 31, 33 may be crimping anvils as depicted in FIG. 1. Similarly, two second crimping dies 35, 37 are provided which may be crimping punches.

(26) As shown, in assembled condition, the second crimping dies 35, 37 are mounted between the guide rails 21, 23, to the substantially U-shaped support arch 29.

(27) The first crimping dies 31, 33 and the second crimping dies 35, 37 correspond to crimping dies as they are used in automated crimping machines in mass production.

(28) The first crimping die 31, 33, is removably mounted to the die carrier 25. The second crimping die 35, 37 is removably mounted to the support arch 29.

(29) Thus, the hand crimp tool 10 can advantageously be used to test crimping dies which, for example, are newly designed for an automated crimping machine such that, for this test, the crimping dies do not need to be mounted to an automated crimping tool used in a production line.

(30) In this document “crimping die removably mounted” means that the crimping die is quite easily took down and disassembled so as to replace it in the crimping frame 20. Indeed, it is a particular advantage of the present invention to use standard crimping dies used in mass production and to select their length, shape, gap in between, in particular with spacers having various thicknesses, etc., according to the wire diameter, to the terminal type, etc. For example, the time for changing the crimping dies should be only few minutes, e.g. less than 10 minutes, and may be less than 5 minutes.

(31) FIG. 2 shows first crimping dies 31, 33 and second crimping dies 35, 37 in a schematic three-dimensional view. The first crimping dies 31, 33 are provided with different anvil heights h.sub.a and/or surfaces 32 of the first crimping dies 31, 33 are provided with different forms and/or radii of curvature. Thereby, the first crimping die's height h.sub.a is used herein to illustrate that the respective first crimping dies 31, 33 operate at different heights and can be selected in correspondence with a desired crimping cross-section. For example, a first crimping die 31 can be used for crimping a corresponding insulation crimping portion of a contact terminal around a non-stripped portion of an electrical cable, while a second first crimping die 33 may be used to crimp the contact crimping portion of a contact terminal around a stripped portion of the inserted cable. The different first crimping die's heights h.sub.a in combination with correspondingly differently shaped second crimping dies 35, 37 allow achieving different crimping cross-sections of the contact crimping portion and the insulation crimping portion.

(32) Similarly, the first crimping dies 31, 33 may be provided with different radii of curvature of the upper crimping surfaces, which may be used similarly to achieve different cross sections of the resulting crimped sections.

(33) The first crimping dies 31, 33 are arranged on the die carrier 25 such that the first crimping dies 31, 33 can be moved with respect to each other in a second direction 63. The second direction 63, as it is shown in FIG. 2, is substantially perpendicular to the longitudinal direction 61 of the guide rails 21, 23.

(34) By providing the first crimping dies 31, 33 movable in this manner, the relative distance between the two first crimping dies 31, 33 can be adjusted as needed, for example, in accordance with the dimensions of an inserted contact terminal. Similarly, also the second crimping dies 35, 37 may be movable in a similar direction with respect to each other.

(35) The hand crimp tool 10 may further comprise a spacer 39 which can be inserted between the two first crimping dies 31, 33 and/or the two second crimping dies 35, 37. As shown in FIG. 2, such a spacer 39 can be used to adjust the relative position of first crimping dies 31, 33 and/or of second crimping dies 35, 37 in the second direction 63.

(36) The crimping frame 20 comprises adjusting means 50 for continuously moving the second crimping die 35, 37 substantially parallel to the longitudinal direction 61 of the guide rails 21, 23 to allow a pre-adjusting of the distance between the corresponding crimping dies. Such adjusting means 50 are exemplarily depicted in FIG. 3. As one can derive from this figure, these means comprise two corresponding adjustment members 51, 53, e.g. corresponding wedges, which are arranged movable in a third direction 65, which may be substantially perpendicular to the longitudinal direction 61 of guide rails 21, 23.

(37) To this end, the first adjustment member 51 is provided with a bore with inner screw threads and the crimping frame 20 is provided with a corresponding screw 55. Upon movement, e.g. due to turning the screw 55, inclined abutment surfaces 52, 54 of adjustment members 51, 53 mutually abut each other, such that the adjustment member 53 is pressed in a fourth direction substantially parallel to the longitudinal direction 61 of the guide rails 21, 23.

(38) As shown, the second crimping die 35, 37 is directly mounted to adjustment member 53 such that upon movement of the adjustment member 53, the second crimping die 35, 37 is moved in a similar way. Thereby, it becomes possible to continuously adjust the position of the second crimping die 35, 37 with respect to the first crimping die 31, 33. In other words, it becomes possible to continuously adjust the minimum distance between the first crimping die 31, 33 and the second crimping die 35, 37 to a desired diameter of a resulting crimp, as illustrated in the lower part of FIG. 3.

(39) In the lower part of FIG. 3, a cross section through a crimp connection of a contact crimping portion of a contact terminal 40 is depicted which is crimped around stripped cable strands 71 of an electrical cable.

(40) As one may derive from the different cross sections depicted in this lower part, upon continuously adjusting the second crimping die 35, 37, the diameter of the resulting crimp connection can be adjusted. Thus, due to these means for continuously moving the second crimping die 35, 37, a continuous pre-adjustment of the distance between corresponding crimping dies, e.g. between crimping anvils and crimping punches, is possible.

(41) FIGS. 4A to 4C illustrate a non-limiting example, wherein the adjusting means for continuously moving the second crimping die 35, 37 comprises at least one screw 55′, 55″ which is configured to be screwed into a corresponding bore hole with inner threads which is provided in the U-shaped support arch 29. As shown in FIGS. 4A and B, to this end, bore holes are provided such that the screw 55′, 55″ can be inserted in a fifth direction substantially parallel to the longitudinal direction 61.

(42) Upon clockwise rotation of the screw 55′, 55″, indicated by a plus sign and rotational arrows 67 in FIG. 4C, the second crimping dies 35, 37 are moved along the longitudinal direction 61 downwardly in the figures as indicated by a plus sign and arrow 69 in FIG. 4C. Similarly, when the screw 55′, 55″ is rotated in a counter clockwise direction as indicated by the minus sign and rotational arrow 67, the crimping dies 35, 37 move along the longitudinal direction 61 upwardly in the figure.

(43) To this end, the crimping dies 35, 37 can, for example, be pressed in a direction downwardly in the figure by the screw 55′, 55″, when the screw 55′, 55″ is rotated in clockwise direction. Upon counter clockwise rotation of the screw 55′, 55″, an upward movement of the crimping dies 35, 37 can, for example, be enabled by a suitable spring mechanism which provides a force which acts on the second crimping dies 35, 37 thereby pressing the same upwardly in the figure.

(44) As illustrated in FIGS. 5A to 5C, at least one means for non-continuously moving, the second crimping die 35, 37 in a direction substantially parallel to the longitudinal direction 61 is provided which is used in combination with the above described means for continuously moving the second crimping die 35, 37.

(45) As illustrated, the means for non-continuously moving the second crimping die 35, 37 can be provided in form of adjusting members 51′, 53′, for example box shaped metal or plastic parts or metal or plastic plates, of suitable size which can be removably provided within the U-shaped support arch 29 and which support the crimping dies 35, 37 as shown in FIG. 5A. These adjusting members 51′, 53′ can be selected based on their size to shift the second crimping dies 35, 37 in a direction downwardly in the figure as illustrated by the plus sign and arrow 69 in FIG. 5C to provide a rough adjustment of the distance between the first crimping dies 31, 33 and the second crimping dies 35, 37.