WO2021231919A1 - Hydraulic adapters for conducting hydraulic operations using an electric drill and methods thereof - Google Patents

Abstract

Disclosed herein are hydraulic adapters capable of converting the low torque energy provided by conventional cordless drills to applications of high pressure hydraulic operations. Hydraulic adapters allow accessories that have conventionally required dedicated hydraulic tools and machinery to be operated using conventional cordless drills. Methods of using the hydraulic adapters in hydraulic operations are also disclosed herein, and demonstrate improved cycle times over conventional dedicated hydraulic tools.

Description

HYDRAULIC ADAPTERS FOR CONDUCTING HYDRAULIC OPERATIONS USING AN ELECTRIC DRILL AND METHODS THEREOF

CROSS REFERENCE TO RELATED APPLICATION This application claims the benefit of and priority to U.S. Provisional Patent Application No. 63/024,877, filed on May 14, 2020, the disclosure of which is incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION Hydraulic accessories are commonly employed during electrical installations to punch, cut, or form metal work pieces according to installation requirements. Specialized tools are typically required and employed. For instance, hand operated hydraulic pumps are known in the art in applying hydraulic pressure to various hydraulic accessories for the purpose of crimping, cutting, and punching holes in metals. However, such conventional manual operations can require long cycle times and tedious resetting procedures. Electrically-powered hydraulic tools are also known in the art, but do not retain the function of a standard cordless drill, and thus require specialized drive systems to operate the hydraulic accessories. Such dedicated tools are tailored to perform high- torque operations, and are not compatible with the high-speed operations typically performed by cordless drills.

As disclosed herein, it would be advantageous for a standardized drive system capable of performing both hydraulic operations and conventional high speed functions of cordless drills within a single device, and without need for dedicated hydraulic driving equipment.

SUMMARY

Hydraulic adapters for converting an electric drill for operation of a hydraulic accessory are disclosed herein, and can comprise a hydraulic pump, a gearbox configured to transfer power between a standard cordless drill and the hydraulic pump, and a hydraulic connector configured to transfer a force from the hydraulic pump to the hydraulic accessory. Tool systems are also disclosed herein comprising a hydraulic adapter, a cordless drill, and a plurality of hydraulic accessories. In certain embodiments, the plurality of hydraulic accessories can comprise a punch accessory, a crimp accessory, and a cutting accessory, each of which may be operated through attachment to the cordless drill through the hydraulic adapter. Methods for conducting hydraulic operations using a cordless drill are also disclosed, and can comprise securing a hydraulic adapter to the cordless drill, attaching a hydraulic accessory to the hydraulic adapter, positioning the hydraulic accessory about a work piece, advancing a component within the hydraulic accessory along a stroke length defined by a starting point to an ending point by forward operation of the cordless drill, and retracting the component from the ending point to the starting point by reverse operation of the cordless drill.

BRIEF DESCRIPTION OF THE FIGURES FIG. 1 depicts a schematic layout of a hydraulic adapter and its connection between a cordless drill and a hydraulic accessory.

FIG. 2 depicts a first embodiment of a hydraulic adapter assembled with a hydraulic accessory.

FIG. 3 depicts a second embodiment of a hydraulic adapter disconnected from a hydraulic accessory.

FIG. 4 depicts a series of hydraulic accessories with a universal connector for a hydraulic adapter.

DEFINITIONS To define more clearly the terms used herein, the following definitions are provided. Unless otherwise indicated, the following definitions are applicable to this disclosure. To the extent that any definition or usage provided by any document incorporated herein by reference conflicts with the definition or usage provided herein, the definition or usage provided herein controls. While compositions and methods are described herein in terms of “comprising” various components or steps, the compositions and methods also can “consist essentially of’ or “consist of’ the various components or steps, unless stated otherwise. For example, a tool set consistent with aspects of the present invention can comprise; alternatively, can consist essentially of; or alternatively, can consist of; a cordless drill, a hydraulic adapter, and a hydraulic accessory.

Several types of characteristic ranges are disclosed in the present invention. When several ranges are disclosed for a single characteristic, it is intended that embodiments of each of the disclosed ranges are also contemplated in combination with every other relevant characteristic and possible range disclosed herein. For example, where a cordless drill may have a maximum torque in a range from 25 to 5,000 in-lbs, from 50 to 2,500 in-lbs, from 100 to 2,000 in-lbs, from 500 to 2,000 in-lbs, from 800 to 1400 in-lbs, or from 1,000 to 1,200 in-lbs. Alternatively, or additionally, adapters and tools contemplated herein can be configured for operation with cordless drills comprising a maximum rpm of at least 100 rpm, at least 200 rpm, at least 400 rpm, all combinations of these characteristics are also contemplated herein. Thus, cordless drills having a maximum torque in a range from 50 to 500 ft-lbs and a maximum rpm of at least 400 rpm are contemplated herein.

The term “about” means that amounts, sizes, parameters, and other quantities and characteristics are not and need not be exact, but can be approximate and/or larger or smaller, as desired, reflecting tolerances, conversion factors, rounding off, measurement errors, and the like, and other factors known to those of skill in the art. In general, an amount, size, formulation, parameter or other quantity or characteristic is “about” or “approximate” whether or not expressly stated to be such. The term “about” also encompasses amounts that differ due to different equilibrium conditions for a composition resulting from a particular initial mixture. Whether or not modified by the term “about,” the claims include equivalents to the quantities. The term “about” can mean within 10% of the reported numerical value, preferably within 5% of the reported numerical value.

The term “hydraulic accessory” describes any accessory to which operates on the basis of hydraulic power, or the basis of a mechanical force applied by the hydraulic connector of the devices disclosed herein. Accessory is meant as describing a component with any number of parts, or may be a unitary part. For instance, hydraulic accessory may be a hydraulic punch which comprises a pulling bolt, a punch die and a face die.

The terms “a,” “an,” “the,” etc., are intended to include plural alternatives, e.g., at least one, unless otherwise specified. For instance, the disclosure of “a hydraulic accessory” or “a pivoting joint” is meant to encompass one, or combinations of more than one, hydraulic accessory or pivoting joint, respectively, unless otherwise specified.

DETAILED DESCRIPTION OF THE INVENTION Devices and tool sets are disclosed herein capable of performing both hydraulic operations and high speed drill operations. Devices for adapting a cordless drill for hydraulic operations are disclosed herein. Tool set systems are also disclosed herein, and can comprise a hydraulic adapter, a cordless drill and a plurality of hydraulic dies. Methods of operating the devices and tools sets are also disclosed.

HYDRAULIC ADAPTERS

Hydraulic adapters are generally disclosed herein as being capable of transferring the force generated by conventional cordless drills to the extension and retraction of a component (e.g., actuator) within the hydraulic accessory. In this sense, the hydraulic adapters disclosed herein are not limited to any particular arrangement or mechanism, and can comprise any combination of mechanical elements suitable to operate hydraulic accessories disclosed herein by the forward and reverse operation of a standard cordless drill.

In certain embodiments, hydraulic adapters disclosed herein generally can comprise a gearbox, a hydraulic pump, and a hydraulic connector. FIG. 1 represents a connection and arrangement of the hydraulic adapters disclosed herein and their components. Generally, a gearbox can connect directly to the cordless drill and convert the relatively high speed, low torque force from the drill into a high torque force to drive the hydraulic pump. In turn, the hydraulic pump can provide hydraulic flow and pressure to the hydraulic connector, the hydraulic connector providing force to the hydraulic accessory necessary to operate the accessory. In certain embodiments, the hydraulic connector can supply hydraulic fluid to the hydraulic accessory for its operation. In alternative embodiments, it hydraulic connector may comprise an actuator configured to transfer the force from the hydraulic pump to the hydraulic accessory without transferring the hydraulic fluid (e.g., by mechanical means).

Certain embodiments may further comprise a pivoting joint between any component to allow for convenient positioning of the device around or near a fixed work piece. For instance, where an electrical panel has been previously installed, and requires modification by the addition of a punched hole, a pivoting joint may allow the user to position the cordless drill in a comfortable position with ample clearance as the hydraulic accessory is operated. In certain embodiments, the hydraulic adapter can comprise a pivoting joint between the hydraulic connector and the hydraulic pump. In such embodiments, the pivoting joint can comprise internal chambers and valves to ensure the hydraulic connector remains in fluid communication with the hydraulic pump. Placement of a pivoting joint between the hydraulic connector and the hydraulic pump in this manner may be advantageous to allow the pivoting joint to be closer to a work piece during operation, allowing the adapter to be operated in spaces of limited clearance.

Gearboxes suitable for the hydraulic adapters disclosed herein are not limited to a particular mechanism, and generally can be any that is suitable for transferring a force from a standard cordless drill to a hydraulic pump, with mechanical advantage. For example, in certain embodiments, the gearbox can be a coaxial helical inline gearbox, a bevel helical gearbox, a skew bevel helical gearbox, a worm reduction gearbox, or a planetary gearbox. In certain embodiments, gearboxes disclosed herein can comprise a standard drill drive connection input, such that attachment of the gearbox, and ultimately the adapter, to a standard cordless drill is straightforward and compatible with conventional drill bits and attachments. Similarly, the output shaft of gearboxes suitable for the invention can be any that are ultimately compatible with a suitable hydraulic pump, such as those described herein.

The mechanical advantage of gearboxes suitable for the adapters disclosed herein can be any that effectively transfer the relatively fast rotating force of the cordless drill to a slower rotational force corresponding to a higher torque to apply to any of the hydraulic pumps disclosed herein. Thus, the gearboxes disclosed herein can have a mechanical advantage of at least 2, at least 5, at least 10, at least 50, at least 100, at least 200, at least 300, at least 500, at least 1,000, or at least 5,000. Gearboxes disclosed herein can have a mechanical advantage in a range from about 2 to 5,000, from about 10 to 3,000, from about 20 to about 500, or from about 50 to about 250.

Hydraulic pumps suitable for the adapters contemplated herein are not limited to any particular mechanism, and generally may be any that are capable of efficiently transferring the force applied by the gearbox to the hydraulic connector. Hydraulic pumps therefore can typically comprise a fluid reservoir comprising a hydraulic fluid, a pump inlet and pump outlet, and means to deliver the hydraulic fluid from the fluid reservoir to the pump inlet and toward the pump outlet. In certain embodiments, the hydraulic pump can comprise a check ball pump, a gear pump, a rotary vane pump, piston pump, a hand pump, a lobe pump, a peristaltic pump, a screw pump, a progressive cavity pump, a fixed displacement pump, a positive displacement pump, a reciprocating pump, or a diaphragm pump. The pressure sustained by the hydraulic pumps contemplated herein can be within any range needed to counter a load acting at the pump outlet, the hydraulic connector, the hydraulic accessory, or any combination thereof. Generally, higher pressures within the pump and hydraulic connector can allow for a greater force to be transferred to a hydraulic accessory and work piece. In certain embodiments, hydraulic pumps contemplated herein can sustain a pressure of at least 100 psi, at least 500 psi, at least 1000 psi, at least 2,000 psi, at least 3,000 psi, at least 5,000 psi, at least 6,000 psi, at least 6,500 psi, at least 7,500 psi, at least 8,000 psi, at least 9,000 psi, at least 10,000 psi, at least 12,000 psi, at least 15,000 psi, at least 20,000 psi or at least 25,000 psi. Hydraulic connectors contemplated herein may be also be configured to operate at a minimum psi (e.g., less than any of the amounts disclosed immediately above), which may in turn reduce the mechanical advantage of the gearbox required to apply a given amount of force to a hydraulic accessory attached to the hydraulic connector. Such improvements ultimately may advantageously reduce the cycle time. Alternatively, the hydraulic pumps contemplated herein can comprise a pressure in a range from about 3,000 psi to about 25,000 psi, about 5,000 psi to about 15,000 psi, or about 8,000 psi to about 12,000 psi.

As for other components, the hydraulic connector is not limited to any particular form or composite of components, and generally can be any that is capable of securing a hydraulic accessory to the hydraulic adapter, and transferring a hydraulic force received by the hydraulic pump to the hydraulic accessory. The hydraulic connector can be configured in any manner suitable to transfer may be any capable to secure a hydraulic accessory to the hydraulic connector, In certain embodiments, the hydraulic connector can comprise threadings, latches, hooks, or any combination thereof to secure the hydraulic accessory to the hydraulic adapters disclosed herein. In certain embodiments, the hydraulic connector can be located on an external surface of a cylindrical chamber, or alternatively within an internal surface of the hydraulic connector. Threadings on the hydraulic accessory may complement those present on the hydraulic connector.

In certain embodiments contemplated herein, the hydraulic connector can further comprise an actuator which advances from a starting point to an end point along a stroke length by application of hydraulic force from the hydraulic pump. In such embodiments, it is contemplated that that the hydraulic connector may apply a mechanical force to the hydraulic accessory The hydraulic adapters disclosed herein are intended to be compatible with conventional hydraulic accessories, as would be understood by persons of ordinary skill in the art. The adapters disclosed herein are contemplated as being compatible with hydraulic punches.

The hydraulic pump, gearbox, hydraulic connector, and all connecting shafts valves, and hydraulic channels may, independently, or in any combination, have an efficiency suitable for high force operations with a cordless drill described herein. In certain embodiments, the efficiency of any component, or any combination of components can approach 1 to minimize the energy lost in the conversion of energy between the cordless drill and the hydraulic accessory. In certain embodiments, the efficiency may be at least 0.6, at least 0.65, at least 0.7, at least 0.8, at least 0.9, or at least 0.95.

Cordless drills suitable for coupling to the adapters contemplated herein are not limited to any particular type, as would be understood by those of ordinary skill in the art. In certain aspects, the cordless drill may have maximum operating characteristics that limit the power or speed of operation, and partly define tool systems and adapters configured for use with standard cordless drills. For instance, adapters contemplated herein can be configured for use with a cordless drill having a maximum revolutions per minute (rpm) of at least 100 rpm, at least 200 rpm, at least 400 rpm, at least 800 rpm, at least 1000 rpm, at least 1500 rpm, at least 2000 rpm or at least 2500 rpm. Adapters contemplated herein can be configured for use with a cordless drill having a maximum torque of at least 5, 10, 15, 20, 25, 50, 75, 100, 150, or 200 ft-lbs. Cordless drills contemplated for use with adapters described herein may alternatively have a torque in a range from 5 to 50 ft-lbs, from 10 to 100 ft-lbs, from 25 to 200 ft-lbs, or from 50 to 500 ft-lbs. Cordless drills may further comprise any features commonly included within standard cordless drills, including variable speed and torque settings, quick-exchange bit mechanism, LED-lights, and other features as would be understood by those of skill in the art.

Adapters disclosed herein may be configured for use with any particular cordless drill described above by consideration of the torque supplied at a maximum rpm, and providing the adapter having any suitable combination of characteristics as described above (e.g., cycle time, overall and individual efficiency of adapter components, etc.). All combinations of such features are contemplated herein as configured for use with cordless drills having the speed and torque characteristics described above.

Tool sets comprising a cordless drill, a hydraulic adapter as described herein, and a plurality of hydraulic accessories are also contemplated herein. Said tool sets may further comprise non-hydraulic accessories as related to the cordless drill and its conventional operation (e.g., extra batteries, battery charger, standard drill bits and driver bits, etc.). Tool sets contemplated herein can comprise a carrying case.

FIG. 2 shows a non-limiting embodiment of the hydraulic adapter 100 attached to a hydraulic accessory 140. Specifically, the hydraulic adapter 100 comprises housing 102 that features a drift shaft 106 configured to connect to a cordless drill drive (not shown). The housing further comprises handle 104 secured to the exterior portion of the housing.

FIG. 3 shows a second non-limiting embodiment of the hydraulic adapter 100 and certain inner components, without a hydraulic accessory attached. As shown, the adapter 100 comprises gearbox 110 is provided with a drive shaft 106 at a first end for connection to an electric drill drive. Gearbox 110 is also mechanically connected to hydraulic pump 120 in order to transfer force from the electric drill drive to the hydraulic pump 120 after having applied a mechanical advantage to the input power. In certain aspects, gearbox 110 as pictured can represent a typical gearbox as found in dedicated hydraulic tools (e.g., hydraulic crimper) and having a reduced mechanical advantage. The housing 102 further comprises the hydraulic reservoir 122 and hydraulic diaphragm cylinder 124. External threadings 126 are provided on the connection end of the adapter to connect the hydraulic accessories (not shown).

FIG. 4 provides a series of hydraulic accessories suitable for use with the hydraulic adapter. Hydraulic crimping head 130, hydraulic cutting head 140, and hydraulic punch 150 each have a universal connection (136, 146, 156) with internal threadings (not shown) to mate with the connection 126 of the hydraulic adapter. Additional hydraulic accessories and features within the hydraulic accessories shown are also contemplated herein. For instance, optional pivoting joint 132 of hydraulic punch 150 can transfer hydraulic pressure from the connector 156 to the punch head, while allowing a range of motion for the hydraulic accessory 150. In certain aspects, the hydraulic punch can be a hydraulic punch head, such as the Southwire^® Max Punch™ Hydraulic Knockout Tool MP360. METHODS FOR OPERATING HYDRAULIC ACCESSORIES

Methods for operating hydraulic accessories are contemplated herein, and generally include operations where extreme forces are required, such as the punching, cutting, and crimping of rigid metal work pieces. Generally, the method can comprise connecting a first end of the hydraulic adapter, such as are described above, to a standard cordless electric drill, attaching a hydraulic accessory to a second end of the hydraulic adapter, and using the cordless drill to operate the hydraulic accessory on a work piece of interest. In certain embodiments, the method can comprise positioning the hydraulic accessory about the work piece according to the function of the hydraulic accessory, advancing an actuator within the hydraulic adapter from a starting position to an ending position by forward operation of the drill, and retracting the actuator from the ending position to the starting position by reverse operation of the drill. Alternatively, the actuator may be advanced by reverse operation of the drill, and retracted by forward operation. Such an arrangement may be advantageous for drill drive systems with higher torque when driven in reverse.

Cycle times of methods contemplated herein can refer to a minimum amount of time to perform the advancing and retracting steps of the hydraulic tool. Cycle times are advantageously reduced through efficient hydraulic accessories, and by applying an appropriate amount of hydraulic pressure to the hydraulic accessory. In certain embodiments, cycle time can be less than 3 seconds, less than 5 seconds, less than 10 seconds, less than 15 seconds, less than 20 seconds, less than 25 seconds, less than 30 seconds, less than 45 seconds, or less than a minute. Alternatively, the cycle time can be measured by average speed of the actuator, and can be in a range from 1 mm/s to 100 mm/s, from 1 mm/s to 50 mm/s, from 1 mm/s to 25 mm/s, from 1 mm/s to 10 mm/s, from 5 mm/s to 30 mm/s, from 5 mm/s to 50 mm/s, or from 20 mm/s to 50 mm/s.

As described briefly above, connecting the first end of the hydraulic adapter can comprise methods analogous to conventional methods of securing drill bits to cordless drills. In certain embodiments, connecting the first end of the hydraulic adapter can comprise inserting an input drive shaft of the gearbox into the bit receiver of the cordless drill, and tightening the bit receiver against the input drive shaft. Additional conventional methods of connecting drill bits to cordless drills are also contemplated herein as relevant to the connecting step. Positioning the hydraulic accessory can comprise any number of steps as are conventionally known to accommodate the particular accessory attached to the adapter. For instance, where a hydraulic crimping accessory is attached, positioning the work piece can comprise inserting a wire crimp within an opening in the crimping accessory. Alternatively, where a punch accessory is attached, positioning the work piece can comprise inserting a punch into a drilled hole of a metal sheet, and securing a punch die to the punch. Further still, where a cutting tool is attached, positioning the work piece can comprise centering the intended cut line within two cutting blades of the hydraulic accessory.

Advancing an actuator within the hydraulic accessory along a stroke length defined by a starting point to an ending point by forward operation of the cordless drill is not restricted to particular methods or structure, and generally can be any that facilitate the motion of hydraulic accessory parts against the work piece in a desired manner. For instance, as with certain hydraulic punch accessories contemplated herein, an actuator within the hydraulic punch can be a hydraulic actuator advanced by hydraulic force applied directly to the actuator, via the hydraulic connector. In alternative embodiments, the actuator may be a universal actuator may be positioned within the hydraulic connector.

The distance between the starting position and the ending position is referred to herein as the actuator stroke length, which may also be any suitable length for conducting the hydraulic operations disclosed and contemplated herein. In certain embodiments, the actuator stroke can be in a range from about 1 mm to about 10 cm, from about 1 cm to about 5 cm, from about 2 cm to about 5 cm, or from about 2.5 cm to about 4 cm.

The results and characteristics of the operations performed by the hydraulic accessories can be equal to, or better than analogous methods performed by dedicate hydraulic tools, such as handheld electric drive hydraulic accessories, and manual drive hydraulic accessories. Methods herein are applicable to work pieces comprising any material, and particularly rigid metal materials such as metals selected from steel, iron, copper, aluminum, nickel, or alloys thereof. In certain embodiments, the work piece can comprise a thickness in a range from about 1/8” to about 2”. The methods disclosed herein can further comprise an auto-stop feature that disengages the force applied by the adapter once the hydraulic accessory has reached a stop position, such that neither the hydraulic adapter nor the hydraulic accessory are damaged by advancing the actuator against the stop position by applying hydraulic force. Methods disclosed herein also can comprise an auto-reset feature, which may free the user’s hands to alternate hydraulic accessories, or ready the next work piece to be operated upon by the hydraulic accessory as the accessory is reset to the starting position.

Claims

CLAIMS What is claimed is:

1. A hydraulic adapter for adapting an electric drill for use in the operation of a hydraulic accessory, the device comprising: a hydraulic pump; a gearbox configured to transfer power between the electric drill and the hydraulic pump; and a hydraulic connector configured to transfer a force from the hydraulic pump to the hydraulic accessory.

2. The adapter of claim 1 , further comprising a pivoting j oint between the hydraulic pump and the hydraulic accessory.

3. The adapter of claim 1, wherein the hydraulic pump is a check ball pump, a gear pump, a rotary vane pump, piston pump, a hand pump, a lobe pump, a peristaltic pump, a screw pump, a progressive cavity pump, a fixed displacement pump, a positive displacement pump, a reciprocating pump, or a diaphragm pump.

4. The adapter of claim 1, wherein the hydraulic pump is a piston pump.

5. The adapter of claim 1, wherein the hydraulic pump is a screw pump.

6. The adapter of claim 1, wherein the hydraulic pump is configured to sustain a pressure of at least 3,000 psi.

7. The adapter of claim 1, wherein the hydraulic pump is configured to sustain a pressure of at least 10,000 psi.

8. The adapter of claim 1, wherein the gearbox is a coaxial helical inline gearbox, a bevel helical gearbox, a skew bevel helical gearbox, a worm reduction gearbox, or a planetary gearbox.

9. The adapter of claim 1, wherein an efficiency of the gearbox is at least 60%.

10. The adapter of claim 1, wherein the gearbox has a mechanical advantage in a range from about 50 to about 5,000.

11. The adapter of claim 10, wherein the mechanical advantage is in a range from about 20 to about 500.

12. The adapter of claim 1, wherein the hydraulic accessory is selected from a cutting accessory, a crimping accessory, or a punching accessory.

13. A tool compri sing : the hydraulic adapter of claim 1; a cordless drill; and a hydraulic accessory.

14. The tool of claim 13, wherein the plurality of hydraulic accessories comprises a cutting accessory, a punch accessory, a crimp accessory, or any combination thereof.

15. The tool of claim 13, wherein the cordless drill has: a maximum drilling speed in a range from about 200 rpm to about 2,500 rpm; and a maximum torque in a range from about 800 in-lbs to 1400 in-lbs.

16. A method for conducting a hydraulic operation using a cordless drill, the method comprising: securing a hydraulic adapter to the cordless drill; attaching a hydraulic accessory to the hydraulic adapter; positioning the hydraulic accessory about a work piece; advancing an actuator within the hydraulic accessory along a stroke length from a starting point to an ending point by forward operation of the cordless drill; and retracting the actuator from the ending point to the starting point by reverse operation of the cordless drill.

17. The method of claim 16, wherein a cycle time encompassing the advancing and retracting steps is in a range from about 5 seconds to about 30 seconds.

18. The method of claim 16, wherein the cordless drill has: a maximum drilling speed in a range from about 200 rpm to about 2,500 rpm; and a maximum torque in a range from about 800 in-lbs to about 1400 in-lbs.

19. The method of claim 16, wherein the hydraulic accessory is selected from a cutting accessory, a punch accessory, or a crimp accessory.

20. The method of claim 16, wherein: the work piece comprises a metal selected from steel, iron, copper, aluminum, nickel, or alloys thereof; and the work piece has a thickness in a range from about 1/8” to about 2”.