Modeling, validation, and investigation of an electrohydraulic crimping hand tool

Eric D. Norquist, Jonathon E. Slightam, Mark L. Nagurka

Research output: Chapter in Book/Report/Conference proceedingConference contributionpeer-review

Abstract

Due to their high power density, hydraulic systems are increasingly adapted for human scale devices. For example, commercial and utility electricians use electrohydraulic cutting and crimping tools, rather than human powered tools, to cut and crimp wires that exceed 25mm in diameter. These tools greatly reduce worker-related fatigue and strain-type injuries. To improve electrohydraulic tool technology, there is a need to increase the number of applications from a single battery charge. This paper develops a high fidelity nonlinear lumped parameter model of an electrohydraulic crimping hand tool used by professional electricians. The eleventh-order model can predict tool performance with an average error of 6.9% and 4.4% with respect to the maximum energy consumption and crimp time, respectively. Simulation studies were conducted to investigate reducing the energy consumption of the tool. An independent parameter sweep was performed on the pump piston diameter. The gear ratio was a dependent parameter linked through the maximum motor torque. Increasing the pump piston diameter while increasing the gear ratio was shown to decrease the energy consumption of the tool during crimping applications. Simulations suggest that up to 30% energy can be saved per crimp by increasing the pump piston diameter and gear train ratio.

Original languageEnglish
Title of host publicationASME/BATH 2019 Symposium on Fluid Power and Motion Control, FPMC 2019
PublisherAmerican Society of Mechanical Engineers (ASME)
ISBN (Electronic)9780791859339
DOIs
StatePublished - 1 Jan 2020
Externally publishedYes
EventASME/BATH 2019 Symposium on Fluid Power and Motion Control, FPMC 2019 - Longboat Key, United States
Duration: 7 Oct 20199 Oct 2019

Publication series

NameASME/BATH 2019 Symposium on Fluid Power and Motion Control, FPMC 2019

Conference

ConferenceASME/BATH 2019 Symposium on Fluid Power and Motion Control, FPMC 2019
Country/TerritoryUnited States
CityLongboat Key
Period7/10/199/10/19

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