Background of the Invention
This invention relates to a cutting tool suitable for severing bundles of cabled strands. It is particularly useful in cutting what is known as "communications" cable, and it will be described in that frame of reference, although it may be used in severing other objects. Communications cable comprises a bundle or group of bundles of very small diameter electrical conductors, each strand of which carries a coating of insulating material. Such cables may contain as many as several hundred filaments in a cable only a few inches in diameter. They are highly resistant to severing.
Until the present invention, there seems to have been no manually-operable commercially-available tool that was capable of cutting cables of this type without causing damage to at least some of the conductors. Saws have a tearing effect; knives and chisels smash the insulation and distort the conducting elements; shears are as destructive as chisels. Previously-known tools for doing this work are bulky and ineffective, since they are difficult to operate without repeated manual adjustment as each cut is made, and the stress imposed by the shearing action flattens the cable and strips the insulating coat.
One of the tools previously used resembles a pair of pliers in which one of the jaws is a knife and the other jaw serves as an anvil. A major objection to this type of tool is its very limited capacity to cut large-diameter cable. Unless the knife is quite thick, its edge will curl or chip instead of cutting. But the thicker the blade, the greater must be the displacement of the metal in the cable being cut, the greater the force required to make the cut, and the greater the tendency to flatten and distort the cable.
Tools having a shearing action are likely to draw the very fine strands of the cable into the zone between the blades of a shear-type tool, thus wedging the blades apart and jamming the jaws, while at the same time stripping insulation from some of the conductors. The result is a ragged cut instead of a smooth one, and the distortion of the cable at the point where it is cut makes it difficult or impossible to fit the severed ends neatly into clamps or fittings of rigid metal.
The problem presents a vicious circle: The blades in a shear-type cutter simply must be thick, not only to resist nicking and curling of their cutting edges, but also to counteract the tendency to spread apart, with resultant outward flaring, when making a cut. Yet the thickness required greatly increases the energy needed to drive them through the cable being cut, and this cannot be remedied in the usual way--namely, by lengthening the handles to add leverage, because the tool itself must often operate in very confined quarters--e.g., in a manhole, where the total clearance available may be not much more than the shoulder width of a sturdy man. There is no room for long handles. This is an unavoidable limitation, because the manhole must accommodate not only the cable sections, but also various accessories for the system as a whole.
While hydraulically or pneumatically driven cutting devices are known which can cut very thick cable, they are in general bulky and expensive, and require use of pneumatic or hydraulic lines and pumps.
Summary of the Invention
The cutting tool of the invention comprises a cutting lever member and a holding lever member pivotally mounted to each other intermediate their respective ends by a main pivot and having, respectively, a blade portion and a holding portion on one side of the main pivot. The holding portion is preferably concave to receive and hold the object to be cut, such as a communications cable, and the blade portion has a cutting edge confronting the holding portion which is urged toward the holding portion and against the object to be cut when the ends of the two lever members on the opposite side of the main pivot are urged toward each other in a closing direction to accomplish cutting. Preferably the holding portion comprises blade receiving and guiding members in the form of a pair of parallel plates which are spaced apart to receive the blade portion when it is closed to the holding portion during cutting, so as to reinforce and rigidify the blade portion, thus permitting use of a thinner blade portion than would otherwise be required.
One of the above-described lever members is provided with an integral handle portion on the other side of the main pivot, while the other lever member is provided with a ratchetting lever member pivotally mounted thereon by a second pivot. Preferably, but not necessarily, the holding lever member is the one on which the ratchetting lever member is pivotally mounted, and the invention will be described with particular reference to such embodiment.
In such case, the cutting lever member is provided with a main gear having gear teeth extending coaxially with the axis of the main pivot, and a drive sprocket is pivotally mounted on said second pivot with its teeth meshing with those of the main gear segment. Controllable pawl means are provided which are engageable with the drive sprocket and which are responsive to angularly reciprocating motion angular range with respect to the holding lever member, to produce ratchetted closing motion between the blade portion and the holding portion of the other two lever members. This ratchetting action provides a desirable high mechanical advantage in forcing the cutting edge of the blade portion through the object to be cut.
In addition, means are provided which limit the angular motion of the ratchetting lever member beyond said angular range in the opening direction, for holding the ratchetting lever member in fixed angular relation to the holding lever member during such further angular opening motion with respect to the cutting lever member, thereby to effect direct and rapid opening of the cutting portion from the holding portion when a section of cable is to be placed between them for cutting. Means are also provided which limit the angular motion of the ratchetting lever member beyond said angular range in the opposite or closing direction, for holding the ratchetting lever member in fixed angular relation to the holding lever member during further angular closing motion of said ratchetting lever member thereby to permit direct and rapid closing of said cutting portion toward said holding portion when the blade edge is to be closed against the cable preparatory to cutting it.
Preferably, the pawl means comprises a pawl mounted on the ratchetting lever member and controllable to be moved between a first position in which it engages said sprocket teeth and a second position in which it is disengaged from said sprocket teeth. In said first position the pawl prevents relative rotation of the drive sprocket with respect to the ratchetting lever member in one angular sense, such that angular motion of said ratchetting lever member in the closing direction within said angular range turns said drive sprocket in the direction to close said blade portion toward said holding portion; when said ratchetting lever member has been closed to the limit of said angular range, further closing motion thereof directly drives the holding lever member in the closing direction so that the main gear teeth drive the sprocket gear teeth in the opposite angular sense of relative rotation with respect to the pawl, the pawl then sliding over the drive sprocket teeth to permit the desired rapid closing motion of the blade portion toward the holding portion. Upon subsequent opening motion of the ratchetting lever member through said angular range, the opposite angular sense of relative angular motion of the sprocket again occurs, so that the pawl slides over the drive sprocket teeth until the opposite limit of said angular range is reached. At this point, if the pawl were permitted to remain in its engaged first position, further opening motion of the ratchetting lever member would not be possible, since such motion directly drives the holding lever member in the opening direction so that the main gear turns the drive sprocket in the one sense of relative rotation with respect to the ratchetting lever member which the pawl does not permit. However, pawlcontrol means are employed which automatically move the pawl to its disengaged second position by the time the ratchetting lever reaches the limit of said angular range in its opening direction, so that the desired rapid opening of blade portion from the holding portion is provided without interference by the pawl.
In a preferred embodiment, the pawl control means comprises spring means for biasing said pawl into said engaged first position and stop means on said holding lever member for contacting said pawl and moving it to its disengaged second position in response to motion of the ratchetting lever member in the opening direction within said angular range.
The tool of the invention thus permits the user, without removing either hand from the handles, rapidly to open the jaws of the tool sufficiently widely to receive and embrace the circumference of a relatively large cable to be cut; to close the jaws rapidly and without ratchetting until the cable is held tightly between blade portion and holding portion preparatory to cutting; to continue the closing action with substantial mechanical advantage, thereby cutting the cable; and to perform a ratchetted cutting by angular reciprocation of the ratchetting lever member, if desired or necessary during the cutting phase of the operation. The blade may be relatively thin, due to its support and reinforcement by the parallel plates of the holding portion, and provides a smooth cut of the cable as desired.
Brief Description of Figures
How these and other objectives and advantages of the invention are to be secured will become evident as this description proceeds, and will be understood from reference to the accompanying drawings, which illustrate a preferred embodiment of the invention, and in which:
FIG. 1 is a view in elevation, with portions broken away to show inner structure, showing the tool of the invention in a fully-closed position suitable for storing or transporting it;
FIG. 2 is a top plan view of the tool shown in FIG. 1;
FIG. 3 is a plan view of the tool shown in FIG. 1, as seen from the bottom;
FIGS. 4 through 8 are enlarged fragmentary transverse sectional views, taken on the lines 4--4, 5--5, 6--6, 7--7, and 8--8 of FIG. 1 showing in detail various of the pivot, spacer and fastener arrangements;
FIG. 9 is an elevational view, similar to FIG. 1, but with the ratchetting handle in a position to begin opening movement of the cutting jaws;
FIG. 10 is a diagrammatic view, showing the tool fully open to receive a cable to be cut;
FIG. 11 is a diagrammatic view showing the tool with its jaws closed against opposite sides of the cable preparatory to the making of a cut; and
FIG. 12 is a fragmentary elevational view of the tool, showing a cable beginning to be severed and indicating, in dot-and-dash lines, alternate positions of the parts during ratchetting movement.
Detailed Description of Specific Embodiments
As seen in these figures, the tool comprises a cutting lever member 10 and a holding lever member 12 pivotally mounted to each other intermediate their ends by a main pivot 14. The cutting lever member 10 comprises a handle portion 18 and a plate-like blade portion 20. In this example the blade portion is in the form of a metal cutting head integrally mounted on handle portion 18 by a neck portion 22 thereof, which fits between flanges 23, 23a of handle portion 18 to be held by threaded fastener 24, as shown in FIG. 8. Blade portion 20 has a cutting edge 26 formed by double bevelling of the otherwise uniform thickness of the blade portion 20. (see FIG. 4).
Holding lever member 12 has a concave portion or nesting area 28 facing the cutting edge 26 of the blade portion and designed to receive and hold the object to be cut; in this case it is assumed that a thick cable of generally cylindrical configuration is to be severed, and the concave holding portion 28 is substantially semicircular in form. Holding lever member 12 is made up of two identical hook-shaped cheek plates 29, 29a, laterally aligned with each other and spaced apart to receive the blade portion 20 closely and supportively between them.
Pivotally mounted on holding lever member 12 on the opposite side of main pivot 14 from the holding portion 28 is a ratchetting lever member 30, having a handle portion 32 at its outer end; its other end is pivotally mounted to holding lever member 12 by pivot means in the form of sprocket pin 34, which also serves other functions described hereinafter. Ratchetting lever member 30 is angularly movable within a limited angular range about the axis of pivot 34, which axis is parallel to the axis of main pivot 14; the limits of this permitted range of pivotting of the ratchet lever member are defined by stop means acting between the ratchet lever member and the holding lever member, as described later. It is noted that the ratchetting lever member 30 is bifurcated at the end thereof adjacent pivot 34 to provide two spaced-apart parallel plate members 40 and 42, through both of which sprocket pin 34 passes. The ratchet plate members 40 and 42 are spaced sufficiently far apart to receive between them the cheek plates 29 and 29a, which in turn are spaced sufficiently far apart to receive and provide a close guiding and supporting function for the blade portion 20 of cutting lever member 10. More particularly, the radially outward portion 50 of blade portion 20 is provi ded with a material thickness such as to fit closely between the cheek plates 29 and 29a thus providing the guiding and reinforcing action at least during the latter portion of the cutting operation.
FIG. 4 illustrates how the outer portion 50 of blade portion 20 is sheathed between the cheek plates 29 and 29a in close guiding and supporting relation thereto, to provide the desired reinforcement and stiffening of the blade portion. Also shown in FIG. 4 is a spacer 51 positioned between the cheek plates, and a bolt 52 and nut 54 which extend through the cheek plates and the spacer 51 to clamp the cheek plates in the desired spaced-apart relation. A suitable carrier clip 56 is also held under the head of bolt 52 to permit convenient carrying of the entire tool by clipping it to the belt of the user, and also permitting it to be hoisted by a suitable cord to any desired working location. A similar bolt 52a, nut 54a and spacer 51a are provided near the tip of the hooked blade portion to assist in maintaining the desired spacing between the cheek plates 29 and 29a.
FIG. 5 shows how the blade portion 20 and the cheek plates 29 and 29a may be mounted on main pivot 14 by the use of a screw 58, threaded into the shank end of the headed pivot 14, together with an appropriate washer 60 under the head of screw 58.
There will now be described apparatus in accordance with the invention by means of which the blade portion 20 may be opened from the concave holding portion 28 by a separating motion of handle portions 18 and 32 with respect to each other when it is desired to receive a cable or other object to be cut in the concave holding portion 28, and by means of which the blade portion 20 and cutting edge 26 may then be advanced toward the holding portion 28 to accomplish cutting of the cable or other object by closing motion of handle portions 18 and 32 toward each other.
A drive sprocket means in the form of a sprocket wheel 62 is rotatably and coaxially mounted on sprocket pin 34 so that the teeth of the sprocket wheel mesh with the teeth of main gear means 64, which is integral with the blade portion 20 of the cutting lever member 10; the teeth of gear means 64 form a gear segment extending along a circular path coaxial with main pivot 14, and in this example are formed in the outer peripheral edge or rim of blade portion 20. The sprocket wheel teeth are engageable by a controllable pawl means comprising a pawl 68 which is controllable to engage with, or disengage from, the sprocket teeth as a function of the angular position of ratchetting lever member 30 with respect to holding lever member 12.
More particularly, in this example the pawl 68 is pivotally mounted on ratchetting lever member 30 by means of pawl pivot 70, to provide pivotting of the pawl 68 about an axis parallel to that of the sprocket pin 34. Pawl 68 is angularly biased toward its engaged position by a pawl tension spring 80, and a pawl stop pin 82 is provided on ratchetting lever member 30 to arrest clockwise motion of the pawl in the tooth-engaging position shown in FIG. 1. When pawl 68 is in its tooth-engaging position, its orientation and shape prevent the drive sprocket wheel 62 from rotating in one angular sense with respect to the ratchetting lever member 30, namely in the counterclockwise direction in FIG. 1; however, pawl 68 in its engaged position permits sprocket wheel 62 to turn in the opposite sense relative to ratchetting lever member 30, namely the clockwise direction as viewed in FIG. 1, the pawl then merely sliding over the successive teeth of the sprocket wheel.
Accordingly, within a predetermined range of angular motion of ratchetting lever member 30 about sprocket pin 34 in the closing or clockwise direction as viewed in FIG. 1, sprocket wheel 62 is locked to ratchetting lever member 30 during such turning and will therefore itself rotate in the clockwise direction and thereby, through its engagement with the teeth of gear segment 64, drive the blade portion 20 of the cutting lever member 10 in the counterclockwise direction, i.e. the closing direction which effects cutting. Also, since pawl 68 does not prevent rotation of the ratchetting lever member 30 in the counterclockwise direction with respect to sprocket wheel 62, the ratchetting lever member 30 may be moved in angular reciprocation, driving the blade portion 20 further toward its closed position with each closing stroke of the ratchetting lever member.
As shown in FIG. 1, the tool is in its maximally closed position, defined by a stop member 88 mounted on blade portion 20 and acting against an edge of the holding lever member 12 to arrest further motion in the closing direction. To open the tool for receiving a cable to be cut, the handles 32 and 18 are moved apart, whereupon, over a predetermined angular range of motion, pawl 68 slides over the teeth of sprocket wheel 62 in the counterclockwise direction, which it can do since this corresponds to the permitted clockwise direction of relative motion of the sprocket wheel with respect to the ratchetting lever member 30. This opening motion of the handles continues without corresponding opening motion of the blade portion 20 from the holding portion 28, until the upper surface of ratchetting lever member 30 has pivotted into engagement with stop member 90 on holding lever member 12, a position which is shown in solid line in FIG. 9. The stop member 90 prevents ratchetting lever member 30 from turning further in the opening direction with respect to holding lever member 12, and in effect locks the latter two members together for further outward angular motion of the ratchetting lever member. Such further outward angular motion therefore tends to open the blade portion 20 from the holding portion 12 directly and rapidly.
However, if at this point pawl 68 were still in its engaged position as shown in FIG. 1, such further opening motion of ratchetting lever member 30 would not be possible, since it would require a counterclockwise rotation of the sprocket wheel 62 with respect to the ratchetting lever member 30, a direction of rotation which pawl 68 does not permit. Accordingly, means are provided for automatically moving pawl 68 out of engagement with the teeth of sprocket wheel 62 prior to the limiting of the opening motion of ratchetting lever member 30 by stop 90.
The pawl release means in this example comprises the pawl release pin 93 on holding lever member 12, extending between the parallel cheek plates 29 and 29a of the holding lever member. Pawl 68 is also mounted between the cheek plates 29 and 29a, and in fact between the plates 40 and 42 of the bifurcated portion of the ratchetting lever member 30, in a position such that, as shown particularly clearly in FIG. 9, pawl release pin 93 contacts pawl 68 on the opposite side of pawl pivot 70 from the point at which the pawl-restraining spring 80 is secured, thereby causing pawl 68 to rotate in the counterclockwise direction as viewed in FIGS. 1 and 9, out of engagement with the teeth of sprocket wheel 62, just prior to the point at which the ratchetting lever member 30 strikes against stop 90. With the pawl 68 thus moved to its disengaged position, continued outward angular motion of the ratchetting lever member 30 is able to act directly on holding lever member 12 and rotate it rapidly in its opening direction, for example to the wide-open position shown in full line in FIG. 10 and determined by stop 88. As also shown in FIG. 10, at this point of full opening the cable 95 may be inserted in the concave nesting portion of the holding lever member 12, where it is held during the cutting operation.
FIG. 11 shows the tool in a position in which the ratchetting lever member 30 has been moved in the closing direction sufficiently for the cable to be clamped between the cutting edge 26 and the holding portion 28, and cutting action is about to begin. In the course of this closing motion of the ratchetting handle 32, the initial closing motion permits the pawl 68 to pivot to its tooth-engaging position under the influence of spring 80. Further closing motion of the ratchetting handle drives sprocket wheel 62 in the direction to close the tool jaws somewhat, and if the original spacing between cable and jaws were small enough, clamping of the cable between the jaws could be effected during this motion; in such event, cutting could then be initiated and brought to completion by pumping the ratchet handle back and forth between its stops. However, this is generally not the case, especially in the preferred embodiment using the hook-shaped holding lever member; as can readily be seen from FIG. 11, in order for the jaws to be initially moved transversely into position about the cable, they must be opened far enough to permit passage of the cable between the outer tips of the opposed jaws, which means that when the cable is thereafter seated in the concave nesting area of the holding lever member it will be substantially spaced from the cutting edge. Accordingly, the jaws cannot in general be closed to the cable-clamping position of FIG. 11 merely by a single stroke of the ratchetting handle 32 within its ratchetting angular range. Instead, a plurality of such ratchetting strokes would be required merely to reach the cable-clamping position. In this connection it will be noted that rotation of the ratchetting lever member can only effect a partial revolution of the sprocket wheel and a correspondingly relatively small amount of closing of the blade portion to the holding portion.
Accordingly, means are also provided for limiting the closing or clockwise angular motion of the ratchetting lever member 30 with respect to the holding lever member 12, so that during further closing motion of the ratchetting lever member it is, in effect, angularly locked with respect to the holding lever member and directly drives it further in the closing direction. During such motion, the teeth on the gear segment 64 of the cutting lever member drive the sprocket wheel 62 in the clockwise direction, a direction which is permitted by pawl 68, which merely slides over the teeth during such motion.
In this example, the limiting of the closing motion of the ratchetting lever member with respect to the holding lever member is again provided by the cooperation of the stop 90 with a portion of the upper surface of the ratchetting lever member. Such position is shown for example in FIG. 1. To enable use of the same stop member 90 to limit both the opening and closing motion of the ratchetting lever with respect to the holding lever member, the latter member is provided with the obtuse notch 98 positioned so that one side of the notch strikes the stop member in the maximum closed position of the ratchetting lever member with respect to the holding lever member, and the opposite side of the notch strikes the same stop member in the maximum open position of the ratchetting lever member. Any of a number of other stop arrangements may be used instead for this purpose.
With the apparatus described, instead of requiring repeated ratchetting motion to achieve clamping, one need merely urge the ratchetting handle in one continuous closing stroke through the ratchetting angular range and against the stop 90 to close the jaws onto the cable; because the latter part of this closing stroke is effected by direct drive of the holding lever member by way of stop 90, and therefore without the mechanical advantage of the sprocket wheel and gear segment arrangement, when the clamped condition is encountered a sudden high resistance to closing motion of the handles will be experienced by the user, and he will then know to proceed with the cutting by retracting the ratchet handle into the ratchetting angular range and pumping the handles within this range until cutting is completed.
FIG. 12 illustrates such ratchetting operation during cutting, the ratchetting lever member and pawl 68 being angularly reciprocated between the upper and lower broken-line positions shown to advance the sprocket wheel one tooth at a time in this example, although it may be driven several teeth at a time by moving the ratchetting handle further on its upward stroke. The full line representation shows the ratchetting handle in an intermediate position in which the pawl has engaged the sprocket wheel to force it in the closing direction in response to the downward stroke of the ratchetting handle.
It is noted that for small cables or other objects it may be possible to accomplish complete severing without using the ratchetting lever member in an angularly reciprocatory manner to produce actual ratchetting advance of the cutting edge. However, if cutting is effected by urging the ratchetting lever member against the limiting stop in the closing direction, the cutting action will have only the mechanical advantage provided by the ratio of the distance between the main pivot and the two handle portions to the distance between the main pivot and the object being cut; to obtain the maximum mechanical advantage of the arrangement, it is highly preferable to back off the ratchetting lever member in its opening direction until the pawl has passed over one or more teeth of the sprocket wheel and then urge the ratchetting lever member in the closing direction, so that the mechanical advantage due to the ratio of the radius of the main gear segment to the radius of the sprocket wheel is also realized. Where the thickness of the object being cut is relatively large, one such backing off and reclosing of the ratchetting lever to its maximum closed position will not result in moving the cutting edge entirely through the object, in which case repeated reciprocatory angular motion of the ratchetting lever member will enable the desired continuing, but intermittent, advance of the cutting edge through the object until it is completely severed.
In operation then, the tool may be maintained in its fully closed position as shown in FIG. 1 for storage and transportation purposes. To open it for receiving a cable to be cut, the ratchetting lever member is swung in its opening direction through a predetermined angular arc during which no opening motion of the tool jaws occurs, the pawl merely sliding over the teeth of the sprocket wheel during such motion; by the time the ratchetting lever member has reached its outward extreme angular position with respect to the holding lever member, as defined by the position of stop 90, the pawl 68 will have been forced out of engagement with the sprocket wheel by stop 93 as is illustrated in FIG. 9, for example. Continued opening motion of the ratchetting lever member will directly drive the holding lever member so as to open the jaws of the tool rapidly to the wide-open position for receiving the object to be cut, as illustrated in FIG. 10; after this, the ratchetting lever member is rotated clockwise again toward its closed position, whereupon the pawl again engages the sprocket teeth to drive the jaws toward their closed position. Assuming that the jaws have been opened wider than necessary to accommodate the object to be cut, the ratchetting lever member is rotated further in its closing direction until it reaches its opposite extreme of motion with respect to the holding lever member as also defined by the position of stop 90, and the closing motion is continued further to drive the jaws together until they clamp the object to be cut. After this, the ratchetting lever member is angularly reciprocated within the angular range of its permitted motion with respect to the holding lever members, to advance the cutting edge of the blade portion through the cable in intermittent steps, but with high mechanical advantage, until complete severing has been accomplished.
In a typical embodiment, the cutter of the invention may be 18 inches or even less in overall length yet still be effective to cut communications cable 2-1/2 inches in diameter when manually operated as described above.
While the invention has been described with particular reference to specific embodiments thereof in the interest of complete definiteness, it will be understood that it may be embodied in a variety of forms diverse from those specifically shown and described, without departing from the spirit and scope of the invention as defined by the appended claims.