WO2026030701A1 - Roll groover and drive mechanism therefor - Google Patents

Abstract

A tool configured to form a groove in a pipe includes a housing including a battery receptacle configured to receive a battery, a motor having a motor shaft that is rotatable about a motor axis, a gear assembly operably coupled to the motor, the gear assembly having a plurality of spur gears operably coupled to the motor shaft and a planetary gear set operably coupled to the spur gears, a drive shaft operably coupled to the planetary gear set, the drive shaft configured to rotate about a drive axis that is offset the motor axis, and a die rotatably coupled to a die shaft about a die axis that is offset relative the drive axis, the die configured to form a groove into the pipe.

Description

ROLL GROOVER AND DRIVE MECHANISM THEREFOR

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims priority to U.S. Provisional Patent Application No. 63/678,351, filed August 1, 2024, to U.S. Provisional Patent Application No. 63/678,945, filed August 2, 2024, and to U.S. Provisional Patent Application No. 63/787,644, filed April 11, 2025, the entire contents of all of which are incorporated herein by reference.

FIELD

[0002] The present disclosure relates to roll groovers for forming grooves in pipes, and, more particularly, to powered roll groovers.

BACKGROUND

[0003] In the pipe fitting industry, different methods are used to join two separate pieces of piping together. In one example, ends of the pipes are threaded and a threaded adapter is used to join the pipes together. An alternative to a threaded connection is a grooved connection. Specifically, a pipe is cut to the desired length and a groove is rolled onto an end of the pipe. A grooved adapter is then used to join the pipe to another pipe.

SUMMARY

[0004] Grooved pipe connections are especially useful to join pipes carrying water and/or steam and to provide a water-tight seal between the pipes. A roll groover is used to produce a groove on the pipes. Roll groovers are typically mechanical devices that are placed on a pipe. A skilled user uses a crank mechanism to rotate the roll groover around the pipe to roll the groove onto the pipe. The crank mechanism involved manually rotating a crank by hand to rotate the roll groover.

[0005] Current roll groovers require skilled users to operate and take a large amount of time to complete one operation. Accordingly, there is a need for powered roll groovers that are simple to operate and reduce the operation time compared to current roll groovers. A need also exists for such powered roll groovers to be portable and readily transportable (e.g.. to a job site). [0006] In some aspects, the techniques described herein relate to a tool configured to form a groove in a pipe, the tool including: a housing including a battery receptacle configured to receive a battery; a motor having a motor shaft that is rotatable about a motor axis, a gear assembly operably coupled to the motor, the gear assembly having a plurality of spur gears operably coupled to the motor shaft and a planetary' gear set operably coupled to the spur gears, a drive shaft operably coupled to the planetary gear set, the drive shaft configured to rotate about a drive axis that is offset the motor axis; and a die rotatably coupled to a die shaft about a die axis that is offset relative the drive axis, the die configured to form a groove into the pipe.

[0007] In some aspects, the techniques described herein relate to a tool, wherein the motor is a first motor and the gear assembly is a first gear assembly, and wherein a second motor is configured to rotate an input shaft about an input shaft axis to rotate the die shaft and vary' a distance between the die axis and the drive axis.

[0008] In some aspects, the techniques described herein relate to a tool, further including a battery removably coupled to the housing, wherein the first motor and the second motor are powered by the battery.

[0009] In some aspects, the techniques described herein relate to a tool, wherein the battery is configured to be inserted within a battery receptacle along a battery' axis, and wherein the battery axis is perpendicular to the drive axis and the motor axis.

[0010] In some aspects, the techniques described herein relate to a tool, wherein the plurality of spur gears includes a first spur gear coupled to the motor shaft such that the first spur gear is rotatable about the motor axis, a second spur gear coupled to a support shaft offset the motor axis, the second spur gear is meshed with the first spur gear such that rotation of the first spur gear rotates the second spur gear about a support axis defined by the support shaft, and a third spur gear supported by a pinion on the planetary gear set, the third spur gear is meshed with the second spur gear such that rotation of the second spur gear rotates the third spur gear about the pinion.

[0011] In some aspects, the techniques described herein relate to a tool, wherein the motor axis is parallel to the drive axis. [0012] In some aspects, the techniques described herein relate to a tool, wherein the tool has a length defined between a rear surface of the tool and a distal end of the drive shaft, and wherein the length is in a range from 15 inches to 20 inches.

[0013] In some aspects, the techniques described herein relate to a tool, wherein the tool has a height that is defined between a top surface of the tool and a support surface of the tool, and wherein height is in a range from 9 inches to 11 inches.

[0014] In some aspects, the techniques described herein relate to a tool, wherein the housing defines a support surface that supports the tool relative to a surface, and wherein the support surface includes a foot portion that is overmolded onto the housing.

[0015] In some aspects, the techniques described herein relate to a tool, further including a mounting interface coupled to the support surface, and wherein the mounting interface is configured to engage a corresponding mounting interface formed on a storage unit.

[0016] In some aspects, the techniques described herein relate to a tool, wherein the mounting interface is removably coupled to the support surface.

[0017] In some aspects, the techniques described herein relate to a tool, further including a manual clamping mechanism having an adjustment mechanism operably coupled to the die shaft to allow a user to manually adjust a distance between the die axis and the drive axis.

[0018] In some aspects, the techniques described herein relate to a tool, further including a support arm coupled to the drive shaft, wherein the support arm has a first portion surrounding a portion of the drive shaft and a second portion engaging a portion of the housing.

[0019] In some aspects, the techniques described herein relate to a tool configured to form a groove in a pipe, the tool including: a housing; a drive shaft rotatable about a drive axis, the drive shaft having a body defining a distal end having a through-hole defined therein; a bolt coupled to the through-hole in the body of the drive shaft, the bolt configured to offset a bending load on the drive shaft when the pipe is supported on the drive shaft; a die shaft defining a die shaft axis; a die rotatably coupled to the die shaft about a die axis that is offset relative the die shaft axis, the die configured to form a groove into the pipe; and a drive assembly including a drive portion configured to rotate the drive shaft about the drive axis and thereby rotate the tool with respect to the pipe, and a die shaft drive portion configured to rotate the die shaft to vary a distance between the die axis and the drive axis.

[0020] In some aspects, the techniques described herein relate to a tool, wherein drive shaft has a first portion that meshes with the drive portion, a second portion with a greater diameter than the first portion, and a trough portion positioned between two axially offset circumferential peak portions.

[0021] In some aspects, the techniques described herein relate to a tool, w herein the drive shaft includes a second end that is opposite the distal end. the second end includes a pair of flat surfaces and a threaded connection, and the flat surfaces and the threaded connection couples the drive shaft to the drive portion.

[0022] In some aspects, the techniques described herein relate to a tool configured to form a groove in a pipe, the tool including: a housing having a front end. a rear end opposite the front end, and a first handle portion extending at least partially between the front end and the rear end; a second handle pivotably coupled to the housing at a position between the front end of the housing and the first handle; a drive shaft rotatable about a drive axis in a drive direction; a die shaft defining a die shaft axis; a die rotatably coupled to the die shaft about a die axis that is offset relative the die shaft axis, the die configured to form a groove into the pipe; and a drive assembly including a drive portion configured to rotate the drive shaft about the drive axis and thereby rotate the tool with respect to the pipe, and a die shaft drive portion configured to rotate the die shaft to vary a distance between the die axis and the drive axis.

[0023] In some aspects, the techniques described herein relate to a tool, wherein the second handle is pivotable between a closed position where the second handle is secured within a recess formed in the housing and an open position where the second handle extends outwardly from the housing.

[0024] In some aspects, the techniques described herein relate to a tool, wherein pivotable movement of the second handle from the open position to the closed position is the drive direction of the drive shaft.

[0025] In some aspects, the techniques described herein relate to a tool, further including a support arm coupled to the drive shaft, wherein the support arm has a first portion rotatably- supporting an end of the drive shaft and a second portion engaging a front end of the housing. [0026] Other aspects of the disclosure will become apparent by consideration of the detailed description and accompanying drawings.

BRIEF DESCRIPTION OF DRAWINGS

[0027] FIG. 1 is a perspective view of a roll groover, according to an embodiment of the present disclosure.

[0028] FIG. 2 is a side view of the roll groover of FIG. 1.

[0029] FIG. 3 is a perspective view of a mounting interface that may be coupled to the roll groover of FIG. 1.

[0030] FIG. 4 is a side view of the roll groover of FIG. 1 including the mounting interface of FIG. 3 attached to a corresponding mounting interface on a tool storage system.

[0031] FIG. 5 is a cross-sectional view of the roll groover of FIG. 1.

[0032] FIG. 6 is an enlarged portion of the cross-sectional view of FIG. 5, illustrating a drive mechanism of the roll groover of FIG. 1.

[0033] FIG. 7A is a side view of a drive shaft of the roll groover of FIG. 1.

[0034] FIG. 7B is a perspective view of another embodiment of a drive shaft that may be incorporated into the roll groover of FIG. 1.

[0035] FIG. 7C is a perspective view of another embodiment of a drive roller including a fastener that may be incorporated into the roll groover of FIG. 1.

[0036] FIG. 7D is another perspective view of the drive roller of FIG. 7C, with the fastener removed.

[0037] FIG. 8 is a perspective view of the roll groover of FIG. 1 , clamped on to an exemplary pipe.

[0038] FIG. 9 is a cross-sectional view of the roll groover of FIG. 1, taken along line 9 — 9 in FIG. 2. [0039] FIG. 10 is a partially exploded view of a portion of the roll groover of FIG. 1. illustrating a manual clamping release mechanism.

[0040] FIG. 11 is a perspective view of the roll groover of FIG. 1, illustrating a front handle of the roll groover in an open position.

[0041] FIG. 12 is a front view of the roll groover of FIG. 1.

[0042] Before any embodiments of the disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

DETAILED DESCRIPTION

[0043] FIG. 1 illustrates a power tool in the form of a roll grooving tool or roll groover 110 that is operable to form a groove (e.g., by deforming, cold working, bending, etc.) in a workpiece, such as a pipe. The roll groover 110 may be used to form grooves in pipes made of a variety of different materials, including but not limited to carbon steel and stainless steel.

[0044] The illustrated roll groover 110 includes a housing 114 with a first motor housing portion 118, a second motor housing portion 120 coupled to the first motor housing portion 118 (e.g.. by a plurality of fasteners), a front housing portion 122 coupled to the first motor housing portion 118 and/or second motor housing portion 120, and a handle portion or first handle 126 extending from the first motor housing portion 118 in a direction generally parallel to the second motor housing portion 120. In the illustrated embodiment, the handle portion 126 and the first motor housing portion 118 are defined by cooperating clamshell halves. Further, the housing includes a front end 123, a rear end 125, and a body extending between the front and rear ends 123, 125. The handle portion 126 extends at least partially between the front and rear ends 123, 125. Other embodiments of the roll groover 1 10 may include multiple handles positioned at different locations of the housing 114 or other housing arrangements. In the illustrated embodiment, the housing 114 further includes a die guard housing portion 130 extending forwardly from the front housing portion 122. [0045] In the illustrated embodiment, the front housing portion 122 includes a removable wear plate defining the front end

[0046] Referring still to FIG. 1, the roll groover 110 includes a battery pack 134 removably coupled to a battery receptacle 138 located at a rear or bottom portion of the housing 114. In some embodiments, the battery receptacle 138 is located at a rear end of the handle portion 126. The roll groover 1 10 further includes a support surface 140 that supports the roll groover 110 relative to a surface. In the illustrated embodiment, the support surface 140 includes a foot portion 136 that is overmolded onto the housing 114 and a mounting interface 144 that is removably coupled to the support surface 140 opposite the foot portion 136. In other words, the foot portion 136 is positioned at a rear end of the roll groover 110 (e.g., proximate the batten- receptacle 138) and the mounting interface 144 is positioned at a front end of the roll groover 110 (e.g., proximate the front housing portion 122).

[0047] Now with reference to FIGS. 2, 3, and 4, the mounting interface 142 (FIG. 3) may selectively engage with a corresponding mounting interface 144 (FIG. 4). In the illustrated embodiment, the corresponding mounting interface 144 is formed on a storage unit 146. For example, the storage unit 146 may be part of Milwaukee Electric Tool Company’s PACKOUT™ modular storage system. In such embodiments, the mounting interface 142 on the roll groover 110 includes one or more cleats, and the mounting interface 144 on the storage unit 146 includes one or more pockets that receive the cleats to removably couple the roll groover 110 to the storage unit 146. In other embodiments, the roll groover 110 may be coupled to any type of wall mount, dolly, or toolbox used to hold objects.

[0048] The illustrated storage unit 146 includes a storage base 150 coupled to a lid 154 via hinges (not shown). The lid 154 includes a plurality of corresponding mounting interfaces 144 that each define a pocket sized to receive the cleat defined by the mounting interface 142. In the illustrated embodiment, the mounting interface 142 includes a plurality of apertures 158 sized to receive fasteners (not shown) to selectively couple the mounting interface 142 to the support surface 140 of the roll groover 110. In other embodiments, the mounting interface 142 may be integrally formed with the housing 114 of the roll groover 110. The mounting interface 142 may allow an operator to use the storage unit 146 as a mobile grooving station or may be used to transport the roll groover 110. In other embodiments, the mounting interface 142 may be formed as a cradle. In such an embodiment, the roll groover 110 may be tilted at an angle or rotated relative to the storage unit 146. [0049] With references to FIGS. 5 and 6, a first electric motor 162 supported within the first motor housing portion 118 and a second electric motor 166 supported within the second motor housing portion 120 each receive power from the battery pack 134 (FIG. 1) via the battery receptacle 138 when the battery pack 134 is coupled to the battery receptacle 138. In the illustrated embodiment, the battery pack 134 is inserted within the battery receptacle 138 along a battery axis 168 (FIG. 5). In other embodiments, the first motor 162 may receive power from a first battery and the second motor 166 may receive power from a second battery. Alternatively, the motors 162, 166 may draw power from multiple batteries wired in series or in parallel. In the illustrated embodiment, the motors 162, 166 are brushless direct current (“BLDC’) motors. In other embodiments, other ty pes of motors may be used (e.g., digital motors, stepper motors, servo motors, brushed motors).

[0050] The first motor 162 is operably coupled to a first drive assembly 170 via a first gear assembly 174 such that the first drive assembly 170 rotates about a drive axis 176. The first motor 162 includes an output rotor or shaft 178. The shaft 178 of the first motor 162 is rotatable about a motor axis 182. The second motor 166 includes an output rotor or shaft 186 (FIG. 9). The shaft 186 of the second motor 166 is rotatable about a drive axis (also referred to herein as an input drive axis) 190. As illustrated in FIG. 9, the roll groover 110 also includes a second gear assembly 194 coupled to the second motor output shaft 186 and a second drive assembly 198 coupled to an output of the second gear assembly 194. The second gear assembly 194 and the second motor shaft 186 are both rotatable about the input drive axis 190. The second gear assembly 194 is at least partially housed within a gear case 202 that may form a portion of the housing 14. Each of the motors 162, 166 may also include a fan coupled to the rotor (e.g., via a splined member fixed to the rotor) to provide cooling air to the motors 162, 166.

[0051] Now with reference to FIGS. 5 and 6, the first gear assembly 174 may be configured in any of a number of different ways to provide a speed reduction between the output shaft 178 and an input of the drive assembly 170. In the illustrated embodiment, the first gear assembly 174 includes a plurality of spur gears 206, 210, 214 and a planetary' gear set 218. The combination of the spur gears 206, 210, 214 and the planetary gear set 218 orientates the motor axis 182 parallel to the drive axis 176. Further, the battery axis 168 is perpendicular to the drive axis 176 and the motor axis 182. In the illustrated embodiment, a first spur gear 206 is coupled to the shaft 178 such that the first spur gear 206 is rotatable about the motor axis 182. The second spur gear 210 is coupled to a support shaft 220 offset the motor axis 182. The second spur gear 210 is meshed with the first spur gear 206. The rotation of the first spur gear 206 rotates the second spur gear 210 about a support axis 224 defined by the support shaft 220. A third spur gear 214 is supported by a pinion 228 on the planetary gear set 218, which is offset the support axis 224. The third spur gear 214 is meshed with the second spur gear 210 such that rotation of the second spur gear 210 rotates the third spur gear 214 about the pinion. In the illustrated embodiment, the planetary gear set 218 is a multi-stage planetary transmission driven by the pinion 228 supporting the third spur gear 214.

[0052] For example, the planetary gear set 216 may include a plurality of planet gears and a ring gear meshed with each of the planet gears and rotationally fixed within a gear case. A last stage carrier (i.e. an output) of the transmission is fixed to a drive shaft 232 of the drive assembly 170 such that the drive shaft 232 is rotatably driven by the motor output shaft 178 through the transmission. That is, rotation of the output shaft 178 rotates the first spur gear 206, which rotates the second and third spur gears 210, 214. Rotation of the third spur gear 214 rotates the planetary gear set 218 which rotates the drive shaft 232 at a reduced rate of speed and increased torque. The planetary gear set 218 could alternatively be bevel gears and/or offset along the drive shaft 232 (e.g., in different planes). In other embodiments, face gearing and cycloidal gears may be utilized in either gear assembly 174, 194.

[0053] It should be appreciated that the combination of the first motor 162, the first gear assembly 174 defines a drive portion of the tool 110. In other embodiments, the tool 110 may have an alternative drive portion (e.g.. a handheld crank, a direct input motor, or the like).

[0054] The construction of the first gear assembly 174 reduces the overall footprint of the roll groover 110. In the illustrated embodiment, the roll groover 110 has a first length LI defined between a rear surface 222 of the roll groover 110 and the front housing portion 122. A second length L2 is defined between the front housing portion 122 and a distal end 226 of the first drive assembly 170. A third length L3 is defined between the rear surface 22 of the roll groover 110 and the distal end 226 of the first drive assembly 170. A height H is defined between a top surface 230 of the roll groover 110 and the support surface 140. Further, a width W (FIG. 1) is defined between side surfaces of the roll groover 1 10. The first length LI is in a range from 11 inches to 17 inches. The second length L2 is in a range from 2 inches to 5 inches. The third length L3 is in a range from 15 inches to 20 inches. The height H is in a range from 9 inches to 11 inches. The width W is in a range from 7 inches to 9 inches. In the illustrated embodiment, the first length LI is 17 inches, the second length L2 is 2 inches, the third length L3 is 19 inches, the height H is 10.5 inches, and the width W is 8.5 inches.

[0055] The roll groover 10 also includes a user interface 234 (FIGS. 1 and 4) supported by the housing 114. The user interface 234 includes a plurality of switches (e.g., a pushbutton switch, dials, or the like) supported by the housing 1 14 for operating each of the motors 162, 166 (e.g., via suitable control circuitry provided on one or more printed circuit board assemblies (“PCBAs”) 238 (FIG. 5) that control power supply and command of the motors 162, 166. In other embodiments, the roll groover 110 may include a power cord for connecting to a source of AC power such as a wall outlet or generator. As a further alternative, the roll groover 110 may be configured to operate using a non-electrical power source (e.g., a pneumatic or hydraulic power source, etc.). In some embodiments, the switching electronics (e.g.. MOSFETs, IGBTs, or the like) for controlling power supplied to each of the motors 162, 166 from the batten’ pack 134 are provided together on the PCBA 238. In other words, the PCBA 238 is a common circuit board for controlling power supply and operation of the two motors 162, 166.

[0056] The battery pack 134 may be a power tool battery pack 134 generally used to power a power tool, such as a roll groover, an electric drill, an electric saw, and the like (e.g., an 18 volt rechargeable battery pack, or an Ml 8 REDLITHIUM™ battery pack sold by Milwaukee Electric Tool Corporation). The battery pack 134 may include lithium ion (Li- ion) cells. In alternate embodiments, the battery’ packs may be of a different chemistry (e.g., nickel-cadmium (NiCa or NiCad). nickel -hydride, and the like). In the illustrated embodiments, the battery pack 34 is an 18-volt battery pack. In alternate embodiments, the capacity of the battery pack may vary’ (e.g., the battery’ pack may be a 28-volt battery’ pack, a 80-volt battery pack, or battery' pack of any other voltage).

[0057] Referring now particularly to FIGS. 6, 7A-7C and 8, the drive shaft 232 extends from the front housing portion 122 to engage and support the pipe 246 (FIG. 8) (which may include supporting the groover 110 on the pipe 246 in some embodiments if the pipe 246 is fixed), and the drive shaft 232 is rotatable about the drive axis 176. In the embodiment illustrated in FIG. 7A, the drive shaft 232 is formed as a single piece. The drive shaft 232 includes a first portion 250 that meshes with the planetary’ gear set 218 (FIG. 6) and a second portion 254 with a greater diameter than the first portion 250. The second portion 254 includes a stop surface 256 that engages the housing 114 to restrict axial movement of the drive shaft 232. Further, the second portion 254 is rotatably supported within the second motor housing portion 120 by a bearing 258. The drive shaft 232 includes a circumferential groove or trough portion 262 positioned between two axially offset circumferential peak portions 266. In other embodiments, the drive shaft 232 may include multiple troughs and multiple peaks corresponding to the multiple troughs. As will be described in greater detail below, the peaks 266 and trough portion 262 are shaped and positioned as a template for forming a groove in the pipe 246. Stated another way, the peaks 266 and the trough portion 262 act as a female die to receive displaced material during a grooving operation.

[0058] Now with reference to FIGS. 7B-7D, drive shafts 232', 232" are illustrated. It should be appreciated that any of the drive shafts 232, 232', 232" may be used with the roll groover 110. That is, the roll groover 110 may include any one of the drive shafts 232, 232', 232". The drive shafts 232', 232" are similar to the drive shaft 232 illustrated in FIG. 7A. As such, like components are numbered with the same reference number appended with ' or ".

[0059] The illustrated drive shaft 232' is formed as a single piece and includes a first portion 250' that meshes with the planetary gear set 218 (FIG. 6) and a second portion 254' with a greater diameter than the first portion 250'. The second portion 254' is rotatably supported within the second motor housing portion 120 by the bearing 258. The drive shaft 232' includes a circumferential groove or trough portion 262' positioned between two axially offset circumferential peak portions 266'. In the illustrated embodiment, the drive shaft 232' includes a tapered portion 270 that extends from the second portion 254’ to peak portion 266'. The tapered portion 270 has a radius of curvature of in a range from 0.3 inches to 0.4 inches (or 7.6 millimeters to 10.2 millimeters). The radius of curvature increases the strength of the drive shaft 232' by reducing the stress to the tapered portion when a pipe 246 is supported. In the illustrated embodiment, the circumferential peak portions 266' have a diameter of less than 30 millimeter (mm) while the tapered portion 270 increases to a diameter in a range from 40 mm to 50 mm. The combination of the circumferential peak portions 266' and the tapered portion defines a bearing surface of the drive shaft 232'.

[0060] Now with reference to FIGS. 7C and 7D, the drive shaft 232" includes body portion having a first portion 250" that meshes with the planetary gear set 218 (FIG. 6) and a second portion 254" with a greater diameter than the first portion 250". The drive shaft 232" also includes a circumferential groove or trough portion 262" positioned between two axially offset circumferential peak portions 266". In the illustrated embodiment, the peak portions 266" have a knurled outer surface. Further, the distal end 226" of the drive shaft 232" proximate the peak portions 266" includes a through-hole defined therein. The through-hole is sized to receive a bolt 274 therein. When the bolt 274 is torqued within the through-hole, the bolt 274 provides a pre-load that increases the stiffness of the drive shaft 232". In the illustrated embodiment, the bolt 274 increases the stiffness of the drive shaft 232" by approximately 20 percent compared, for example, to the drive shaft 232. A second end of the drive shaft 232", which is opposite the distal end 226", includes a pair of flat surfaces 280 and a threaded connection 282 the combination of the flat surfaces 280 and the threaded connection 282 couples the drive shaft 232" to the planetary gear set 218.

[0061] Now with reference to FIGS. 6 and 9, the second drive assembly 198 supports a die shaft 284 that defines a major die shaft axis 288. The die shaft 284 is further supported by the housing 114 in an orientation generally transverse to the input drive axis 190. The die shaft 284 includes an input portion 292 having an input axis 296 colinear with the die shaft axis 288, an output portion 300 having an output axis 304 offset relative the input axis 296, and a stem portion 308 centered about the die shaft axis 288. In the illustrated embodiment, the input portion 292 has a first diameter, the output portion 300 has a second diameter, and the stem portion 308 has a third diameter. The first and third diameters may be less than the second diameter. In other embodiments, portions of the die shaft 284 may have different diameters.

[0062] Referring now to FIGS. 6 and 9, the output portion 300 of the die shaft 284 supports a grooving member or die 312 (FIG. 6) that is engageable with the pipe 246 (FIG. 8) to form the groove in the pipe 246. More particularly, the die 312 includes, as illustrated in FIGS. 6, a die peak 316 that is complementary' to the trough portion 262 of the drive shaft 232. The die peak 316 is shaped to be pressed against the pipe 246 (FIG. 8) to deform a portion of the pipe 246 into the trough portion 262 of the drive shaft 232. Similarly, the die 312 includes troughs that are complementary to the peaks 266 of the drive shaft 232. The die troughs may engage an outer periphery of the pipe 246 on either side of the groove formed by the die peak 316 during a grooving process once the groove is fully formed. In the illustrated embodiment, the die 312 is rotatably mounted on the die shaft 284 via a bearing such that the die 312 is free to rotate against the pipe 246 during a grooving operation. The die guard housing portion 130 (FIG. 11) is provided on the housing 14 to inhibit a user from inadvertently contacting the die 312. as the die may be sharp or covered with grooving residue (e.g., sharp metal shavings, lubricant, or the like).

[0063] As illustrated in FIG. 9, the second drive assembly 198 is positioned in the housing 114 and includes a worm gear 320 supported on a distal end of the second motor 166 output shaft 186. In the illustrated embodiment, the worm gear 320 is rigidly supported by the shaft 186 for co-rotation therewith such that rotation of the second motor 166 imparts rotation to the worm gear 320. The worm gear 320 includes an elongated helical tooth or ramp that is positioned around the output shaft 186 to mesh with a gear 324, which may be any type of gear suitable for meshing with the worm gear 320, and which is rigidly attached to the input portion 292 (FIG. 6) of the die shaft 284. The gear 324 may have helical threads, which may help reduce noise (e.g., operating noise) within the tool 110. In the illustrated embodiment, the gear 324 includes gear teeth radially spaced around an entire circumference of the gear 324. In other embodiments, the gear 324 may include gear teeth that only extend around a portion of a circumference of the gear 324, such as 270 degrees around the gear 324. In such embodiments, a portion of the gear 324 that does not include gear teeth could be utilized as a stop portion, a free-rotation portion, or the like.

[0064] During a tooling/die engagement operation in which the die 312 is moveable relative the pipe 246, the second motor 166 rotates the worm gear 320 to thereby impart rotation to the gear 324, which in turn rotates the die shaft 284 and die 314 between a first position in which the die 312 is distanced from the pipe 246 and a second position in which the die 312 engages the pipe 246 to form the groove. In contrast to typical tooling/die engagement mechanisms, the tooling/die engagement operation of the present disclosure utilizes rotation of a motor (e g., second motor 166) separate from a drive motor (e.g., first motor 162) to vary a spacing between the die/output axis 304 and the pipe 246 and drive axis 176. Because the output axis 304 is eccentric (i.e. offset) relative the die shaft axis 288, rotation of the die shaft 284 varies a spacing between the drive axis 176 and die output axis 304.

[0065] Once the second motor 166 has been actuated/energized a sufficient amount to contact the die 312 to the pipe 246, a user may energize the first motor 162 to rotate the drive shaft 232 via the drive assembly 170. Once the drive shaft 232 begins to rotate, a user may release the tool 110 to rotate about the pipe 246 as the groove is being formed. Stated another way, once the grooving process begins, a user may release the tool 110 and allow the tool 110 to walk around an outer surface of the pipe 246 to form the groove therein. In other embodiments, a user maintains hold of the tool such that the pipe 246 rotates relative the tool 110. The second motor 166 may continue to be energized during the grooving process to maintain the die 312 against the pipe 246 and/or drive the die 312 further into the pipe 246 to create a groove with a desired depth.

[0066] During a groove forming operation, a significant amount of resistance or push- back force may be generated by the pipe 246 and imparted on the die 312 in a radially- outward direction as the tool 110 rotates relative to the pipe 246. Such push-back may cause typical tooling dies to back-off the pipe 12. In the illustrated embodiment, the second motor 166 and second gear assembly 194 are operable to output a maximum radial force of 340,000 Newtons (N) to the pipe 246 via the die 312. The second gear assembly 194 also resists a push-back force of at least 340,000 N due to the large back-drive torque reduction provided by the worm gear 320.

[0067] In some embodiments, the roll groover 110 is configured to output a maximum grooving torque on the pipe of 850 Nm to the pipe 246. In some embodiments, the roll groover 110 is configured to provide a nominal torque output to the shaft of 120 Nm. In some embodiments, the roll groover is configured to output 400 Nm and a nominal torque of 70 Nm. While the preferred embodiment of the roll groover 10 is configured to form the groove in an outer surface/wall of the pipe 12, other arrangements of the roll groover 10 for forming a groove in another part of the pipe (e.g., inner surface) are contemplated.

[0068] Referring now to FIGS. 9 and 10, the roll groover 110 includes a manual clamping mechanism 330. In the illustrated embodiment, the manual clamping mechanism 330 includes a cover 334 and an adjustment mechanism 338 secured within the second motor housing portion 120. The adjustment mechanism 338 is operably coupled to the second drive assembly 198 to allow a user to adjust the position of the die 312 manually (e.g.. without the use of the second motor 166). In other words, the user can manually adjust the distance between the die shaft axis 288 and the drive axis 176. For example, the adjustment mechanism 338 is operably coupled to the worm gear 320 such that the user is able to rotate the worm gear 320 clockwise or counter-clockwise to drive the gear 324. In operation, the manual clamping mechanism 330 may be used to rotate the worm gear 320 to thereby impart rotation to the gear 324, which in turn rotates the die shaft 284 and die 314. The manual clamping mechanism 330 may be used to remove the roll groover 110 from the pipe 246 or tighten the die 312 so it engages the pipe 246. In the illustrated embodiment, the adjustment mechanism 338 is a hexagonal recess formed in the shaft 186 of the second motor 166. The user may include a hexagonal wrench to rotate the output shaft 186 via the manual clamping mechanism 330. In other embodiments, the manual clamping mechanism 330 may be a tool- free adjustment mechanism (e.g., a dial or the like) that the user may adjust.

[0069] Now with reference to FIGS. 2 and 11, the roll groover 110 includes a second or front handle 342 pivotably coupled to the housing 114. In the illustrated embodiment, the handle 342 is coupled to the housing 114 at a position between the front end 123 and the first handle 126. The front handle 342 is pivotable between a closed position (FIG. 2) where the front handle 342 is secured within a recess 346 formed in the housing 114 and an open position (FIG. 11) where the handle 342 extends outwardly from the housing 1 14. In the illustrated embodiment, the handle 342 includes a locking mechanism (e.g., a ball detent mechanism) that is configured to secure the handle in the open or closed position. When the locking mechanism is overcome, the handle 342 may pivot between the open and closed positions. Further, the handle 342 is configured to collapse in a direction the roll groover 1 10 rotates such that handle 342. In other words, the movement of the handle 342 from the open position to the closed position is the same as a drive direction of the drive shaft 232 and the roll groover 110. For example, the roll groover 110 may rotate in a counter-clockwise direction about the drive axis 176. Therefore, if the handle 342 is in the open position and contacts an object, the object would contact a rear surface of the handle 342 to move the handle 342 towards the closed position. In other words, the pivotable movement handle from the open to closed position is in the drive direction of the roll groover.

[0070] Now with reference to FIGS. 11-12, the roll groover 110 further includes a support arm 350, which in some embodiments is removably coupled to the drive shaft 232. The support arm 350 includes a first portion 354 that engages and surrounds a front end portion of the drive shaft 232 and a second portion or foot 358 that engages the front housing portion 122, such that the drive shaft 232 is supported in double shear. The first portion 354 of the support arm 350 may include a bushing or bearing that surrounds and rotationally supports the drive shaft 232. The support arm 350 thus provides additional support to the drive shaft 232 to increase the stiffness of the shaft 232. which may be advantageous for grooving larger pipes and also improve the overall life of the drive shaft 232. In some embodiments, with the support arm 350 coupled to the drive shaft 232, the roll groover 110 may accommodate larger diameter pipes and apply a greater pressure than when the support arm 350 is not present. In addition, when the support arm 350 is removed, smaller pipes maybe accommodated, since the support arm 350 otherwise requires additional clearance within the pipe.

[0071] The foot 358 of the support arm 350 may be connected to the front housing portion 122 in various ways. For example, in the illustrated embodiment, the foot 358 of the support arm 350 is connected to the front housing portion 122 by one or more fasteners (e.g., screws), which, in some embodiments, may pass through the wear plate. The foot 358 may be removably coupled to the front housing portion 122, such as by removing the fasteners.

[0072] In some embodiments, the roll groover 110 may accommodate pipes 246 from 1.25 inches to 6 inches. In some embodiments (e.g., with the support arm 350 in place), the roll groover 110 is capable of grooving Schedule 40 pipe with diameters between 2 inches and 6 inches. In some embodiments, (e.g., with the support arm 350 in place), the roll groover 110 is capable of grooving Schedule 10 pipe with diameters between 2 inches and 6 inches. In some embodiments (e.g., with the support arm 350 removed), the roll groover 110 is capable of grooving Schedule 40 pipe with diameters between 1.25 inches and 4 inches. In some embodiments (e.g., with the support arm 350 removed), the roll groover 110 is capable of grooving Schedule 10 pipe with diameters between 1.25 inches and 6 inches.

[0073] Although the disclosure has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects of the disclosure as described.

REPRESENTATIVE FEATURES

[0074] Representative features are set out in the following clauses, which stand alone or may be combined, in any combination, with one or more features disclosed in the text and/or drawings of the specification.

[0075] Clause 1. A tool configured to form a groove in a pipe, the tool comprising: a housing including a battery receptacle configured to receive a battery: a motor having a motor shaft that is rotatable about a motor axis, a gear assembly operably coupled to the motor, the gear assembly having a plurality of spur gears operably coupled to the motor shaft and a planetary gear set operably coupled to the spur gears, a drive shaft operably coupled to the planetary gear set, the drive shaft configured to rotate about a drive axis that is offset the motor axis; and a die rotatably coupled to a die shaft about a die axis that is offset relative the drive axis, the die configured to form a groove into the pipe.

[0076] Clause 2. The tool of clause 1, wherein the motor is a first motor and the gear assembly is a first gear assembly, and wherein a second motor is configured to rotate an input shaft about an input shaft axis to rotate the die shaft and vary a distance between the die axis and the drive axis.

[0077] Clause 3. The tool of clause 2, further comprising a battery removably coupled to the housing, wherein the first motor and the second motor are powered by the battery.

[0078] Clause 4. The tool of clause 3, wherein the battery is configured to be inserted within a battery receptacle along a battery axis, and wherein the battery axis is perpendicular to the drive axis and the motor axis.

[0079] Clause 5. The tool of clause 1, wherein the plurality⁷ of spur gears comprises a first spur gear coupled to the motor shaft such that the first spur gear is rotatable about the motor axis, a second spur gear coupled to a support shaft offset the motor axis, the second spur gear is meshed with the first spur gear such that rotation of the first spur gear rotates the second spur gear about a support axis defined by the support shaft, and a third spur gear supported by a pinion on the planetary gear set, the third spur gear is meshed with the second spur gear such that rotation of the second spur gear rotates the third spur gear about the pinion.

[0080] Clause 6. The tool of any preceding clause, wherein the motor axis is parallel to the drive axis.

[0081] Clause 7. The tool of any one of clauses 1-5, wherein the tool has a length defined between a rear surface of the tool and a distal end of the drive shaft, and wherein the length is in a range from 15 inches to 20 inches.

[0082] Clause 8. The tool of any one of clauses 1-5, wherein the tool has a height that is defined between a top surface of the tool and a support surface of the tool, and wherein height is in a range from 9 inches to 11 inches. [0083] Clause 9. The tool of any one of clauses 1-5, wherein the housing defines a support surface that supports the tool relative to a surface, and wherein the support surface includes a foot portion that is overmolded onto the housing.

[0084] Clause 10. The tool of clause 9, further comprising a mounting interface coupled to the support surface, and wherein the mounting interface is configured to engage a corresponding mounting interface formed on a storage unit.

[0085] Clause 11. The tool of clause 10, wherein the mounting interface is removably coupled to the support surface.

[0086] Clause 12. The tool of any one of clauses 1-5, further comprising a manual clamping mechanism having an adjustment mechanism operably coupled to the die shaft to allow a user to manually adjust a distance between the die axis and the drive axis.

[0087] Clause 13. The tool of any one of clauses 1-5, further comprising a support arm coupled to the drive shaft, wherein the support arm has a first portion surrounding a portion of the drive shaft and a second portion engaging a portion of the housing.

[0088] Clause 14. A tool configured to form a groove in a pipe, the tool comprising: a housing; a drive shaft rotatable about a drive axis, the drive shaft having a body defining a distal end having a through-hole defined therein; a bolt coupled to the through-hole in the body of the drive shaft, the bolt configured to offset a bending load on the drive shaft when the pipe is supported on the drive shaft; a die shaft defining a die shaft axis; a die rotatably coupled to the die shaft about a die axis that is offset relative the die shaft axis, the die configured to form a groove into the pipe; and a drive assembly including a drive portion configured to rotate the drive shaft about the drive axis and thereby rotate the tool with respect to the pipe, and a die shaft drive portion configured to rotate the die shaft to vary a distance between the die axis and the drive axis.

[0089] Clause 15. The tool of clause 14. wherein drive shaft has a first portion that meshes with the drive portion, a second portion with a greater diameter than the first portion, and a trough portion positioned between two axially offset circumferential peak portions.

[0090] Clause 16. The tool of clause 14 or 15. wherein the drive shaft includes a second end that is opposite the distal end. the second end includes a pair of flat surfaces and a threaded connection, and the flat surfaces and the threaded connection couples the drive shaft to the drive portion.

[0091] Clause 17. A tool configured to form a groove in a pipe, the tool comprising: a housing having a front end, a rear end opposite the front end, and a first handle portion extending at least partially between the front end and the rear end; a second handle pivotably- coupled to the housing at a position between the front end of the housing and the first handle; a drive shaft rotatable about a drive axis in a drive direction; a die shaft defining a die shaft axis; a die rotatably coupled to the die shaft about a die axis that is offset relative the die shaft axis, the die configured to form a groove into the pipe; and a drive assembly including a drive portion configured to rotate the drive shaft about the drive axis and thereby rotate the tool with respect to the pipe, and a die shaft drive portion configured to rotate the die shaft to vary a distance between the die axis and the drive axis.

[0092] Clause 18. The tool of clause 17. wherein the second handle is pivotable between a closed position where the second handle is secured within a recess formed in the housing and an open position where the second handle extends outwardly from the housing.

[0093] Clause 19. The tool of clause 18. wherein pivotable movement of the second handle from the open position to the closed position is the drive direction of the drive shaft. Clause 20. The tool of any one of clauses 17-19, further comprising a support arm coupled to the drive shaft, wherein the support arm has a first portion rotatably supporting an end of the drive shaft and a second portion engaging a front end of the housing.

[0094] Clause 20. The tool of any one of clauses 17-19, further comprising a support arm coupled to the drive shaft, wherein the support arm has a first portion rotatably supporting an end of the drive shaft and a second portion engaging a front end of the housing.

[0095] Various features of the disclosure are set forth in the following claims. When used in this specification and claims, the terms “comprises"’ and “comprising” and variations thereof mean that the specified features, steps or integers are included. The terms are not to be interpreted to exclude the presence of other features, steps or components.

Claims

CLAIMS What is claimed is:

1. A tool configured to form a groove in a pipe, the tool comprising: a housing including a battery receptacle configured to receive a battery: a motor having a motor shaft that is rotatable about a motor axis, a gear assembly operably coupled to the motor, the gear assembly having a plurality of spur gears operably coupled to the motor shaft and a planetary gear set operably coupled to the spur gears, a drive shaft operably coupled to the planetary gear set, the drive shaft configured to rotate about a drive axis that is offset the motor axis; and a die rotatably coupled to a die shaft about a die axis that is offset relative the drive axis, the die configured to form a groove into the pipe.

2. The tool of claim 1, wherein the motor is a first motor and the gear assembly is a first gear assembly, and wherein a second motor is configured to rotate an input shaft about an input shaft axis to rotate the die shaft and vary a distance between the die axis and the drive axis.

3. The tool of claim 2, further comprising a batten removably coupled to the housing, wherein the first motor and the second motor are powered by the battery⁷.

4. The tool of claim 3, wherein the battery is configured to be inserted within a battery receptacle along a battery axis, and wherein the battery axis is perpendicular to the drive axis and the motor axis.

5. The tool of claim 1, wherein the plurality of spur gears comprises a first spur gear coupled to the motor shaft such that the first spur gear is rotatable about the motor axis, a second spur gear coupled to a support shaft offset the motor axis, the second spur gear is meshed with the first spur gear such that rotation of the first spur gear rotates the second spur gear about a support axis defined by the support shaft, and a third spur gear supported by a pinion on the planetary gear set, the third spur gear is meshed with the second spur gear such that rotation of the second spur gear rotates the third spur gear about the pinion.

6. The tool of any preceding claim, wherein the motor axis is parallel to the drive axis.

7. The tool of any one of claims 1-5, wherein the tool has a length defined between a rear surface of the tool and a distal end of the drive shaft, and wherein the length is in a range from 15 inches to 20 inches.

8. The tool of any one of claims 1-5, wherein the tool has a height that is defined between a top surface of the tool and a support surface of the tool, and wherein height is in a range from 9 inches to 11 inches.

9. The tool of any one of claims 1-5, wherein the housing defines a support surface that supports the tool relative to a surface, and wherein the support surface includes a foot portion that is overmolded onto the housing.

10. The tool of claim 9, further comprising a mounting interface coupled to the support surface, and wherein the mounting interface is configured to engage a corresponding mounting interface formed on a storage unit.

11. The tool of claim 10, wherein the mounting interface is removably coupled to the support surface.

12. The tool of any one of claims 1-5, further comprising a manual clamping mechanism having an adjustment mechanism operably coupled to the die shaft to allow a user to manually adjust a distance between the die axis and the drive axis.

13. The tool of any one of claims 1-5, further comprising a support arm coupled to the drive shaft, wherein the support arm has a first portion surrounding a portion of the drive shaft and a second portion engaging a portion of the housing.

14. A tool configured to form a groove in a pipe, the tool comprising: a housing; a drive shaft rotatable about a drive axis, the drive shaft having a body defining a distal end having a through-hole defined therein; a bolt coupled to the through-hole in the body of the drive shaft, the bolt configured to offset a bending load on the drive shaft when the pipe is supported on the drive shaft; a die shaft defining a die shaft axis; a die rotatably coupled to the die shaft about a die axis that is offset relative the die shaft axis, the die configured to form a groove into the pipe; and a drive assembly including a drive portion configured to rotate the drive shaft about the drive axis and thereby rotate the tool with respect to the pipe, and a die shaft drive portion configured to rotate the die shaft to vary a distance between the die axis and the drive axis.

15. The tool of claim 14. wherein drive shaft has a first portion that meshes with the drive portion, a second portion with a greater diameter than the first portion, and a trough portion positioned between two axially offset circumferential peak portions.

16. The tool of claim 14 or 15. wherein the drive shaft includes a second end that is opposite the distal end, the second end includes a pair of flat surfaces and a threaded connection, and the flat surfaces and the threaded connection couples the drive shaft to the drive portion.

17. A tool configured to form a groove in a pipe, the tool comprising: a housing having a front end, a rear end opposite the front end, and a first handle portion extending at least partially between the front end and the rear end: a second handle pivotably coupled to the housing at a position between the front end of the housing and the first handle; a drive shaft rotatable about a drive axis in a drive direction; a die shaft defining a die shaft axis; a die rotatably coupled to the die shaft about a die axis that is offset relative the die shaft axis, the die configured to form a groove into the pipe; and a drive assembly including a drive portion configured to rotate the drive shaft about the drive axis and thereby rotate the tool with respect to the pipe, and a die shaft drive portion configured to rotate the die shaft to vary a distance between the die axis and the drive axis.

18. The tool of claim 17, wherein the second handle is pivotable between a closed position where the second handle is secured within a recess formed in the housing and an open position where the second handle extends outwardly from the housing.

19. The tool of claim 18, wherein pivotable movement of the second handle from the open position to the closed position is the drive direction of the drive shaft.

20. The tool of any one of claims 17-19, further comprising a support arm coupled to the drive shaft, wherein the support arm has a first portion rotatably supporting an end of the drive shaft and a second portion engaging a front end of the housing.