Handheld strapping tool comprising ultrasonic blocker

Abstract

Various embodiments of the present disclosure provide a handheld strapping tool including an ultrasonic blocker.

Description

priority

[0001] This application claims priority and benefit to U.S. Provisional Patent Application No. 63 / 515,712, filed July 26, 2023, the entire contents of which are incorporated herein by reference. Technical Field

[0002] This disclosure relates to strapping tools, and more specifically to hand-held strapping tools configured to tension straps around a load and attach overlapping layers of straps to each other to form a tensioned strap loop around the load. Background Technology

[0003] The strapping tool is configured to tension the strap around a load and attach overlapping layers of the strap to each other to form a tensioned strap loop around the load. Many strapping tools utilize friction welding to attach overlapping upper and lower strap layers to each other. To form a tensioned strap loop around a load using one of these strapping tools, the operator first pulls the front end of the strap from the strap supply source, wraps the strap around the load, and positions the lower layer of the strap (including the front end) below the upper layer. The operator introduces the overlapping strap layers into the strapping tool and presses a button to initiate a tensioning cycle, during which a tensioning wheel rotates to move the upper strap layer above the lower strap layer and tension the strap around the load. After the tensioning cycle is complete, a locking cycle is initiated. During the locking cycle, toothed welding feet force the strap layers against a toothed welding plate. As the welding feet apply welding force to the strap layers, a motor causes the welding feet to oscillate at a high frequency. The oscillating welding shoe causes the upper layer of the strap to oscillate relative to the lower layer, which generates friction between the overlapping portions of the strap layers, causing these portions to melt locally. The motor stops oscillating the welding shoe, but the welding shoe continues to apply welding force. The molten portions of the overlapping strap layers join together and solidify as they cool, thus attaching the upper and lower strap layers to form a tensioned strap loop.

[0004] One problem with these strapping tools is the noise generated during the friction welding process. Another problem is that they are battery-powered, which adds to the tool's weight. Since strapping tool operators may use the tools hundreds of times a day, there is a continuous need to make the strapping devices as quiet and lightweight as possible to improve the operator experience. Summary of the Invention

[0005] Various embodiments of this disclosure provide a handheld strapping tool including an ultrasonic stun gun. Attached Figure Description

[0006] Figure 1 This is a perspective view of an example embodiment of the handheld strapping tool of this disclosure.

[0007] Figure 2 yes Figure 1Side view of the binding tool.

[0008] Figure 3 yes Figure 1 A block diagram of some components of a binding tool.

[0009] Figures 4A to 4C yes Figure 1 A diagram showing how a strapping tool secures a load to a tray.

[0010] Figure 5A and Figure 5B Similar to Figure 2 However, it shows that the housing of the binding tool has been partially removed to expose some of the internal components of the binding tool.

[0011] Figure 6 and Figure 7 They are Figure 1 A perspective view and a side view of the anvil of the binding tool.

[0012] Figure 8 yes Figure 1 A three-dimensional diagram of an ultrasonic sealing device used for securing and binding.

[0013] Figure 9 yes Figure 8 A front view of the ultrasonic welding electrode head of an ultrasonic sealing device.

[0014] Figure 10A and Figure 10B During the lockdown cycle Figure 9 ultrasonic welding electrode head, Figure 6 and Figure 7 Front view of the anvil, and the upper and lower portions of the strap.

[0015] Figure 11 It is by Figure 1 A top view of an example strap joint formed by a strapping tool. Detailed Implementation

[0016] While the systems, apparatuses, and methods described herein can be implemented in various forms, the accompanying drawings and the specification describe certain exemplary and non-limiting embodiments. Not all components shown in the drawings and described in the specification may be necessary, and some implementations may include additional, different, or fewer components. The arrangement and type of components; the shape, size, and material of components; and the manner in which components are connected may vary without departing from the spirit or scope of the claims. Unless otherwise stated, any orientation mentioned in the specification reflects the orientation of the corresponding component shown in the drawings and does not limit the scope of this disclosure. Furthermore, terms relating to installation methods such as mounting and connecting are not intended to be limited to direct installation methods but should be broadly interpreted to include indirect and operatively mounted, connected, etc. This specification is intended to be considered as a whole and interpreted in accordance with the principles of this disclosure and as understood by one of ordinary skill in the art.

[0017] Figures 1 to 10B An example embodiment of the handheld strapping tool 50 of this disclosure and some of its components and parts is shown. Figures 4A to 4C As shown, the strapping tool 50 is configured to perform a strapping cycle to tension and lock the strap S (a plastic strap in this example embodiment) around the load L on the tray P, forming a tensioned strap loop that secures the load L to the tray P. The operator pulls the strap S from a strap supply source (not shown) and wraps the strap around the load L and through an opening in the tray P until the lower layer LL of the strap S (which includes the front end of the strap S) is below the upper layer UL of the strap S, as shown. Figure 4A As shown. The operator then introduces the overlapping upper UL and lower LL of the strap S into the strapping tool 50 and actuates one or more buttons to initiate the strapping cycle. As... Figure 4B As shown, the tensioning driver drives the tensioning wheel to perform a tensioning cycle, during which the strapping tool 50 tensions the strapping belt S around the load L. Once the preset tension is reached in the strapping belt S, as... Figure 4C As shown, the ultrasonic closure device is activated to perform a closure cycle, during which the strapping tool 50 ultrasonically welds the upper UL and lower LL of the strap S to each other to form a strap joint SJ, as shown. Figure 11 As shown, the strap S is cut from the strap supply source.

[0018] The strapping tool 50 includes a housing 100, a tensioning assembly, a locking assembly, an opening device 700, one or more input devices 800, a display device 900, one or more sensors 1000, and a controller 1100.

[0019] exist Figure 1 , Figure 2 , Figure 5A and Figure 5B The housing 100, best shown in the diagram, is formed of a plurality of components that collectively at least partially enclose and / or support some (or all) of the other components and parts of the strapping tool 50. The housing 100 includes a base section 110 and a handle 120. The base section 110 at least partially encloses and / or supports the rocker arm 300, tension plate 420, tension actuator 490, anvil 500, and controller 1100. The handle 120 extends upward from the base section 110 and along the handle axis A. 120 Extending longitudinally. Handle axis A 120 An angle β is formed relative to the vertical axis, such as Figure 2 As best shown. Angle β can be any suitable angle, such as between 0 and 60 degrees, most preferably between 0 and 20 degrees (this angle can also be negative). 120 The handle 120 is generally vertical and generally perpendicular to the longitudinal direction of the strap. The interior of the handle 120 defines a cavity whose size and shape are configured to accommodate at least a portion of the ultrasonic occluder 600 (and, in this example embodiment, the occluder actuator 690). The exterior of the handle 120 is sized and shaped for gripping by the operator of the strapping tool 50. The housing 100 can be formed from any suitable number of components joined together in any suitable manner. In this example embodiment, the housing 100 is formed of plastic, but in other embodiments, the housing can be made of any other suitable material.

[0020] Tensioning components in Figure 5A and Figure 5B As shown, and configured to tension the belt around the load during a tensioning cycle. The tensioning assembly includes a rocker arm 300, a toothed tensioning wheel 400, a tensioning plate 420, a tensioning driver 490, and a tensioning gear mechanism.

[0021] The tension wheel 400 is annular, has a textured (e.g., toothed) outer surface, and is rotatable to tension the belt around a load. A tension drive 490 (in this example embodiment, a rotary motor, but in other embodiments, any suitable type of device) is operatively connected to the tension wheel 400 via a tension gear assembly and is configured to rotate the tension wheel 400. The tension gear assembly can be any suitable gear assembly or combination of gear assemblies configured to convert rotation of the output shaft of the tension drive 490 into rotation of the tension wheel 400. In some embodiments, the tension gear assembly is configured, for example, via a planetary gear assembly, eccentric gear assembly, involute gear assembly, bevel gear assembly, etc., to convert relatively low-torque, high-speed rotation of the output shaft of the tension drive 490 into relatively high-torque, low-speed rotation of the tension wheel 400.

[0022] A rocker arm 300 is movably connected to and configured to move relative to the base section 110. In some embodiments, the rocker arm 300 is pivotable relative to the base section 110, while in other embodiments, the rocker arm 300 is linearly movable relative to the base section 110. In this example embodiment, the tension wheel 400 is supported by the rocker arm 300, and a tension plate 420 having a toothed upper surface is supported by the base section 110 of the housing 100 below the tension wheel 400. In these embodiments, the rocker arm 300 is movable via actuation of an opening device 700 (described below) to move the rocker arm 300 (and the tension wheel 400 supported by the rocker arm 300) away from the tension plate 420, separating the tension wheel 400 and the tension plate 420, thereby creating a space between these components for strap insertion. In other embodiments, the tension plate 420 is supported by the rocker arm. In these embodiments, the rocker arm is movable via actuation of the opening device 700, causing the rocker arm (and the tension plate 420 supported by the rocker arm) to move away from the tension wheel 400, separating the tension wheel 400 and the tension plate 420, thereby creating a space between these components for the insertion of the strap. A spring or other suitable biasing element biases the rocker arm 300 such that the tension wheel 400 and the tension plate 420 are biased toward each other.

[0023] The blocking component is in Figures 5A to 10B As shown, and configured to attach overlapping layers of the strap to each other via ultrasonic welding during a locking cycle to form a tensioned strap loop around a load. The locking assembly includes an anvil 500, an ultrasonic locking device 600, and a locking actuator 690.

[0024] exist Figure 6 and Figure 7 The anvil 500, best illustrated, serves as a clamping surface against which the ultrasonic occluder 600 clamps the overlapping strap layers during occlusion cycles. The anvil 500 includes an anvil body 510 and a plurality of elongated anvil teeth 520 formed on the upper surface of the anvil body 510. This example anvil 500 includes six anvil teeth, but in other embodiments, the anvil may include any other suitable number of teeth. Each anvil tooth 520 has a generally triangular cross-section and includes side surfaces 520a and 520b angled to opposing planes, and a generally planar contact surface 520c connecting the side surfaces 520a and 520b. The anvil defines anvil contact plane P. 500 The anvil contact plane forms an angle β with respect to the horizontal plane. In this case, the horizontal plane corresponds to the longitudinal direction of the strap path (and the straps within the strap path). In this example embodiment, the anvil contact plane P... 500Defined by a generally coplanar contact surface 520c of the anvil teeth 520. The side surfaces of adjacent anvil teeth 520 are separated by an angle α (in this example embodiment, the angle is 90 degrees, but in other embodiments, the angle can be any suitable angle), such that a generally V-shaped groove is formed between adjacent anvil teeth. The cross-section of these grooves (and thus the cross-section of the anvil teeth forming the grooves) is generally constant along its entire length. The base of each anvil tooth 520 has a width D1, and the contact surface 520c of each anvil tooth 520 has a width D2 less than D1. Each anvil tooth 520 has a height D3. In this example embodiment, D1 is 0.5 mm, D2 is 2 mm, and D3 is 0.75 mm (but these dimensions may differ in other embodiments). The anvil teeth extend generally parallel to the strap path and the longitudinal direction of the strap (from... Figure 6 and Figure 7 (See the view shown for entering and exiting the page), and in this example embodiment, its length is greater than or equal to the length of the ultrasonic welding electrode tooth (described below).

[0025] like Figure 5A and Figure 5B As shown, the anvil 500 is supported by the base section 110 of the housing 100, such that the anvil teeth 520 face the ultrasonic stopper 600 (described below). In this example embodiment, the anvil 500 is removably attached to the base section 110 (e.g., via fasteners) so that the operator can replace the anvil 500 if the anvil teeth 520 become excessively worn and cannot be operated properly.

[0026] exist Figure 8 and Figure 9 The ultrasonic band clamp 600, best illustrated herein, is configured to apply ultrasonic vibrations to two overlapping layers of a strap to attach them to each other to form a strap joint. The ultrasonic band clamp 600 includes an ultrasonic welding electrode 610 and an ultrasonic transducer 640, and is located along the axis A of the ultrasonic band clamp. 600 Extending longitudinally, the ultrasonic welding electrode 610 includes an ultrasonic welding electrode body 615, an ultrasonic welding electrode neck 620 connected to (and integrally formed therewith) the ultrasonic welding electrode body 615, and an ultrasonic welding electrode head 630 connected to (and integrally formed therewith) the ultrasonic welding electrode neck 620. The ultrasonic welding electrode head 630 includes a tooth support 632. A plurality of elongated ultrasonic welding electrode teeth 634 are formed on the top surface of the tooth support 632. This example ultrasonic welding electrode includes seven ultrasonic welding electrode teeth, but in other embodiments, the ultrasonic welding electrode may include any other suitable number of teeth. Each ultrasonic welding electrode tooth 634 has a generally triangular cross-section and includes side surfaces 634a and 634b angled to opposing planes, and a generally planar contact surface 634c connecting the side surfaces 634a and 634b. The ultrasonic welding electrode head 630 defines an ultrasonic welding electrode contact plane P. 630Specifically, in this example embodiment, the ultrasonic welding electrode contact plane P 630 Defined by the generally coplanar contact surface 634c of the ultrasonic welding electrode teeth 634. Ultrasonic welding electrode contact plane P 630 Approximately perpendicular to the axis A of the ultrasonic blocker 600 (However, their orientation may differ in other embodiments). The side surfaces of adjacent ultrasonic welding electrodes 634 are separated by an angle α, such that a generally V-shaped groove is formed between adjacent ultrasonic welding electrodes. The cross-section of these grooves (and thus the cross-section of the ultrasonic welding electrodes forming the grooves) is generally constant along their entire length. The base of each ultrasonic welding electrode 634 has a width D1, and the contact surface 634c of each ultrasonic welding electrode 634 has a width D2. Each ultrasonic welding electrode 634 has a height D3. In this example embodiment, the ultrasonic welding electrodes extend generally parallel to the belt path and the longitudinal direction of the belt (and the anvil teeth), and their length is less than or equal to the length of the anvil teeth. In other words, the size, shape, and orientation of the ultrasonic welding electrodes 634 are designed and otherwise configured to be substantially the same as the anvil teeth 520 (however, they may differ in other embodiments).

[0027] The ultrasonic transducer 640 is configured to convert a high-frequency electrical signal received from a power source into high-frequency mechanical vibrations within an ultrasonic range (e.g., 20 kHz to 100 kHz). In some embodiments, the ultrasonic transducer 640 is configured to generate vibrations in the range of 20 kHz to 40 kHz. In other embodiments, the ultrasonic transducer 640 is configured to generate vibrations in the range of 34 kHz to 36 kHz. In yet another embodiment, the ultrasonic transducer 640 is configured to generate vibrations in the range of 35 kHz. The ultrasonic transducer 640 is connected to the ultrasonic electrode body 615 of the ultrasonic welding electrode 610 such that the mechanical vibrations generated by the ultrasonic transducer 640 are transmitted to the ultrasonic welding electrode 600, and the size, shape, and orientation of the ultrasonic welding electrode 600 are designed, and otherwise configured, such that these vibrations are transmitted to the ultrasonic welding electrode head 630, including the ultrasonic welding electrode teeth 634. Accordingly, the ultrasonic transducer 640 is configured to convert high-frequency electrical signals into mechanical vibrations of the ultrasonic welding pole teeth 634 at ultrasonic frequencies.

[0028] An ultrasonic sealing device 600 is mounted within the handle 120 of the housing 100, such that the ultrasonic welding electrode teeth 634 face the anvil teeth 520 of the anvil 500. The ultrasonic sealing device 600 is oriented such that the ultrasonic welding electrode contact plane P... 630 Approximately parallel to the contact plane P of the anvil 500 And it is transverse to the longitudinal direction of the strap. In this example embodiment, the ultrasonic occluder 600 is mounted within the handle 120, such that the axis A of the ultrasonic occluder is... 600 Roughly parallel to the handle axis A 120(In this example embodiment, it is coaxial with the handle axis), such as Figure 5A and Figure 5B As shown, the axis A of the ultrasonic sealing device is... 600 An angle β is formed relative to the vertical axis. As used herein, when referring to the orientation of the handle axis and the ultrasonic suffocator axis, "coaxial" is a subset of "parallel". In some embodiments, the ultrasonic suffocator axis A 600 Generally perpendicular to the longitudinal direction of the strap. The locking actuator 690 (in this example embodiment, it is a linear actuator, but it can be any other suitable actuator) is operatively connected to the ultrasonic locking device 600 and is configured to move the ultrasonic locking device 600 toward and away from the anvil 500 within the handle 120.

[0029] Figure 10A and Figure 10B An ultrasonic stun gun 600 is shown, which attaches the overlapping upper UP and lower LP layers of a strap S to each other. Initially, as Figure 10A As shown, the ultrasonic sealing device 600 is positioned such that the ultrasonic welding electrode head 630 is spaced apart from the anvil 500, thereby making room for the strap. Once the upper UP and lower LP of the strap S are positioned between the ultrasonic welding electrode head 630 and the anvil 500, the sealing actuator 690 moves the ultrasonic sealing device 600 toward the anvil 500. When this occurs, the ultrasonic welding electrode teeth 634 engage the upper UL and force it toward the anvil 500, thereby forcing the lower LL against the anvil teeth 520. Figure 10B As shown, because the anvil teeth 520 and the ultrasonic welding electrode teeth 634 are in an engaging arrangement (i.e., the teeth of one component are positioned opposite the corresponding grooves between the teeth of the other component), the upper layer UL and the lower layer LL of the strap are bent and in the transverse direction of the strap (from Figure 10A and 10B The tape (which appears horizontal from the viewpoint shown) exhibits a roughly wavy profile (including alternating peaks and valleys). When the ultrasonic stopper 600 and anvil 500 sandwich the upper UL and lower LL layers of the strap S, the ultrasonic transducer 640 is activated for a specified period. As explained above, this causes the ultrasonic welding electrodes 634 to vibrate at an ultrasonic frequency, causing the upper UL and lower LL layers of the strap S to partially melt together to form a strap joint. Figure 11 This type of cable tie joint SJ is shown, which has a width D4 (corresponding to the length of the ultrasonic welding electrode teeth), which is in the longitudinal direction of the cable tie (from...). Figure 11 Extending horizontally (as shown from the perspective), this longitudinal direction is perpendicular to the transverse direction of the strap (from...). Figure 11 (The view shown is vertical). In this example embodiment, the width D4 is 14 mm, but in other embodiments, the width can be any other suitable value (e.g., 5 mm to 32 mm). Figure 10B As shown, the cross-section of the strap connector SJ has a wavy profile with several alternating peaks WP and valleys WV formed by the offset anvil teeth and ultrasonic welding pole teeth.

[0030] exist Figure 1 , Figure 2 , Figure 5A and Figure 5B The opening device 700, best shown in the diagram, is operatively connected to the rocker arm 300 and configured to move the rocker arm 300 to separate the tension wheel 400 and the tension plate 420. In this example embodiment, the opening device 700 is formed as a trigger that is pivotally connected to and extends partially from the front of the handle 120. The size, shape, position, and orientation of the trigger are designed, and otherwise configured, to be actuated (pulled) by the operator's index finger when the operator holds the handle 120. In some embodiments, the strapping tool 50 includes one or more mechanical linkages that operatively connect the rocker arm 300 to the opening device 700, such that actuating the opening device 700 forces the rocker arm 300 to move. In other embodiments, the strapping tool 50 includes a suitable actuator operatively connected to the rocker arm 300 and configured to move the rocker arm 300 in response to a switch being triggered when the opening device 700 is actuated.

[0031] One or more input devices 800 are suitable mechanical or electromechanical devices, such as buttons, rollers, dials, etc., configured to receive input from the operator. In this example embodiment of the strapping tool 50, one or more input devices 800 include a first button actuator 810, a second button actuator 820, and a roller 830 supported on the upper surface of the handle 120 of the housing 100. The first button actuator 810 and the second button actuator 820 are operable to initiate tensioning and / or locking cycles, as described below. The roller 830 is operable to change various settings of the strapping tool 50, such as tension level, welding time, or operating mode. In this example embodiment, the size, shape, position, and orientation of the input devices are designed and otherwise configured to be operated by the operator's thumb when the operator holds the handle 120.

[0032] The display device 900 is configured to display information about the strapping tool 50. In this example embodiment, the display device 900 is supported by the upper surface of the handle 120 of the housing 100 and is adjacent to the input devices 810, 820 and 830.

[0033] In some embodiments, the bundling tool 50 includes one or more output devices, such as lights. In one such embodiment, the output device is a light surrounding the edge of the display device 900, which can be activated by one of three different colors: green, yellow, and red. In an example embodiment, the light is activated green to indicate successful bundling, yellow to indicate the need for maintenance, and red to indicate unsuccessful bundling.

[0034] Sensor 1000 includes any suitable sensor, such as a microswitch, optical sensor, ultrasonic sensor, magnetic position sensor, etc., configured to detect the position of certain components of the strapping tool 50 and send appropriate signals to the controller 1100. Sensor 1000 may include, for example, sensors configured to detect when the tension wheel 400 and tension plate 420 separate, sensors configured to detect when the opening device 700 is actuated, and sensors configured to detect actuation of the first button actuator 810 and the second button actuator 830.

[0035] exist Figure 3 The controller 1100 shown includes one or more processing devices communicatively connected to one or more memory devices. For example, the controller may be a programmable logic controller. The processing devices may include any suitable processing devices, such as, but not limited to, general-purpose processors, special-purpose processors, digital signal processors, one or more microprocessors, one or more microprocessors associated with a digital signal processor core, one or more application-specific integrated circuits (ASICs), one or more field-programmable gate arrays (FPGAs), one or more integrated circuits, and / or state machines. The memory devices may include any suitable memory devices, such as, but not limited to, read-only memory, random access memory, one or more digital registers, cache memory, one or more semiconductor memory devices, magnetic media such as integrated hard disks and / or removable memory, magneto-optical media, and / or optical media. The memory devices store instructions executable by the processing devices to control the operation of the strapping tool 50. The controller 1100 is communicatively and operatively connected to the tension driver 490, ultrasonic transducer 640, locking driver 690, input device 800, display device 900, and sensor 1000, and is configured to receive signals from and control these components. The controller 1100 can also be communicatively connected to an external device, such as a computing device, to send information to and receive information from the external device (e.g., via Wi-Fi, Bluetooth, near field communication or other suitable wireless communication protocols).

[0036] The controller 1100 is configured to operate the strapping device in one of three operating modes to perform a strapping cycle: (1) manual operation mode; (2) semi-automatic operation mode; and (3) automatic operation mode. In manual operation mode, in response to the actuation of the first button actuator 810 and its actuation state, the controller 1100 operates the tension driver 490 to rotate the tension wheel 400. In response to the actuation of the second button actuator 820, the controller 1100 operates the locking driver 690 to move the ultrasonic locking device 600 toward the anvil 500 and activates the ultrasonic transducer 640 to form a locking joint as explained above, thereby performing a locking cycle. In semi-automatic operation mode, in response to the actuation of the first button actuator 810 and its actuation state, the controller 1100 operates the tension driver 490 to rotate the tension wheel 400. Once the controller 1100 determines that the tension in the strap has reached the (preset) desired strap tension, the controller 1100 automatically operates the locking driver 690 to move the ultrasonic locking device 600 toward the anvil 500 and activates the ultrasonic transducer 640 to form a locking joint as explained above, thereby executing a locking cycle (no additional operator input required). In automatic operation mode, in response to the actuation of the first button actuator 810, the controller 1100 operates the tension driver 490 to rotate the tension wheel 400. Once the controller 1100 determines that the tension in the strap has reached the (preset) desired strap tension, the controller 1100 automatically operates the locking driver 690 to move the ultrasonic locking device 600 toward the anvil 500 and activates the ultrasonic transducer 640 to form a locking joint as explained above, thereby executing a locking cycle (no additional operator input required).

[0037] The strapping tool 50 is configured to be powered by a power supply external to the strapping tool 50. For example, the strapping tool 50 includes a power line electrically connectable to a power supply external to the strapping tool 50. In some embodiments, the power supply is part of a strap distributor carrying the strap roll from which the strapping tool 50 pulls the strap. In other embodiments, the strapping tool 50 includes an onboard power supply, such as a rechargeable battery.

[0038] The following describes an example of forming a tensioned strap loop around a load using a strapping tool 50. For the purposes of this example, the strapping tool 50 is in automatic mode. The operator first pulls the front end of the strap from a strap supply source (not shown), wraps the strap around the load, and positions the front end of the strap S below another layer of strap to form an upper and lower strap layer. The operator then actuates the opening device 700 to move the rocker arm 300 to separate the tension wheel 400 and the tension plate 420. While continuing to actuate the opening device 700 to hold the rocker arm 300 in place, the operator introduces the overlapping upper and lower layers of strap between the tension wheel 400 and the tension plate 420, and between the ultrasonic welding electrode tooth 634 and the anvil tooth 520. The operator then releases the opening device 700, thereby allowing the appropriate biasing element to force the rocker arm 300 back toward the tension plate 420.

[0039] Then, the operator actuates the first button actuator 810. Once one of the sensors 1000 detects the actuation of the first button actuator 810, the controller 1100 initiates the strapping process. The controller 1100 operates the tension driver 490 to rotate the tension wheel 400. As the tension wheel 400 rotates, it pulls the upper layer of the strap S over the lower layer of the strap S, thereby tensioning the strap S around the load. Throughout the tensioning process, the controller 1100 monitors the current drawn by the tension driver 490. When this current reaches a preset value related to the (preset) desired strap tension for the strapping process, the controller 1100 stops the tension driver 490, thereby terminating the tensioning process.

[0040] After the tensioning process is completed, the controller 1100 automatically initiates the sealing process by controlling the sealing actuator 690 to move the ultrasonic sealing device 600 toward the anvil 500 and activating the ultrasonic transducer 640. Once the ultrasonic welding electrode head 630 forces the overlapping upper and lower layers of the strap against the anvil 500, the ultrasonic mechanical vibration of the ultrasonic welding electrode head 630 locally melts a portion of the upper and lower layers of the strap together. After a preset time period, the controller 1100 stops the ultrasonic transducer 640. After the cooling period expires, the controller 1100 controls the sealing actuator 690 to move the ultrasonic sealing device 600 away from the anvil 500 to release the now-sealed strap, thus completing the sealing process.

Claims

1. A handheld strapping tool, comprising: Tensioner plate; A rotatable tensioning wheel is provided adjacent to the tensioning plate, wherein one of the tensioning wheel and the tensioning plate is movable relative to the other of the tensioning wheel and the tensioning plate to separate the tensioning wheel and the tensioning plate. Anvil, the anvil including a plurality of anvil teeth and defining anvil contact plane; and An ultrasonic choke, the ultrasonic choke extending longitudinally along an ultrasonic choke axis transverse to the contact plane of the anvil, wherein one of the ultrasonic choke and the anvil is movable toward and away from the other of the ultrasonic choke and the anvil, the ultrasonic choke comprising: An ultrasonic welding electrode, the ultrasonic welding electrode comprising a plurality of ultrasonic welding electrode teeth and defining an ultrasonic welding electrode contact plane substantially parallel to the anvil contact plane; and An ultrasonic transducer configured to generate mechanical vibrations at ultrasonic frequencies and transmit the mechanical vibrations to the ultrasonic welding electrode.

2. The handheld strapping tool of claim 1, further comprising one or more drivers operatively connected to and configured to rotate the tension wheel, and operatively connected to one of the ultrasonic stun gun and the anvil and configured to move the one of the ultrasonic stun gun and the anvil toward or away from the other of the ultrasonic stun gun and the anvil.

3. The handheld binding tool as described in claim 2, wherein, The one or more drives include: A tensioning actuator, operatively connected to and configured to rotate the tensioning wheel; and A blocking actuator, operatively connected to one of the ultrasonic blocking device and the anvil and configured to move one of the ultrasonic blocking device and the anvil toward or away from the other of the ultrasonic blocking device and the anvil.

4. The handheld binding tool as described in claim 3, wherein, The tensioning drive includes a rotary motor, and the locking drive includes a linear actuator.

5. The handheld strapping tool as described in claim 2, wherein, The one or more actuators include a single actuator operatively connected to and configured to rotate the tension wheel, and operatively connected to one of the ultrasonic blocker and the anvil and configured to move the one of the ultrasonic blocker and the anvil toward or away from the other of the ultrasonic blocker and the anvil.

6. The handheld strapping tool of claim 2, further comprising a tension gear device that operatively connects the one or more actuators to the tension wheel.

7. The handheld strapping tool of claim 1, further comprising a movable rocker arm, wherein one of the tensioning wheel and the tensioning plate is mounted on the movable rocker arm.

8. The handheld strapping tool of claim 7, further comprising an opening device operatively connected to the rocker arm, such that actuation of the opening device causes the rocker arm to move to separate the tension wheel and the tension plate.

9. The handheld strapping tool of claim 8, further comprising a housing, the housing including a handle extending longitudinally along the handle axis, wherein, The handle is sized and shaped to be held by the operator of the binding tool, wherein the ultrasonic stun gun is at least partially enclosed within the handle.

10. The handheld strapping tool as described in claim 9, wherein, The opening device is supported by the handle.

11. The handheld strapping tool as described in claim 10, wherein, The axis of the ultrasonic blocker is approximately parallel to the axis of the handle.

12. The handheld strapping tool as described in claim 11, wherein, The axis of the ultrasonic sealing device and the axis of the handle are coaxial.

13. The handheld strapping tool as described in claim 11, wherein, The handle axis and the ultrasonic blocker axis are approximately perpendicular to the anvil contact plane.

14. The handheld strapping tool as described in claim 13, further comprising: One or more actuators, operatively connected to and configured to rotate the tension wheel, and operatively connected to one of the ultrasonic choke and the anvil, and configured to move the one of the ultrasonic choke and the anvil toward or away from the other of the ultrasonic choke and the anvil; as well as An input device, which is supported by the handle and actuable to operate the one or more drivers.

15. The handheld strapping tool of claim 14, further comprising a controller configured to respond to actuation of the input device: Control the one or more drivers to rotate the tension wheel to tension the belt loop around the object until a specified tension is reached in the belt; Controlling the one or more drivers to move one of the ultrasonic sealing device and the anvil toward the other of the ultrasonic sealing device and the anvil, such that the two overlapping layers of the strap are sandwiched between the ultrasonic welding electrode teeth and the anvil teeth; and The ultrasonic transducer is activated to cause the ultrasonic welding electrode teeth to vibrate and attach the overlapping layers of the straps to each other.

16. The handheld strapping tool as described in claim 15, wherein, The one or more drivers and the controller can be electrically connected to a power source remote from the handheld strapping tool.

17. The handheld strapping tool as described in claim 15, wherein, The input device is supported by the upper surface of the handle.

18. The handheld strapping tool of claim 1, further comprising a housing, the housing including a handle extending longitudinally along the handle axis, wherein, The handle is sized and shaped to be held by the operator of the binding tool, wherein the ultrasonic stun gun is at least partially enclosed within the handle.

19. The handheld strapping tool as described in claim 17, wherein, The axis of the ultrasonic blocker is approximately parallel to the axis of the handle.

20. The handheld strapping tool as described in claim 19, wherein, The axis of the ultrasonic sealing device and the axis of the handle are coaxial.

21. The handheld strapping tool as described in claim 19, wherein, The handle axis and the ultrasonic blocker axis are approximately perpendicular to the anvil contact plane.

22. The handheld strapping tool of claim 21, further comprising an input device supported by the handle and actuable to operate the one or more actuators.

Images