Strapping tool with rocker-position indicator

Abstract

Various embodiments of the present disclosure provide a strapping device including a tension plate, a rocker movable between a home position and a strap-insertion position, a rotatable tension wheel, and a rocker-position indicator. The tension wheel is a first distance from the tension plate when the rocker is in the home position and a second distance from the tension plate when the rocker is in the strap-insertion position. The second distance is greater than the first distance. The rocker-position indicator has a first configuration and a second configuration. Movement of the rocker from the home position to the strap-insertion position causes the rocker-position indicator to switch from the first configuration to the second configuration to indicate that the rocker is in the strap-insertion position.

Description

STRAPPING TOOL WITH ROCKER-POSITION INDICATORPriority

[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 517,230, filed August 2, 2023, the entire contents of which is incorporated herein by reference.Field

[0002] The present disclosure relates to strapping devices, and more particularly to strapping devices configured to tension strap around a load and to attach overlapping layers of the strap to one another to form a tensioned strap loop around the load.Background

[0003] Strapping devices are configured to tension strap around a load and to attach overlapping layers of the strap to one another to form a tensioned strap loop around the load. To use one of these strapping devices to form a tensioned strap loop around a load, an operator pulls strap leading end first from a strap supply, wraps the strap around the load, and positions a lower layer of the strap including the leading end of the strap below an upper layer of the strap. The operator separates a tension wheel from a tension plate, introduces the overlapped strap layers between the tension wheel and the tension plate, and presses a button to initiate a tensioning cycle. During the tensioning cycle, the tension wheel rotates to move the upper strap layer over the lower strap layer and tension the strap around the load. After completion of the tensioning cycle, a sealing cycle is initiated. During the sealing cycle, a sealing device (such as a friction welder) joins portions of the overlapping strap layers together, thereby attaching the upper and lower strap layers to form the tensioned strap loop.

[0004] In some strapping devices, the tension wheel is supported by a pivotable rocker. To separate the tension wheel from the tension plate, the operator pulls a hand lever to actuate one or more mechanical linkages that cause the rocker to pivot from a lower position at which the tension wheel is adjacent the tension plate to an upper position at which the tension wheel is spaced-apart from the tension plate. These strapping devices include a cover that at least partially encloses the rocker and the tension wheel. The cover hides the rocker and the tension wheel from view from the operator’s perspective when using the strapping tool. This prevents the operator from quickly and easily verifying the position of the rocker, i .e., whether it is in the lower position or the upper position, via a quick glance at the tool.Summary

[0005] Various embodiments of the present disclosure provide a strapping device including a tension plate, a rocker movable between a home position and a strap-insertion position, a rotatable tension wheel, and a rocker-position indicator. The tension wheel is a first distance from the tension plate when the rocker is in the home position and a second distance from the tension plate when the rocker is in the strap-insertion position. The second distance is greater than the first distance. The rocker-position indicator has a first configuration and a second configuration. Movement of the rocker from the home position to the strap-insertion position causes the rocker-position indicator to switch from the first configuration to the second configuration to indicate that the rocker is in the strap-insertion position.Brief Description of the Figures

[0006] Figure l is a perspective view of one example embodiment of a strapping device of the present disclosure.

[0007] Figure 2 is a block diagram of certain components of the strapping device ofFigure 1.

[0008] Figures 3A-3C are diagrammatic views of the strapping device of Figure 1 securing a load to a pallet.

[0009] Figure 3D is a perspective view of a friction- weld strap joint formed by the strapping device of Figure 1 to attach two overlapping strap layers.

[0010] Figures 4A and 4B are perspective views of the working assembly of the strapping device of Figure 1.

[0011] Figures 5A-5F are side elevational views of part of one side of the working assembly of Figures 4A and 4B showing the tensioning assembly moving from a home position to a strap-insertion position and from the strap-insertion position to a tensioning position after strap is inserted into the strapping device. Certain components of the working assembly are not shown for clarity.

[0012] Figure 6A is a front elevational view of the working assembly of Figures 3A and 3B showing the sealing assembly in a home configuration.

[0013] Figure 6B is a front elevational view similar to Figure 6A showing the sealing assembly between the home configuration and a sealing configuration and forcing the overlapping upper and lower strap layers against the weld plate.

[0014] Figure 6C is a front elevational view similar to Figures 6A and 6B showing the sealing assembly in the sealing configuration and the weld shoe oscillating.

[0015] Figure 7A is a side elevational view of a strap guide and the rocker-position indicator of the strap guide of the strapping device of Figure 1.

[0016] Figure 7B is a cross-sectional side elevational view of the strap guide of Figure 7A mounted to the cover of the housing of the strapping device of Figure 1.

[0017] Figures 8A and 8B are perspective and side elevational views, respectively, of the strapping device of Figure 1 with the tensioning assembly in the home position, the strap guide of Figure 7A in a lower position, and a rocker-position indicator of the strap guide in a first configuration.

[0018] Figure 8C is a cross-sectional side elevational view of part of the strapping device of Figure 1 taken substantially along line 8C-8C of Figure 8A.

[0019] Figures 9A and 9B are perspective and side elevational views, respectively, of the strapping device of Figure 1 after the tensioning assembly has moved to the strap-insertion position, the strap guide has moved to an upper position, and the rocker-position indicator of the strap guide has switched to a second configuration.

[0020] Figure 9C is a cross-sectional side elevational view of part of the strapping device of Figure 1 taken substantially along line 9C-9C of Figure 9A.

[0021] Figures 10A and 10B are perspective and side elevational views, respectively, of the strapping device of Figure 1 after overlapping upper and lower layers of strap have been positioned between a tension wheel of the tensioning assembly and a tension plate of the working assembly of Figures 4A and 4B and the tensioning assembly has moved to the tensioning position at which the tension wheel forces the over lapping layers of strap against the tension plate.

[0022] Figure 10C is a cross-sectional side elevational view of part of the strapping device of Figure 1 taken substantially along line 10C-10C of Figure 10A.

[0023] Figures 11 A and 1 IB are perspective and side elevational views, respectively, of the strapping device of Figure 1 after overlapping upper and lower layers of strap have been inserted into the strapping device and trapped beneath between the feet of the strap guide of Figure 7A.

[0024] Figure 11C is a cross-sectional side elevational view of part of the strapping device of Figure 1 taken substantially along line 11C-11C of Figure 11A.

[0025] Figure 12 is a perspective view of part of the strapping device with the housing cover removed.

[0026] Figure 13 is a cross-sectional perspective view of part of the strapping device of Figure 1 taken substantially along line 13-13 of Figure 12.

[0027] Figures 14A-14C are cross-sectional front elevational views of part of the strapping device during installation of the housing cover.Detailed Description

[0028] While the systems, devices, and methods described herein may be embodied in various forms, the drawings show and the specification describes certain exemplary and nonlimiting embodiments. Not all of the components shown in the drawings and described in the specification may be required, and certain implementations may include additional, different, or fewer components. Variations in the arrangement and type of the components; the shapes, sizes, and materials of the components; and the manners of connections of the components may be made without departing from the spirit or scope of the claims. Unless otherwise indicated, any directions referred to in the specification reflect the orientations of the components shown in the corresponding drawings and do not limit the scope of the present disclosure. Further, terms that refer to mounting methods, such as mounted, connected, etc., are not intended to be limited to direct mounting methods but should be interpreted broadly to include indirect and operably mounted, connected, and like mounting methods. This specification is intended to be taken as a whole and interpreted in accordance with the principles of the present disclosure and as understood by one of ordinary skill in the art.

[0029] Figures 1-14C show one example embodiment of a strapping device of the present disclosure in the form of a battery-powered portable strapping device 50 and certain subassemblies and components thereof. As shown in Figures 3A-3C, the strapping device 50 is configured to carry out a strapping cycle to tension and seal strap S (plastic strap in this example embodiment) around a load L on a pallet P to form a tensioned strap loop that secures the load L to the pallet P. An operator pulls strap S from a strap supply (not shown) and wraps the strap around the load L and through the openings in the pallet P until a lower layer LL of the strap S (which includes the leading end of the strap S) is positioned below an upper layer UL of the strap S, as shown in Figure 3A. The operator then introduces the overlapping upper and lower layersUL and LL of the strap S into the strapping device 50 and actuates one or more buttons to initiate the strapping cycle. As shown in Figure 3B, a motor drives a tensioning assembly to carry out a tensioning cycle during which the strapping device 50 tensions strap S around the load L. Once a preset tension is reached in the strap S, as shown in Figure 3C, the motor drives a sealing assembly to carry out a sealing cycle during which the strapping device 50 connects the upper and lower layers UL and LL of the strap S to one another via friction welding to form a strap joint SJ, as shown in Figure 3D, and cuts the strap S from the strap supply.

[0030] The strapping device 50 includes a housing 100, a working assembly 200, a strap guide 700, a rocker-position indicator 750, first and second pushbutton actuators 1410 and 1440, a display assembly 1490, a power supply 1500, a controller 1600, and one or more sensors 1700.

[0031] The housing 100, best shown in Figure 1, is formed from multiple components (not individually labeled) that collectively at least partially enclose and / or support some (or all) of the other assemblies and components of the strapping device 50. In this example embodiment, the housing 100 includes a front housing section 110, a housing cover 115, a rear housing section 120, a motor housing section 130, and a handle section 150. The front housing section 110 at least partially encloses and / or supports at least some of the components of the working assembly 200. The housing cover 115 includes a cover body 115b that at least partially encloses some of the components of the working assembly 200 — including the tension wheel 400w — and supports the strap guide 700 that is described below. An opening 115o is defined through an upper surface of the cover body 115b. The opening 115o is sized and shaped such that part of the rocker-position indicator 750 (which is connected to the strap guide 700 in this example embodiment) can extend into or through the opening 115o, depending on the embodiment, as described below.

[0032] The rear housing section 120 at least partially encloses and / or supports at least some of the components of the display assembly 1490 and defines a receptacle sized, shaped, and otherwise configured to receive and at least partially enclose and / or support thepower supply 1500 and the controller 1600. The motor housing section 130 extends between and connects the bottoms of the front and rear housing sections 110 and 120 and at least partially encloses and / or supports at least some of the components of the working assembly 200, including the motor 1100. The handle housing section 150 extends between and connects the tops of the front and rear housing sections 110 and 120 and defines a handle used by the operator. This is merely one example, and in other embodiments the components of the strapping device may be supported and / or enclosed by any suitable portion of the housing 100. The housing 100 may be formed from any suitable quantity of components joined together in any suitable manner. In this example embodiment, the housing 100 is formed from plastic, though it may be made from any other suitable material in other embodiments.

[0033] The working assembly 200, which is best shown in Figures 4A and 4B, includes most of the components of the strapping device 50 that are configured to carry out the strapping cycle to tension the strap around the load, attach the overlapping layers of the strap to one another, and cut the strap from the strap supply. The working assembly 200 includes a support 300, a tensioning assembly 400, a trigger 600, a sealing assembly 900, a transmission 1000, and a motor 1100.

[0034] The support 300, which is best shown in Figures 4A and 4B, serves as a direct or indirect common mount for the tensioning assembly 400, the trigger 600, the sealing assembly 900, the transmission 1000, and the motor 1100. The support 300 includes a base 300b and a frame 300f extending from the base 300b. The base 300b supports a toothed tension plate 312 below the tension wheel 400w of the tensioning assembly 400 (described below) and a toothed weld plate 314 below the weld shoe 942 of the sealing assembly 900 (described below).

[0035] The tensioning assembly 400 is operable via the motor 1100 to tension the strap around the load during the tensioning cycle. The tensioning assembly 400 includes a rocker 400r, tensioning-assembly gearing (not labeled), a tension wheel 400w, and a tension-wheel cover 400c. The tension wheel 400w is supported by the tensioning-assembly gearing, which is in turn supported by the rocker 400r. The tension-wheel cover 400c, which is best shown inFigure 12, is attached to the tensioning-assembly gearing such that it partially covers the tension wheel 400w and maintains it in place. The tensioning-assembly gearing is configured to rotate the tension wheel 400w about a tension-wheel rotational axis A400W in a tensioning rotational direction to tension the strap around the load. The tensioning assembly 400 is movably mounted to the support 300 via the rocker 400r and a tensioning-assembly mounting shaft 395 (Figures 4A and 4B) and configured to pivot relative to the support 300 — and particularly relative to the base 300b of the support 300 and the tension plate 312 — about a rocker-pivot axis A4oor among a home position (Figures 5A and 5B), a strap-insertion position (Figures 5C-5E), and a tensioning position (Figure 5F). When the tensioning assembly 400 is in the home position, the tension wheel 400w is adjacent to the tension plate 312 of the support 300. When the tensioning assembly 400 is in the strap-insertion position, the tension wheel 400w is spaced-apart from the tension plate 312 to enable the overlapping upper and lower layers of the strap to be inserted between the tension wheel 400w and the tension plate 312. When the tensioning assembly 400 is in the tensioning position and overlapping strap layers are between the tension wheel 400w and the tension plate 312, the tension wheel 400w engages the upper layer of strap and forces the strap layers onto the tension plate 312. The weight of the tensioning assembly 400 and one or more springs or other biasing elements (not shown) bias the tensioning assembly 400 to the home position.

[0036] The trigger 600 is operable (here, pivotable) to cause the tensioning assembly 400 to move from the home position to the strap-insertion position. In this example embodiment, when the trigger 600 is pulled it triggers a switch that causes the motor 1100 to cooperate with the tensioning assembly 400 to pivot the tensioning assembly 400 from the home position to the strap-insertion position. In other embodiments, the trigger 600 is operably connected to the tensioning assembly 400 via one or more mechanical linkages such that pulling the trigger 600 forces the tensioning assembly 400 to pivot from the home position to the strap-insertion position.

[0037] The sealing assembly 900, which is best shown in Figures 6A-6C, is configured to attach overlapping portions of the strap to one another to form a tensioned strap loop around the load during the sealing cycle via friction welding. The sealing assembly 900 includes a first link arm 910, a second link arm 920, a first sealing-assembly biasing element 930, a second sealing-assembly biasing element 932, a weld arm 940, a weld shoe 942, a cutter 944, and an eccentric shaft (not shown). The weld shoe 942 is slidably mounted to the weld arm 940 such that the weld shoe 942 can oscillate relative to the weld arm 940 in the transverse direction of the strap (left and right from the perspective of Figures 6A-6C). The eccentric shaft is operably connected to the weld shoe 942 and configured to, when rotated, cause the weld shoe 942 to oscillate. A toothed belt 900b operably connects the transmission 1000 to a driven gear 905 to rotate the driven gear 905. The driven gear 905 is fixed in rotation with the eccentric shaft such that rotation of the driven gear 905 results in rotation of the eccentric shaft and oscillation of the weld shoe 942. The cutter 944 is removably mounted to the weld arm 940.

[0038] The weld arm 940 is pivotably mounted to the support 300 and is pivotable relative to the support 300 and the weld plate 314 about a weld-arm axis A940 between a home position (Figures 4A and 6A) in which the weld shoe 942 is spaced-apart from the weld plate 314 and a sealing position (Figure 6C) in which the weld shoe 942 is adjacent to the weld plate 314 and positioned to weld the strap. The first and second link arms 910 and 920 operably connect the transmission 1000 to the weld arm 940 such that the transmission 1000 can move the weld arm 940 from the home position to the sealing position. The first link arm 910 is pivotably mounted to the support 300 via a first pivot 900pl (such as a pivot pin). The second link arm 920 links the first link arm 910 to the weld arm 940. Specifically, one end of the second link arm 920 is pivotably connected to one end of the first link arm 910 via a second pivot 900p2 (such as a pivot pin), and the other end of the second link arm 920 is pivotably connected to the weld arm 940 via a third pivot 900p3 (such as a pivot pin). The first sealing-assembly biasing element 930 circumscribes the second link arm 920 and, as explained below, biases the sealing assembly 900to its sealing confi uration. The second sealing-assembly biasing element 932 biases the sealing assembly to its home configuration.

[0039] When the sealing assembly 900 is in the home configuration in which the weld arm 940 is in the home position — shown in Figures 3A and 6A — the first and second link arms 910 and 920 are oriented such that they form an angle greater than 0 degrees and less than 180 degrees (i.e., an acute or obtuse angle). When the sealing assembly 900 is in the sealing configuration in which the weld arm 940 is in the sealing position — shown in Figure 6C — the first and second link arms 910 and 920 form an angle greater than 180 degrees and less than 360 degrees (i.e., a reflex angle). As described in detail below, the transmission 1000 is configured to switch the sealing assembly 900 from its home configuration to its sealing configuration by manipulating the orientation of the first and second link arms 910 and 920.

[0040] The transmission 1000, which is best shown in Figures 4A and 4B, is driven by the motor 1100, is operably connected to the tensioning assembly 400 and configured to cause the tension wheel 400w to rotate in the tensioning direction to tension the strap, and is operably connected to the sealing assembly 900 and configured to cause the sealing assembly 900 to attach the overlapping portions of the strap to one another. The transmission 1000 includes transmission gearing including a drive gear 1012 (which is a bevel pinion gear in this example embodiment) and a variable offset coupling 800. The transmission gearing and the variable offset coupling 800 are mounted to the support 300 such that the drive gear 1012 is configured to drive the variable offset coupling 800.

[0041] The transmission gearing includes suitable components (such as gears, bearings, and freewheels) that transmit rotational movement of the output shaft of the motor 1100 in a first drive direction to the drive gear 1012 to rotate the drive gear 1012 (but not to drive any components of the sealing assembly 900 in this example embodiment). The drive gear 1012 drives the variable offset coupling 800, which transmits the rotational movement of the drive gear 1012 to the tensioning-assembly gearing to rotate the tension wheel 400w.

[0042] The components of the transmission gearing transmit rotational movement of the output shaft of the motor 1100 in a second drive direction opposite the first drive direction to the sealing assembly 900 to switch the sealing assembly 900 from its home configuration to its sealing configuration and to drive the toothed belt 900b to rotate the driven gear 905 and the eccentric shaft and cause the weld shoe 942 to oscillate (but not to drive the drive gear 1012 in this example embodiment). More specifically, the transmission gearing includes a cam 1010c (Figure 6A) driven in rotation by the output shaft of the motor 1100 when the output shaft is rotated in the second drive direction. The cam 1010c engages the free end (not shown) of the first link arm 910 of the sealing assembly 900, which causes the first link arm 910 of the sealing assembly 900 to rotate clockwise about the first pivot 900pl (from the viewpoint shown in Figures 6A-6C) to raise the second pivot 900p2 and switch the sealing assembly 900 to the sealing configuration, thereby moving the weld arm 940 into its sealing position.

[0043] This is merely one example transmission assembly, and the strapping device may include any suitable transmission assembly or assemblies operably connecting one or more motors to the tensioning and sealing assemblies to drive those assemblies.

[0044] The motor 1100, which is best shown in Figures 4A and 4B, is operably connected to (via the transmission 1000) the tensioning assembly 400 and the sealing assembly 900 and is configured to drive those assemblies as explained herein. The motor 1100 includes the output shaft (not shown) referenced above. The motor 1100 is an electric motor in this example embodiment but may be any suitable motor.

[0045] The strap guide 700, which is best shown in Figures 7A and 7B, includes a body 710 and a neck 720 extending transversely from the body 710. The body 710 has opposing front and rear ends 712 and 714, respectively. The front end 712 includes a downwardly extending front guide 712f, and the rear end 714 includes a downwardly extending rear guide 714f. The neck 720 includes the rocker-position indicator 750 at its free end. First and second slots 710s 1 and 710s2 are defined through the body 710 and the neck 720 and facilitate mounting the strap guide 700 to the housing cover 115 as described below. The body 710 includes a springmount 710m that extends into the bottom of the second slot 710s2. An opening 720o is defined through the neck 720 and facilitates mounting the strap guide 700 to the tensioning assembly 400, as explained below.

[0046] As shown in Figure 7B, the strap guide 700 is slidably mounted to the housing cover 115. Specifically, the cover body 115b includes a first strap-guide mount 115g that extends from an inner surface of the cover body 115b. The first strap-guide mount 115g is received in the first slot 710sl of the strap guide 700. The cover body 115b also includes a spring mount 115r that extends from the inner surface of the cover body 115b. The spring mount 115r extends through the second slot 710s2 of the strap guide 700. A strap-guide spring 700s — which is a compression spring in this example embodiment but may be any other suitable biasing element in other embodiments — is mounted to and extends between the spring mount 115r of the cover body 115b and the spring mount 710m of the strap guide 700.

[0047] As best shown in Figures 8C, 9C, 10C, 11C, and 12, when the housing cover 115 is attached to the housing 100, the strap guide 700 is mounted to the tensioning assembly 400 via a second strap-guide mount 790 — which is a retractable pin in this example embodiment — that is supported by the cover 400c and that extends into (and in some embodiments through) the opening 720o. The strap guide 700 is positioned so the front guide 712f is forward of the tension plate 312 and the rear guide 714f is rearward of the weld plate 314.

[0048] The strap guide 700 is vertically movable relative to various other components of the strapping device 50 — including the housing cover 115 and the support 300 — among a lower position (Figures 8A-8C), an upper position (Figures 9A-9C), and a tensioning position (Figures 10A-10C). The strap-guide spring 700s biases the strap guide 700 to the lower position. The second strap-guide mount 790 operably connects the tensioning assembly 400 to the strap guide 700 such that the position of the tensioning assembly 400 controls the position of the strap guide 700. Specifically, when the tensioning assembly 400 is in the home position, the strap guide 700 is in the lower position; when the tensioning assembly 400 is in the strapinsertion position, the strap guide 700 is in the upper position; and when the tensioning assembly400 is in the tensioning position, the strap guide 700 is in the tensioning position. Accordingly, movement of the tensioning assembly 400 among these positions causes the strap guide 700 to move among these positions.

[0049] When the strap guide 700 is in the lower position, as shown in Figures 8A- 8C, the free end of the front guide 712f is received in a divot defined in the base 300b of the support 300 and the rear guide 714f extends below the upper surface of and behind the base 300b. When the strap guide 700 is in the upper position, as shown in Figures 9A-9C, the front and rear guides 712f and 714f are above the space between the tension wheel 400w and the tension plate 312 and the space between the weld shoe 942 and the weld plate 314. When in the upper position, the strap guide 700 does not interfere with insertion of strap into those spaces. When the strap guide is in the tensioning position, as shown in Figures 10A-10C, the front and rear guides 712f and 714f extend below the lower layer LL of strap S to prevent the strap S from moving transversely out from beneath the tension wheel 400w and / or the weld pad 942 (out of the page from the perspective shown in Figures 10B and 10C).

[0050] The rocker-position indicator 750 is configured to indicate to the operator that the rocker 400r is in the strap-insertion position so the operator can insert strap into the strapping device 50. Generally, the rocker-position indicator 750 has a first configuration, a second configuration, and a third configuration. The rocker-position indicator 750 is in the first configuration when the rocker 400r is in the home position, in the second configuration when the rocker 400r is in the strap-insertion position, and in the third configuration when the rocker 400r is in the tensioning position. Moving the rocker 400r from the home position to the strapinsertion position causes the rocker-position indicator 750 to switch from the first configuration to the second configuration, moving the rocker 400r from the strap-insertion position to the tensioning position causes the rocker-position indicator 750 to switch from the second configuration to the third configuration, and moving the rocker 400r from the tensioning position to the home position causes the rocker-position indicator to switch from the third configuration to the first configuration.

[0051] In this example embodiment, the rocker-position indicator 750 is connected to (and here an integral part of) the free end of the neck 720 of the strap guide 700, and the first, second, and third configurations are first, second, and third positions. When the strap guide 700 is in the lower position, the rocker-position indicator 750 is in the first position at which the rocker-position indicator 750 does not extend through the opening 115o of the housing cover 115, as shown in Figures 8A-8C. When the strap guide 700 is in the upper position, the rockerposition indicator is in the second position at which at least part of the rocker-position indicator 750 extends through the opening 115o of the housing cover 115, as shown in Figures 9A-9C. When the strap guide 700 is in the tensioning position, the rocker-position indicator 750 is in the third position at which the rocker-position indicator 750 does not extend through the opening 115o of the housing cover 115, as shown in Figures 10A-10C. Since the opening 115o is positioned within the operator’s line of sight, the operator can quickly and easily verify whether the rocker 400r is in the strap-insertion position and ready to receive strap by confirming whether the rocker-position indicator 750 extends from the opening.

[0052] The front and rear guides 712f and 714f are each sized, shaped, oriented, positioned, and otherwise configured to prevent the tension wheel 400w from tensioning the strap if the strap is misaligned such that it is sandwiched between either of the front and rear guides 712f and 714f and the base 300b of the support 300. Figures 11A-11C illustrate a scenario in which the upper layer UL and lower layer LL of strap S are trapped between the front and rear guides 712f and 714f and the base 300b of the support 300. In this example embodiment, the bottom ends of the front and rear guides 712f and 714f are below the tension wheel 400w, meaning that the tension wheel 400w does not engage (or if the strap is curved, slightly engages) the upper layer UL of the strap S. In any event, the tension wheel 400w does not exert enough pressure on the strap S to force the strap S against the tension plate 312 such that the tension wheel 400w tensions the strap when rotated. In other words, if the tensioning process is initiated with the strap trapped between one or both of the front and rear guides and the base of the support, the strapping device will not tension the strap.

[0053] As best shown in Figures 12 and 13, the second strap-guide mount 790 includes a cylindrical head 790h and a cylindrical body 790b extending from the head 790h. The second strap-guide mount 790 extends through a bore defined through the tension-wheel cover 400c and is secured at its rear end via a retainer 794, which is a retaining clip in this example embodiment. A spring 792 — which is a compression spring in this example embodiment but may be any other suitable biasing element in other embodiments, circumscribes the body 790b and extends between the head 790h and the rear wall of the bore in tension-wheel cover 400c. The second strap-guide mount 790 is movable relative to the cover 400c between an extended position (Figures 12, 13, 14A, and 14C) in which at least part of the head 790h projects from the cover 400c and a retracted position (Figure 14B) in which the head 790h is retracted substantially entirely into the bore in the tension-wheel cover 400c. The spring 792 biases the second strap-guide mount 790 to the extended position.

[0054] The retractable second strap-guide mount 790 facilitates attaching the housing cover 115 to the housing 100 and in doing so operably connecting the tensioning assembly 400 to the strap guide 700. As explained above, the tensioning assembly 400 is operably connected to the strap guide 700 via insertion of the second strap-guide mount 790 into the opening 720o of the strap guide 700. As shown in Figure 14A, in certain situations the opening 720o and the second strap-guide mount 790 may not be aligned when the operator is moving the housing cover 115 into position relative to the housing 100. When this occurs, as shown in Figure 14B, the strap guide 700 engages the second strap-guide mount 790 and forces it to the retracted position. Later when the second strap-guide mount 790 moves along with the tensioning assembly 400 relative to the strap guide 700 (because there is no operative connection between the two at this point), the second strap-guide mount 790 eventually aligns with the opening 720o, and the spring 792 forces the second strap-guide mount 790 back to its extended position to operably connect the tensioning assembly 400 to the strap guide 700, as shown in Figure 14C.

[0055] The display assembly 1490, which is shown in Figures 1 and 2, includes a suitable display screen 1492 with a touch panel 1494. The display screen 1492 is configured to display information regarding the strapping device 50 (at least in this embodiment), and the touch screen 1494 is configured to receive operator inputs such as the desired operating mode (described below), a desired strap tension, and a desired weld cooling time. A display controller (not shown) may control the display screen 1492 and the touch panel 1494 and, in these embodiments, is communicatively connected to the controller 1600 to send signals to the controller 1600 and to receive signals from the controller 1600. Other embodiments of the strapping device do not include a touch panel. Still other embodiments of the strapping device do not include a display assembly. Certain embodiments of the strapping device include a separate pushbutton panel instead of a touch panel beneath or integrated with the display screen.

[0056] The first and second pushbutton actuators 1410 and 1440 are operable to initiate the tensioning and / or sealing cycles as described below. Other embodiments of the strapping device 50 do not have pushbutton actuators and instead incorporate their functionality into the display assembly 1490. For instance, in one of these embodiments two areas of the touch panel define virtual buttons that have the same functionality as mechanical pushbutton actuators.

[0057] The controller 1600, which is shown in Figure 2, includes a processing device (or devices) communicatively connected to a memory device (or devices). For instance, the controller may be a programmable logic controller. The processing device may include any suitable processing device such as, but not limited to, a general-purpose processor, a specialpurpose processor, a digital-signal processor, one or more microprocessors, one or more microprocessors in association with a digital-signal processor core, one or more applicationspecific integrated circuits, one or more field-programmable gate array circuits, one or more integrated circuits, and / or a state machine. The memory device may include any suitable memory device 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 opticalmedia. The memory device stores instructions executable by the processing device to control operation of the strapping device 50. The controller 1600 is communicatively and operably connected to the motor 1100, the display assembly 1490, the pushbutton actuators 1410 and 1440, and the sensor(s) 1700 and configured to receive signals from and to control those components. The controller 1600 may also be communicatively connectable (such as via Wi-Fi, Bluetooth, near-field communication, or other suitable wireless communications protocol) to an external device, such as a computing device, to send information to and receive information from that external device.

[0058] The controller 1600 is configured to operate the strapping device in one of three operating modes to carry out the strapping cycle: (1) a manual operating mode; (2) a semiautomatic operating mode; and (3) an automatic operating mode. In the manual operating mode, the controller 1600 operates the motor 1100 to cause the tension wheel 400w to rotate responsive to the first pushbutton actuator 1410 being actuated and maintained in its actuated state. The controller 1600 operates the motor 1100 to cause the sealing assembly 900 to carry out the sealing cycle responsive to the second pushbutton actuator 1440 being actuated. In the semiautomatic operating mode, the controller 1600 operates the motor 1100 to cause the tension wheel 400w to rotate responsive to the first pushbutton actuator 1410 being actuated and maintained in its actuated state. Once the controller 1600 determines that the tension in the strap reaches the (preset) desired strap tension, the controller 1600 automatically operates the motor 1100 to cause the sealing assembly 900 to carry out the sealing cycle (without requiring additional input from the operator). In the automatic operating mode, the controller 1600 operates the motor 1100 to cause the tension wheel 400w to rotate responsive to the first pushbutton actuator 1410 being actuated. Once the controller 1600 determines that the tension in the strap reaches the (preset) desired strap tension, the controller 1600 automatically operates the motor 1100 to cause the sealing assembly 900 to carry out the sealing cycle (without requiring additional input from the operator).

[0059] The sensors 1700 include any suitable sensors, such as microswitches, optical sensors, ultrasonic sensors, magnetic position sensors, and the like, configured to detect the position of certain components of the strapping device 50 and to send appropriate signals to the controller 1600. The sensors 1700 may include, for instance: one or more tensioning-assembly- position sensors configured to detect when the tensioning assembly 400 is in its home position and / or its strap-insertion position; one or more trigger-position sensors configured to detect when the trigger 600 is pulled; and one or more actuating assembly sensors configured to detect actuation of the first and second pushbutton actuators 1410 and 1440.

[0060] The power supply 1500 is electrically connected to (via suitable wiring and other components) and configured to power several components of the strapping device 50, including the motor 1100, the display assembly 1490, the controller 1600, and the sensor(s) 1700. The power supply 1500 includes a rechargeable battery (such as a lithium-ion or nickel cadmium battery) in this example embodiment, though it may be any other suitable electric power supply in other embodiments. The power supply 1500 is sized, shaped, and otherwise configured to be received in the receptacle defined by the rear housing section 120 of the housing 100. The strapping device 50 includes one or more power-supply-securing devices (not shown) to releasably lock the power supply 1500 in place upon receipt in the receptacle. Actuation of a release device of the strapping device 50 or the power supply 1500 unlocks the power supply 1500 from the housing 100 and enables an operator to remove the power supply 1500 from the receptacle.

[0061] Use of the strapping device 50 to carry out a strapping cycle to form a tensioned strap loop around a load is now described below. Initially, the tensioning assembly 400 is in its home position and the sealing assembly 900 is in its home configuration, as shown in Figures 5A and 6A. The strapping device 50 is in the automatic mode for the purposes of this example.

[0062] The operator pulls the strap S leading-end first from a strap supply (not shown), wraps the strap S around the load, and positions a lower layer LL including the leadingend of the strap S below an upper layer UL of the strap S. The operator then pulls the trigger 600, as shown in Figure 5B, to lift the tensioning assembly 400 to its strap-insertion position, as shown in Figure 5C. As explained above, this results in the rocker-position indicator 750 extending through the opening 115o and alerting the operator that the strapping device is ready to receive strap. With the tensioning assembly 400 in its strap-insertion position and while continuing to pull the trigger 600, the operator introduces the overlapping upper and lower layers UL and LL of the strap S between the tension wheel 400w and the tension plate 312 and between the weld shoe 942 and the weld plate 314, as shown in Figure 5D. The operator then releases the trigger 600, as shown in Figure 5E, enabling the appropriate biasing elements to force the tensioning assembly 400 pivot to its tensioning position to sandwich the overlapping upper and lower strap layers UL and LL between the tension wheel 400w and the tension plate 312, as shown in Figure 5F.

[0063] The operator then actuates the first pushbutton actuator 1410. Once one of the sensors 1700 detects the actuation of the first pushbutton actuator 1410, the controller 1600 starts the tensioning cycle by controlling the motor 1100 to rotate the output shaft in the first drive direction. As explained above, the transmission 1000 transmits this rotational movement of the output shaft to the tensioning-assembly gearing which, in turn, rotates the tension wheel 400w about the tension-wheel rotational axis A400w in the tensioning direction. As the tension wheel 400w rotates in the tensioning direction, it pulls the upper layer UL of the strap S over the lower layer LL of the strap S, thereby tensioning the strap S around the load. Throughout the tensioning cycle, the controller 1600 monitors the current drawn by the motor 1100. When this current reaches a preset value that is correlated with the (preset) desired strap tension for this strapping cycle, the controller 1600 stops the motor 1100, thereby terminating the tensioning cycle.

[0064] In this example embodiment, after completion of the tensioning cycle, the controller 1600 automatically starts the sealing cycle by controlling the motor 1100 to begin rotating the output shaft in the second drive direction. This causes the transmission 1000 to drive the toothed belt 900b to begin rotating the eccentric shaft and oscillating the weld shoe 942 andto switch the sealing assembly 900 from its home configuration to its sealing configuration, and in doing so pivot the weld arm 940 to its sealing position. As the weld arm 940 reaches the sealing position, the weld shoe 942 forces the overlapping upper and lower layers of strap UL and LL against the weld plate 314 while the cutter 944 cuts the upper strap layer UL from the strap supply. Figures 6B and 6C show this movement of the weld arm 940 and oscillation of the weld shoe 942. As explained above, the oscillation of the weld shoe 942 is fast enough to generate friction and heat substantial enough to locally melt and join the portions of the overlapping strap layers, thereby attaching the upper and lower strap layers UL and LL to form the tensioned strap loop. The controller 1600 controls the motor 1100 to stop rotating the output shaft, completing the sealing cycle. The operator can then pull the trigger 600 to raise the tensioning assembly 400 and to switch the sealing assembly 900 back to its home configuration to release the tensioned strap loop.

[0065] The above-described example embodiment of the strapping device includes a single motor configured to drive both the tensioning assembly and the sealing assembly. In other embodiments, the strapping device includes separate motors configured to drive the respective tensioning and sealing assemblies and may include separate transmissions for each motor.

[0066] Other embodiments of the strapping device may include fewer assemblies, components, and / or features than those included in the strapping device 50 described above and shown in the Figures. In other words, while the strapping device 50 includes all of the assemblies, components, and features described above, they are independent of one another and may be independently included in other strapping devices.

[0067] While the strapping device described above is a handheld strapping device, the strapping device may be any other suitable strapping device in other embodiments, such as a standalone automatic or semi-automatic strapping machine.

[0068] In the strapping device described above, the movable rocker supports the tension wheel and moves the tension wheel relative to the stationary tension plate as the rocker pivots among the home, strap-insertion, and tensioning positions. In other embodiments, themovable rocker supports the tension plate and the support of the working assembly supports the tension wheel. In these embodiments, the movable rocker moves the tension plate relative to the stationary tension wheel as the rocker pivots among the home, strap-insertion, and tensioning positions.

[0069] In certain embodiments, the rocker-position indicator has a color that differs from the color of the cover. This contrast provides an additional benefit for the operator to enables the operator to easily differentiate the rocker-position indicator from the cover.

[0070] In certain embodiments, when in the first and third configurations, the rockerposition indicator is positioned so as not to be visible by the operator through the opening in the cover. When in the second configuration, the rocker-position indicator is positioned so as to be visible by the operator through the opening in the cover. In these embodiments, the rockerposition indicator does not extend through the opening in the cover when in the second configuration.

[0071] In other embodiments, the rocker-position indicator includes a light. In the first and third configurations, the light is off, while in the second configuration the light is on. In these embodiments, the controller is configured to control the light to switch from off to on (i.e., from the first configuration to the second configuration) responsive to the rocker reaching the strap-insertion position. In certain of these embodiments, one of the sensors is a rocker sensor configured to detect the rocker, and the controller is configured to switch the light based on feedback from that sensor. For instance, in one embodiment the sensor is configured to detect the rocker when the rocker reaches the strap-insertion position, and the controller is configured to switch the light from off to on responsive to that detection.

[0072] In certain embodiments, the display screen is or acts as the rocker-position indicator. The display screen has a first configuration in which it does not indicate that the rocker is in the strap-insertion position and a second configuration in which it indicates that the rocker is in the strap-insertion position. In these embodiments, the controller is configured to switch thedisplay screen from the first configuration to the second configuration responsive to sensor feedback.

[0073] In certain embodiments, the rocker-position indicator includes a haptic device. When in a first configuration, the haptic device does not generate haptic feedback, and when in a second configuration, the haptic device generates haptic feedback (e.g., vibrates). In these embodiments, the controller is configured to switch the haptic device from the first configuration to the second configuration responsive to sensor feedback. For instance, the haptic device is located within the handle portion of the housing of the strapping device and configured to vibrate when in the second configuration to indicate to the operator that the rocker is in the strap-insertion position.

[0074] In certain embodiments, the rocker-position indicator includes an auditory output device. When in a first configuration, the auditory output device does not generate audio output (such as a tone or series of tones), and when in a second configuration, the auditory output device generates audio output (e.g., the tone or series of tones). In these embodiments, the controller is configured to switch the auditory output device from the first configuration to the second configuration responsive to sensor feedback. For instance, the auditory output device is configured to output a tone or series of tones when in the second configuration to indicate to the operator that the rocker is in the strap-insertion position.

Claims

Claims1. A strapping device comprising: a tension plate; a rocker movable between a home position and a strap-insertion position; a rotatable tension wheel, wherein the tension wheel is a first distance from the tension plate when the rocker is in the home position and a second distance from the tension plate when the rocker is in the strap-insertion position, wherein the second distance is greater than the first distance; and a rocker-position indicator having a first configuration and a second configuration, wherein movement of the rocker from the home position to the strap-insertion position causes the rocker-position indicator to switch from the first configuration to the second configuration to indicate that the rocker is in the strap-insertion position.

2. The strapping device of claim 1, wherein the rocker-position indicator is in a first position when in the first configuration and in a second position when in the second configuration, wherein the rocker is operably connected to the rocker-position indicator and configured to move the rocker-position indicator from the first position to the second position as the rocker moves from the home position to the strap-insertion position.

3. The strapping device of claim 2, further comprising a cover at least partially enclosing the tension wheel, wherein the cover defines an opening therethrough, wherein part of the rocker-position indicator is visible through the opening when in the second position and not visible through the opening when in the first position.

4. The strapping device of claim 2, further comprising a cover at least partially enclosing the tension wheel, wherein the cover defines an opening therethrough, wherein part of the rocker-position indicator protrudes from the opening when in the second position and does not protrude from the opening when in the first position.

5. The strapping device of claim 4, wherein the part of the rocker-position indicator has a first color and a portion of the cover surrounding the opening has a second color different from the first color.

6. The strapping device of claim 4, further comprising a strap guide comprising the rocker-position indicator, wherein the strap guide is movable between a lower position and an upper position, wherein the rocker-position indicator is in the first position when the strap guide is in the lower position and in the second position when the strap guide is in the upper position.

7. The strapping device of claim 6, further comprising a connector operably connecting the rocker to the strap guide.

8. The strapping device of claim 6, wherein the strap guide comprises a body, a front guide extending downward from the body forward of the tension plate, and a rear guide extending downward from the body rearward of the tension plate.

9. The strapping device of claim 8, wherein the front and rear guides extend below the tension plate when the strap guide is in the lower position.

10. The strapping device of claim 6, further comprising a cover at least partially enclosing the tension wheel, wherein the cover defines an opening therethrough, wherein part of the rocker-position indicator protrudes from the opening when in the second position and does not protrude from the opening when in the first position.

11. The strapping device of claim 10, wherein the part of the rocker-position indicator has a first color and a portion of the cover surrounding the opening has a second color different from the first color.

12. The strapping device of claim 10, further comprising a support supporting the tension plate, wherein the tension wheel is carried by and movable with the rocker relative to the tension plate.

13. The strapping device of claim 10, further comprising a support supporting the tension wheel, wherein the tension plate is carried by and movable with the rocker.

14. The strapping device of claim 1, further comprising a controller configured to control the rocker-position indicator to switch from the first configuration to the second configuration responsive to the rocker reaching the strap-insertion position.1 . The strapping device of claim 14, further comprising a rocker-position sensor configured to detect the rocker, wherein the controller is configured to control the rockerposition indicator to switch from the first configuration to the second configuration responsive to feedback form the rocker-position sensor.

16. The strapping device of claim 15, wherein the rocker-position sensor is configured to detect the rocker when the rocker is in the strap-insertion position.

17. The strapping device of claim 14, wherein the rocker-position indicator comprises a light, wherein the light is off when in the first configuration and on when in the second configuration.

18. The strapping device of claim 1, further comprising a support supporting the tension plate, wherein the tension wheel is carried by and movable with the rocker relative to the tension plate.

19. The strapping device of claim 1, further comprising a support supporting the tension wheel, wherein the tension plate is carried by and movable with the rocker.

20. A strapping device comprising: a support comprising a base; a tension plate supported by the base; a rocker movable between a home position and a strap-insertion position; a rotatable tension wheel carried by and movable with the rocker, wherein the tension wheel is a first distance from the tension plate when the rocker is in the home position and a second distance from the tension plate when the rocker is in the strap-insertion position, wherein the second distance is greater than the first distance; and a strap guide comprising a body, a front guide extending downward from the body forward of the tension plate, and a rear guide extending downward from the body rearward of the tension plate, wherein the strap guide is movable between a lower position and an upper position.

21. The strapping device of claim 20, wherein the body, the front guide, and the rear guide are integrally formed.

22. The strapping device of claim 20, wherein the front guide and the rear guide each have a bottom end, wherein the bottom ends of the front and rear guides are below a bottom of the tension wheel.

23. The strapping device of claim 20, wherein the strap guide is in the lower position when the rocker is in the home position and in the upper position when the rocker is in the strapinsertion position.

24. The strapping device of claim 23, wherein the rocker is operably connected to the strap guide to move the strap guide from the lower position to the upper position as the rocker moves from the home position to the strap-insertion position.

25. The strapping device of claim 24, wherein the rocker is operably connected to the strap guide to move the strap guide from the upper position to the lower position as the rocker moves from the strap-insertion position to the home position.

26. The strapping device of claim 25, further comprising a connector operably connecting the rocker to the strap guide.

27. The strapping device of claim 26, wherein the connector comprises a pin.

28. The strapping device of claim 20, further comprising a weld plate supported by the base and a weld pad movable relative to the weld plate, wherein the rear guide extends downward from the body rearward of the weld plate and the weld pad.

29. The strapping device of claim 20, wherein the strap guide further comprises a rocker-position indicator having a first position when the strap guide is in the lower position and a second position when the strap guide is in the upper position, wherein when in the second position, the rocker-position indicator indicates that the rocker is in the strap-insertion position.

30. The strapping device of claim 29, further comprising a cover at least partially enclosing the tension wheel, wherein the cover defines an opening therethrough, wherein part of the rocker-position indicator is visible through the opening when in the second position and not visible through the opening when in the first position.31 . The strapping device of claim 29, further comprising a cover at least partially enclosing the tension wheel, wherein the cover defines an opening therethrough, wherein part of the rocker-position indicator protrudes from the opening when in the second position and does not protrude from the opening when in the first position.

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