Strapping device with a decoupling assembly

Abstract

Various embodiments of the present disclosure provide a strapping device including tensioning-assembly gearing comprising a driven shaft and a first gear, a tension wheel drivable by the tensioning-assembly gearing, a decoupling assembly switchable between a coupled configuration and a release configuration, and a locking device. The decoupling assembly includes a decoupling-assembly shaft operably connected to the first gear, a first engageable element connected to and rotatable with the decoupling-assembly shaft, a second engageable element, and an expandable element circumscribing at least part of the first engageable element and the second engageable element. The locking device substantially prevents rotation of the second engageable element relative to the first engageable element.

Description

STRAPPING DEVICE WITH A DECOUPLING ASSEMBLYPriority

[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 518,753, filed August 10, 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 tools 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. Many strapping tools utilize friction welding to attach overlapping upper and lower strap layers to one another. To use one of these strapping tools 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 introduces the overlapped strap layers into the strapping tool and presses a button to initiate a tensioning process during which a 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 process, a sealing process is initiated. During the sealing process, a toothed weld shoe forces the strap layers against a toothed weld plate. A motor oscillates the weld shoe at a high frequency as the weld shoe exerts a welding force on the strap layers. The oscillating weld shoe oscillates the upper strap layer relative to the lower strap layer, which generates friction between portions of the overlapping strap layers that locally melts them. The motor stops oscillating the weld shoe while the weld shoe continues to exert the welding force. The meltedportions of the overlapping strap layers join together and solidify as they cool, thereby attaching the upper and lower strap layers to form the tensioned strap loop.Summary

[0004] Various embodiments of the present disclosure provide a strapping device including tensioning-assembly gearing comprising a driven shaft and a first gear, a tension wheel drivable by the tensioning-assembly gearing, a decoupling assembly switchable between a coupled configuration and a release configuration, and a locking device. The decoupling assembly includes a decoupling-assembly shaft operably connected to the first gear, a first engageable element connected to and rotatable with the decoupling-assembly shaft, a second engageable element, and an expandable element circumscribing at least part of the first engageable element and the second engageable element. The locking device substantially prevents rotation of the second engageable element relative to the first engageable element. When the decoupling assembly is in the coupled configuration, the expandable element frictionally engages the first and second engageable elements such that the first engageable element, the decoupling-assembly shaft, and the first gear are prevented from rotating relative to the second engageable element. When the decoupling assembly is in the release configuration, the frictional engagement between the expandable element and the first engageable element is at least partially eliminated such that the first engageable element, the decoupling-assembly shaft, and the first gear are rotatable relative to the second engageable element.Brief Description of the Figures

[0005] Figures 1A and IB are perspective views of one example embodiment of a strapping device of the present disclosure.

[0006] Figure 1C is a block diagram of certain components of the strapping device of Figures 1A and IB.

[0007] Figures 2A-2C are diagrammatic views of the strapping device of Figures 1 A and IB securing a load to a pallet.

[0008] Figure 2D is a perspective view of a friction- weld strap joint formed by the strapping device of Figures 1A and IB.

[0009] Figures 3 A and 3B are perspective views of the working assembly of the strapping device of Figures 1A and IB.

[0010] Figure 4A is a perspective view of the tensioning assembly of the working assembly of Figures 3A and 3B.

[0011] Figure 4B is an exploded perspective view of the tensioning assembly of Figure 4A.

[0012] Figure 4C is a cross-sectional perspective view of the tensioning assembly of Figure 4 A taken along line 4C-4C of Figure 4 A.

[0013] Figure 4D is a front elevational view of the rocker mover of the tensioning assembly of Figure 4A.

[0014] Figure 5A is a perspective view of the decoupling assembly of the working assembly of Figures 3A and 3B.

[0015] Figure 5B is an exploded perspective view of the decoupling assembly of Figure 5A.

[0016] Figure 5C is a cross-sectional perspective view of the decoupling assembly of Figure 5 A taken along line 5C-5C of Figure 5 A.

[0017] Figure 5D is a perspective view of part of the working assembly of Figure 3A showing the decoupling assembly of Figure 5A.

[0018] Figures 6A and 6B are perspective views of the actuating assembly of the working assembly of Figures 3A and 3B.

[0019] Figures 7A and 7B are perspective views of the cam-engaging assembly of the working assembly of Figures 3 A and 3B.

[0020] Figures 7C and 7D are side views of the cam-engaging assembly of Figures 7A and 7B with the cam engager in its home and actuated positions, respectively.

[0021] Figures 8A-8G are side views of part of one side of the working assembly of Figures 3A and 3B showing the tensioning assembly moving from a home position to a strapinsertion 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.

[0022] Figures 9A-9G are side views of part of the opposite side of working assembly of Figures 3 A to 3B that correspond to Figures 8A-8G. Certain components of the working assembly are not shown for clarity.Detailed Description

[0023] 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.

[0024] Figures 1A-9G 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 assemblies and components thereof. As shown in Figures 2A-2C, the strapping device 50 is configured to carry out a strapping process 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 2A. The operator then introduces the overlapped upper and lower layers UL and LL of the strap S into the strapping device 50 and actuates one or more buttons to initiate the strapping process. As shown in Figure 2B, a motor drives a tensioning assembly tocarry out a tensioning process 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 2C, the motor drives a sealing assembly to carry out a sealing process 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 2D, and cuts the strap S from the strap supply.

[0025] The strapping device 50 includes a housing 100, a working assembly 200, a cover 1300, 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.

[0026] The housing 100, which is shown in Figures 1 A and IB, 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 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 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 the power 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 sized and shaped to be held by a hand of 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. The cover 1300 is attached to the front housing section 110 and covers part of the working assembly 200.

[0027] The working assembly 200, which is best shown in Figures 3A and 3B, includes the majority of the components of the strapping device 50 that are configured to carryout the opening process to prepare the strapping device 50 to receive strap and the strapping process 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 decoupling assembly 500, an actuating assembly 600, a camengaging assembly 700, a sealing assembly 900, a transmission 1000, and a motor 1100.

[0028] The support 300, which is best shown in Figures 3A and 3B, serves as a direct or indirect common mount for the tensioning assembly 400, the decoupling assembly 500, the actuating assembly 600, the cam-engaging assembly 700, 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 912 of the sealing assembly 900 (described below).

[0029] The tensioning assembly 400, which is best shown in Figures 4A-4D, is operable (with the motor 1100) to move the tensioning assembly 400 relative to the support 300 during an opening process and to tension the strap around the load during a tensioning process. The tensioning assembly 400 includes a rocker 400r, a rocker cover 400c, tensioning-assembly gearing, and a tension wheel 400w driven by the tensioning-assembly gearing. The tension wheel 400w is supported by the tensioning-assembly gearing, which is in turn supported by the rocker 400r.

[0030] The tensioning-assembly gearing includes: a driven shaft 410; a tensioningassembly freewheel 412; a first set of planet gears 414a, 414b, and 414c; a gear cover 415; a rocker mover 420; a rollback ring gear 430; a rollback intermediate gear 431; a carrier 432; a second set of planet gears 434a, 434b, and 434c; a third set of planet gears 436a, 436b, and 436c; and bearings 405bl, 405b2, 405b3, and 405b4. Certain components of the tensioning-assembly gearing are centered on, and certain components of the tensioning-assembly gearing are rotatable about, a tension-wheel rotational axis A o . The driven shaft 410 includes a shaft portion 410a having a driven end 410al and a first sun gear 410b at the end opposite the driven end 410al. The first set of planet gears 414a-414c are rotatably mounted (such as via respective bearings and mounting pins) to the rocker cover 400c and secured in place via the gear cover 415. The rollback ring gear 430 includes internal teeth 430it and external teeth 430ot. The carrier 432 includes a planet-gear carrier 432a to which the second set of planet gears 434a-434c arerotatably mounted (such as via respective bearings and mounting pins) and a second sun gear 432b rotatable with (and here integrally formed with) the planet-gear carrier 432a about the tension-wheel rotational axis Aww. The third set of planet gears 436a-436c are rotatably mounted to the rocker 400r (such as via respective bearings and mounting pins).

[0031] The rocker mover 420, which is best shown in Figure 4D, includes a ring gear 421 having internal teeth 42 lit and supporting an annular cam support 422 that includes angularly spaced, triangularly shaped first and second cams 424 and 426. The first cam 424 has a leading end 4241e and a trailing end 424te connected by a convexly curved finger-engaging surface 424s and a concavely curved lower surface. The finger-engaging surface 424s has an apex 424s’ that corresponds to the point on the finger-engaging surface 424s furthest from the center of the cam support 422. The apex 424s’ of the finger-engaging surface 424s is a distance Rmax from the center of the cam support 422, the leading end 4241e of the cam 424 is a distance Rie from the center of the cam support 422, and the trailing end 424te of the cam 424 is a distance Rte from the center of the cam support 422. Rmax is greater than Rie and Rte such that the apex 424s’ is further from the center of the cam support 422 than the leading and trailing ends 4241e and 424te. In this example embodiment, Rte is greater than Rie though the opposite may be true or they may be the same in other embodiments.

[0032] The portion of the finger-engaging surface 424s extending between the leading end 4241e and the apex 424s’ is curved such that the distance between the fingerengaging surface 424s and the center of the cam support 422 increases moving from the leading end 4241e to the apex 424s’. The portion of the finger-engaging surface 424s extending between the apex 424s’ and the trailing end 424te is curved such that the distance between the fingerengaging surface 424s and the center of the cam support 422 decreases moving from the apex 424s’ to the trailing end 424te. The second cam 426 is identical to the first cam 424 and not separately described for brevity. Its components are identified herein with similar numbers as the components of the first cam 424, with the leading “424” being replaced with “426”. The first and second cams 424 and 426 are angularly spaced apart by the angle a, which is 180 degrees in this example embodiment. While the rocker mover includes two cams in this example embodiment, it may include any suitable quantity of one or more cams in other embodiments.

[0033] The shaft portion 410a of the driven shaft 410 extends through and is engaged by the tensioning-assembly freewheel 412, which is itself supported by and positionedwithin a bore defined through the cover 400c, which is attached to the rocker 400r. The tensioning-assembly freewheel 412 is configured to permit rotation of the driven shaft 410 relative to the rocker 400r in a tensioning rotational direction T — referred to as the tensioning direction T — and to prevent rotation of the driven shaft 410 in a rollback direction TREV, which is the rotational direction opposite the tensioning direction T. The first sun gear 410b of the driven shaft 410 meshes with and drivingly engages the first set of planet gears 414a-414c. The first set of planet gears 414a-414c mesh with the internal teeth 42 lit of the ring gear 421 of the rocker mover 420. The bearing 405b 1 rotatably supports the rocker mover 420 and separates it from the rocker 400r and the cover 400c. The first sun gear 410b of the driven shaft 410 extends through the gear cover 415 and meshes with and drivingly engages the second set of planet gears 434a- 434c. The second set of planet gears 434a-434c mesh with the internal teeth 43 Oit of the rollback ring gear 430. The bearing 405b2 rotatably supports the carrier 432 such that the carrier 432 is rotatable relative to the rocker 400r. The second sun gear 432b of the carrier 432 meshes with and drivingly engages the third set of planet gears 436a-436c. The tension wheel 400w is rotatably mounted to the rocker 400r via bearings 405b3 and 405b4 such that the third set of planet gears 436a-436c mesh with internal teeth (not labeled) of the tension wheel 400w and therefore drivingly engage the tension wheel 400w. The tension wheel 400w is held in place longitudinally (in the direction of the tensioning-wheel axis A400w) via a suitable retainer and suitable fasteners (not shown for clarity).

[0034] The tensioning assembly 400 is movably mounted to the support 300 via the rocker 400r and a tensioning-assembly mounting shaft 395 (Figures 3A and 3B) and configured to pivot relative to the support 300 — and particularly relative to the base 300b of the support 300 — under control of the motor 1100 (as described below) and about a rocker-pivot axis A4oor among a home position (Figures 8A-8C), a strap-insertion position (Figures 8D-8F), and a tensioning position (Figure 8G). 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 thestrap 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.

[0035] Specifically, the tensioning-assembly mounting shaft 395 extends through openings defined through the frame 300f of the support 300 and openings defined through first and second mounting ears 400rl and 400r2 of the rocker 400r. The rollback intermediate gear 431 is rotatably mounted to the tensioning-assembly mounting shaft 395 and positioned between the mounting ears 400rl and 400r2 of the rocker 400r such that teeth of the rollback intermediate gear 431 mesh with the external teeth 430ot of the rollback ring gear 430.

[0036] The decoupling assembly 500, which is best shown in Figures 5A-5D, controls whether the rollback ring gear 430 can rotate about the tensioning-wheel axis A4oow. When the decoupling assembly 500 is in a coupled configuration, the decoupling assembly 500 prevents the rollback ring gear 430 from rotating about the tensioning-wheel axis A400W, which enables the motor 1100 to drive the tension wheel 400w to tension the strap and enables the tension wheel 400w to hold tension in the strap after the tensioning process is complete. Conversely, when the decoupling assembly 500 is in a release configuration, the rollback ring gear 430 is rotatable about the tensioning-wheel axis A4oo» such that the tension wheel 400w can release the held tension. The decoupling assembly 500 includes a decoupling-assembly shaft 510, a first engageable element 520, a second engageable element 530, an expandable element 540, a sleeve 550, and a spacer 570.

[0037] The decoupling-assembly shaft 510 includes a body 512 having a first end 512a having an irregular cross-section and second end 512b having radially extending teeth around its circumference. A cylindrical first support 514 extends from the first end 512a, and a cylindrical second support 516 extends from the second end 512b. The first engageable element 520 comprises a tubular bushing having a cylindrical outer surface and an interior surface having a perimeter shaped to match the shape of the perimeter of the first end 512a of the body 512 of the decoupling-assembly shaft 510. The second engageable element 530 includes a tubular body 532, a neck 534 at one end of the body 532, and a head 536 at the end of the neck 534. These components are integrally formed in this example embodiment. As shown in Figure 5B, an opening 534o is defined in an outer cylindrical surface of the neck 534. As best shown in Figure 5D, the head 536 includes multiple radially extending fingers 536f and multiple concave surfaces536s. Each pair of adjacent fingers 536f is separated by one of the surfaces 536s. The expandable element 540 includes a torsion spring having a first end 540a and a second end 540b. The sleeve 550 includes a tubular body 552 having teeth 554 extending around its outer circumference. The body 552 defines an opening 554o.

[0038] As best shown in Figure 5C, the first engageable element 520 is mounted on the first end 512a of the body 512 of the decoupling-assembly shaft 510 for rotation therewith about a decoupling-assembly rotational axis Asoo. The second engageable element 530 circumscribes the first support 514 of the body 512 of the decoupling-assembly shaft 510 and is positioned such that the body 532 is adjacent and coaxial with the first engageable element 520. The expandable element 540 circumscribes the first engageable element 520 and the body 532 of the second engageable element 530. The outer diameters of the first engageable element 520 and the body 532 of the second engageable element 530 are substantially the same and are equal to or larger than the resting inner diameter of the expandable element 540. This means that when the decoupling assembly 500 is in a coupled configuration (described below), the expandable element 540 exerts a compressive force on the first engageable element 520 and the body 532 of the second engageable element 530 that prevents those components (and the decouplingassembly shaft 510) from rotating relative to one another about the decoupling-assembly rotational axis A500. The second end 540b of the expandable element 540 is received in the opening 534o defined in the neck 534 of the second engageable element 530. At least part of the decoupling-assembly shaft 510, the first engageable element 520, the second engageable element 530, and the expandable element 540 are housed within and circumscribed by the sleeve 550. The first end 540a of the expandable element is received in the opening 554o defined through the body 552 of the sleeve 550. The spacer 570 separates the first engageable element 520 and the gear 580 and acts as a support for the sleeve 550.

[0039] As best shown in Figures 5C and 5D, the decoupling assembly 500 is mounted to the frame 300f of the support 300 and operatively connected to the tensioningassembly gearing. More specifically, the second support 516 of the decoupling-assembly shaft 510 and the neck 534 of the second engageable element 530 are rotatably supported by the frame 300f. The decoupling assembly 500 is positioned such that the decoupling-assembly shaft 510 is operably connected to the rollback ring gear 430 of the tensioning-assembly gearing. Specifically, the teeth on the second end 512a of the body 512 of the decoupling-assembly shaft510 mesh with the teeth of the rollback intermediate gear 431 , which in turn mesh with the external teeth 430ot of the rollback ring gear 430. In other embodiments, the rollback intermediate gear 431 is omitted and the teeth on the second end of the body of the decouplingassembly shaft mesh with the external teeth of the rollback ring gear.

[0040] As shown in Figure 5D, a locking device 590 secures the second engageable element 530 in place and, in particular, prevents the second engageable element 530 from being removed from the frame 300f and fixes the second engageable element 530 in rotation relative to the frame 300f such that the second engageable element 530 — and the second end 540b of the expandable element 540 received in the opening 534o of the neck 534 of the second engageable element 530 — cannot rotate relative to the frame 300f about the decoupling-assembly rotational axis Asoo. In this example embodiment, the locking device 590 includes a fastener including a head 590h, an annular flange 590f surrounding the head 590h, and a threaded body (not shown). The flange 590f is sized and shaped to follow the curve of the concave surfaces 536s separating adjacent fingers 536f of the head 536 of the second engageable element 530. When the body of the locking device 590 is threadably received in a suitable bore in the frame 300f, part of the flange 590f is adjacent to (and in certain embodiments contacts) two adjacent fingers 536f and the concave surface 536s separating them such that it occupies the space between the two adjacent fingers. The flange 590f thus prevents the second engageable element 530 from rotating about the decoupling-assembly rotational axis A500 and prevents the second engageable element 530 from being removed from the frame 300f.

[0041] The threaded fastener is merely one example embodiment of the locking device, and the locking device may include any suitable components in other embodiments. For instance, in another example embodiment, the locking device includes a mechanical switch that can be toggled between a locked configuration in which it prevents rotation and removal of the second engageable element and an unlocked configuration in which it enables rotation and / or removal of the second engageable element. In further embodiments, the locking device includes a dual-pronged pin with one prong that fits into an opening in the support and another that fits into an opening in the second engageable element. In other embodiments, the locking device includes a grab screw configured to engage the curved portion of the second engageable element.

[0042] The decoupling assembly 500 has a coupled configuration and a release configuration. Figure 5C shows the decoupling assembly 500 in the coupled configuration. Whenthe decoupling assembly 500 is in the coupled configuration, the expandable element 540 exerts a compressive force on the first engageable element 520 and the body 532 of the second engageable element 530 that prevents them from rotating relative to one another about the decoupling-assembly rotational axis Asoo. Since the body 532 of the second engageable element 530 is fixed in rotation relative to the frame 300f of the support 300 and the decoupling-assembly shaft 510 is fixed in rotation with the first engageable element 520, the decoupling-assembly shaft 510 is fixed in rotation relative to the frame 300f. Since the teeth on the second end 512a of the body 512 of the decoupling-assembly shaft 510 mesh with the rollback intermediate gear 431, when in the coupled configuration the decoupling assembly 500 prevents the rollback intermediate gear 431 from rotating about the rocker axis A4oor, which in turn prevents the rollback ring gear 430 from rotating about the tensioning-wheel axis A400W.

[0043] The decoupling assembly 500 is switchable (such as by the actuating assembly 600 as described below) from the coupled configuration to the release configuration to enable the first engageable element 520 and the decoupling-assembly shaft 510 to rotate relative to the second engageable element 530 about the decoupling-assembly rotational axis Asoo. As explained above, the second engageable element 530 and the second end 540b of the expandable element 540 (that is received in the opening 534o of the neck 534 of the second engageable element 530) are fixed in rotation relative to frame 300f. To switch the decoupling assembly 500 from the coupled configuration to the release configuration, the sleeve 550 is rotated about the decoupling-assembly rotational axis Asoo from a coupled position to a release position in a release direction R550 relative to the frame 300f, the second end 540b of the expandable element 540, and the second engageable element 530. Since the first end 540a of the expandable element 540 is received in the opening 554o defined in the body 552 of the sleeve 550, the first end 540a rotates with the sleeve 550. As this occurs, the inner diameter of the expandable element 540 near its first end 540a begins expanding, and eventually expands enough (thereby reducing the compression force or eliminating it altogether) to enable the first engageable element 520 and the decoupling-assembly shaft 510 to rotate about the decoupling-assembly rotational axis A500 relative to the second engageable element 530 (and the expandable element 540). When the sleeve 550 is released, the first end 540a of the expandable element 540 biases the sleeve 550 to rotate in a coupling direction C550 opposite the release direction R550 until the sleeve 550 reaches the coupled position (meaning the decoupling assembly 500 is back in its coupled configuration).

[0044] The actuating assembly 600, which is best shown in Figures 6A and 6B, is operably connected to the decoupling assembly 500 to switch it between the coupled and release configurations and is actuatable to initiate the opening process described below. The actuating assembly 600 includes an actuating-assembly body 610 and a decoupling-assembly actuator 620. The actuating-assembly body 610 includes a trigger 612, spaced-apart first and second mounting ears 614a and 614b extending from the trigger 612, a cam-engaging-assembly actuator 616 extending from the second mounting ear 614b, and an actuating plate 618 extending between the mounting ears 614a and 614b. The decoupling-assembly actuator 620 includes an actuated arm 622, a gear arm 624 connected to the actuated arm 622, and a gear 626 at a free end of the gear arm 624.

[0045] The first and second mounting ears 614a and 614b of the actuating-assembly body 610 are pivotably mounted to the frame 300f. The decoupling assembly actuator 620 is pivotably mounted to an actuator mounting rod 690 supported by the frame 300f. The actuated arm 622 of the decoupling assembly actuator 620 is positioned above the actuating plate 618. The actuating-assembly body 610 is pivotable relative to the frame 300f about an actuatingassembly-body axis A6io between a home position (Figures 8A, 8F, and 8G) and an actuated position (Figures 8B-8E). A biasing element (not shown), such as a compression or torsion spring, biases the actuating-assembly body 610 to the home position. The decoupling-assembly actuator 620 is pivotable relative to the frame 300f about an actuator axis A620 between a home position (Figure 8A) and an actuated position (Figures 8B-8G). A biasing element 620b, which is a torsion spring in this example embodiment but may be any suitable biasing element, biases the decoupling-assembly actuator 620 to its home position. The actuating-assembly body 610 is operably connected to the decoupling-assembly actuator 620 to move the decoupling-assembly actuator 620 from its home position to its actuated position. Specifically, as the actuatingassembly body 610 moves from its home position toward its actuated position, the actuating plate 618 engages the actuated arm 622 of the decoupling-assembly actuator 620 and forces it to pivot about the actuator axis Ae2o until it (and the actuating-assembly body 610) reaches its actuated position.

[0046] The decoupling-assembly actuator 620 is positioned, oriented, and otherwise configured to control which configuration the decoupling assembly 500 is in. Specifically, when the decoupling-assembly actuator 620 is in its home position, as shown in Figure 8A, thedecoupling assembly 500 is in its coupled configuration. The teeth of the gear 626 are unmeshed from the teeth 554 of the sleeve 550, and the sleeve 550 is in its coupled position. When the decoupling assembly actuator 620 moves from its home position to its actuated position, as shown in Figure 8B, the gear 626 meshes with the teeth 554 of the sleeve 550 and rotates the sleeve 550 in the release direction R550 until the sleeve 550 reaches its release position and the decoupling assembly 500 is in its release configuration. When the decoupling-assembly actuator 620 moves from its actuated position back to its home position, the gear 626 moves to enable the sleeve 550 to rotate in the coupling direction C550 back to its coupled position such that the decoupling assembly 500 is in its coupled configuration. In this embodiment, the gear 626 unmeshes from the teeth 554 of the sleeve 550 near the end of its movement.

[0047] The cam-engaging assembly 700, which is best shown in Figures 7A-7D, is movable by the actuating assembly 600 into a position to be engaged by one of the cams 424, 426, and 428 of the rocker mover 420 of the tensioning assembly 400 to raise the tensioning assembly 400 from its home position to its strap-insertion position. The cam-engaging assembly 700 includes a cam engager 710, an actuating-assembly engager 720, and a biasing element 730. The cam engager 710 includes a cam-engager body 712 and a cam-engaging finger 714 extending transversely from the cam-engager body 712. The actuating-assembly engager 720 includes an actuating-assembly-engager body 722, an actuator-engaging finger 724 extending from the actuating-assembly-engager body 722, and a stop 726 extending from the actuating- assembly-engager body 722. The cam engager 710 is pivotably connected to the actuatingassembly engager 720 such that the cam engager 710 and the actuating-assembly engager 720 can pivot relative to one another about a cam-engager rotational axis A710. Figure 7C shows the cam-engaging assembly 700 when the cam engager 710 is in a home position relative to the actuating-assembly engager 720 such that the cam-engaging finger 714 of the cam actuator 710 is spaced-apart from the actuating-assembly-engager body 722 of the actuating-assembly engager 720. Figure 7D shows the cam-engaging assembly 700 when the cam engager 710 is in an actuated position relative to the actuating-assembly engager 720 such that the cam-engaging finger 714 is closer to (and in certain embodiments engaging) the actuating-assembly-engager body 722. The biasing element 730, which is a compression spring in this example embodiment but may be any other suitable biasing element, biases the cam engager 710 to its home position, and the cam engager 710 engages the stop 726, which prevents further rotation.

[0048] As best shown in Figures 9A-9G, the cam-engaging assembly 700 — and particularly the cam engager 710 and the actuating-assembly engager 720 — are pivotably mounted to the tensioning-assembly mounting shaft 395 and configured to pivot about a cam- engaging-assembly axis A720 (which is coaxial with the rocker axis A-wor) relative to the support 300 between a home configuration (Figures 9A and 9G); a cam-engaging configuration (Figure 9B); and a stop configuration (Figures 9C-9G). When the cam-engaging assembly 700 is in the home configuration, the cam engager 710 is in its home position relative to the actuatingassembly engager 720, the actuator-engaging finger 724 is below the cam-engaging-assembly actuator 616, and the cam-engaging finger 714 is in a home position removed from the rotational path of the first and second cams 424 and 426 of the rocker mover 420. A biasing element, which as an extension spring or any other suitable spring, biases the cam-engaging assembly 700 to the home configuration. When the cam-engaging assembly 700 is in the cam-engaging configuration, the cam engager 710 is in its home position relative to the actuating-assembly engager 720 and the cam-engaging finger 714 is in a cam-engaging position. When the camengaging finger 714 is in the cam-engaging position, the cam-engaging finger 714 extends across the rotational path of the first and second cams 424 and 426 of the rocker mover 420. When the cam-engaging assembly 700 is in the stop configuration, the cam engager 710 is in its home position relative to the actuating-assembly engager 720 and the cam-engaging finger 714 is in a stop position and engages a stop 390 mounted to the frame 300f Accordingly, when the camengaging finger 714 is in the cam-engaging position, the cam-engaging finger 714 extends across the rotational path of the first and second cams 424 and 426 of the rocker mover 420 such that rotation of the rocker mover 420 results in one of the cams engaging and forcing the camengaging finger 714 toward the stop position.

[0049] The sealing assembly 900, which is best shown in Figure 3A, is configured to attach overlapping layers of the strap to one another to form a tensioned strap loop around the load during the sealing process via friction welding. The sealing assembly 900 includes a weld arm 910, a weld shoe 912, a cutter 914, a linkage 916, and an eccentric shaft (not shown). The weld shoe 912 is slidably mounted to the weld arm 910 such that the weld shoe 912 can oscillate relative to the weld arm 910. The cutter 914 is mounted to the weld arm 910. The weld arm 910 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 A910 between a home position (Figure 3A) in which the weldshoe 912 is spaced-apart from the weld plate 314 and a welding position (not shown) in which the weld shoe 912 is adjacent the weld plate 314 and positioned to weld the strap. The linkage 916 operably connects the transmission 1000 to the weld arm 910 such that the transmission 1000 can move the weld arm 910 from the release home position to the welding position (and vice-versa in certain embodiments). The eccentric is operably connected to the weld shoe 912 and configured to, when rotated, cause the weld shoe 912 to oscillate. A toothed belt 900b operably connects the transmission 1000 to the eccentric to rotate the eccentric.

[0050] The transmission 1000, which is best shown in Figures 3 A and 3B, 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 T to tension the strap and to cause the tensioning assembly 400 to pivot to its strap-insertion position, and is operably connected to the sealing assembly 900 and configured to cause the sealing assembly 900 to attach the overlapping layers of the strap to one another. The transmission 1000 includes transmission gearing including a drive gear (which is a bevel pinion gear in this example embodiment) and a variable offset coupling 800 including a driven gear (which is a bevel wheel gear in this example embodiment). The transmission gearing and the variable offset coupling 800 are mounted to the support 300 such that the drive gear meshes with the driven gear.

[0051] The transmission gearing includes suitable components (such as gears, bearing, and freewheels) that transmit rotational movement of the output shaft of the motor 1100 in a first drive direction to the drive gear to rotate the drive gear (but not to drive any components of the sealing assembly 900 in this example embodiment). The drive gear drives the driven gear to rotate in the tensioning direction T, and the other components of the variable offset coupling 800 transmit the rotational movement of the driven gear to the driven shaft 410 of the tensioning assembly 400 to rotate the driven shaft 410 in the tensioning direction T. 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: (1) the linkage 916 of the sealing assembly 900 to move the weld arm 910 from its home position to its welding position; and (2) the toothed belt 990 to rotate the eccentric and cause the weld shoe 912 to oscillate (but not to drive the drive gear in this example embodiment).

[0052] 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.

[0053] The motor 1100, which is best shown in Figures 3 A and 3B, 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.

[0054] The display assembly 1490, which is shown in Figures 1A-1C, 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 a desired strap tension and 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.

[0055] The first and second pushbutton actuators 1410 and 1440 are operable to initiate the tensioning and / or sealing processes 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.

[0056] The controller 1600, which is shown in Figure 1C, 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 moreintegrated 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 optical media. 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.

[0057] The controller 1600 is configured to operate the strapping device in one of three operating modes to carry out the strapping process: (1) a manual operating mode; (2) a semi-automatic 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 process responsive to the second pushbutton actuator 1440 being actuated. In the semi-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 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 process (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 process (without requiring additional input from the operator).

[0058] 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.

[0059] 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.

[0060] One example use of the strapping device 50 to form a tensioned strap loop around a load is described below in connection with Figures 8A-9G. Initially, the tensioning assembly 400 is in its home position, the actuating-assembly body 610 is in its home position (meaning that the decoupling assembly 500 is in its coupled configuration), the cam-engaging assembly 700 is in its home configuration, and the weld arm 910 is in its home position, as shown in Figures 8A and 9A. The strapping device 50 is in the automatic mode for the purposes of this example.

[0061] The operator pulls the strap leading-end first from a strap supply (not shown), wraps the strap around the load, and positions the leading end of the strap S below another layer of the strap to form upper and lower layers of strap. The operator then pulls the trigger 612 and in doing so moves the actuating-assembly body 610 from the home position to the actuatedposition, as shown in Figures 8B and 9B. As this occurs, and as described above, the decouplingassembly actuator 620 switches the decoupling assembly 500 from the coupled configuration to the release configuration. Additionally, the pivoting of the actuating-assembly body 610 causes the cam-engaging-assembly actuator 616 to engage the actuator-engaging finger 724 and force the cam-engaging assembly 700 to move to its cam-engaging configuration. Once the second sensor 1720 detects that the actuating-assembly body 610 has reached the actuated position, the controller 1600 begins an opening process and controls the motor 1100 to rotate the output shaft in the first drive direction to begin carrying out the opening process.

[0062] As explained above, the transmission 1000 transmits this rotational movement of the output shaft to the drive shaft 410 of the tensioning assembly 400 and rotates it in the tensioning direction T. This causes the first sun gear 410b to rotate about the tensionwheel rotational axis A400W in the tensioning direction T. The first sun gear 410b drives the first set of planet gears 414a-414c. Since the first set of planet gears 414a-414c are fixed in rotation about the tensioning-wheel axis A4oow, they drive the rocker mover 420 to rotate about the tension-wheel rotational axis A400w in the tensioning direction T. Eventually, the leading end of one of the cams 424 and 426 — here the leading end 4241e of the first cam 424 — engages the cam-engaging finger 714 — which extends across the rotational path of the cams — and forces the cam-engaging finger 714 to pivot until it engages the stop 390, thereby moving the camengaging assembly 700 to its stop configuration, as shown in Figures 8C and 9C. Since the stop 390 prevents further pivoting of the cam-engaging finger 714 and the cam 424 bears against the cam-engaging finger 714, continued rotation of the rocker mover 420 forces the rocker 400r and the entire tensioning assembly 400 to pivot upward about the rocker axis A4oor toward its strapinsertion position.

[0063] The first sun gear 410b also drives the second set of planet gears 434a-434c. Since the decoupling assembly 500 is in its release configuration, the rollback ring gear 430 is rotatable about the tension-wheel rotational axis A400W, and rotation of the second set of planet gears 434a-434c causes the rollback ring gear 430 to rotate about the tension-wheel rotational axis A400w in the tensioning direction T rather than causing the second carrier 430 — and the tension wheel 400w — to rotate (though there may be a small amount of rotation due to drag torque). Once the controller 1600 determines that the tensioning assembly 400 has reached its strap-insertion position (such as based on feedback from one of the sensors 1700), as shown inFigures 8D and 9D, the controller 1600 controls the motor 1 100 to stop rotating the output shaft to complete the opening process. Generally, the apex 424s’ of the finger-engaging surface 424s of the cam 424 engages the cam-engaging finger 714 when the tensioning assembly 400 is in its strap-insertion position. In other words, the bearing point of the cam 424 against the camengaging finger 714 is the apex 424s’. The tensioning-assembly freewheel 412 prevents the driven shaft 410 from reversing, ensuring the tensioning assembly 400 remains in the strapinsertion position. Accordingly, the tensioning-assembly gearing operatively connects the motor 1100 and the transmission 1000 to the tensioning assembly 400 to move the tensioning assembly 400 from its home position to its strap-insertion position.

[0064] With the tensioning assembly 400 in its strap-insertion position and while continuing to pull the trigger 612 to hold the actuating-assembly body 610 in the actuated position, the operator introduces the overlapping upper and lower layers of the strap between the tension wheel 400w and the tension plate 312 and between the weld shoe 912 and the weld plate 314, as shown in Figures 8E and 9E. The operator then releases the trigger 612, enabling the appropriate biasing elements to force the actuating-assembly body 610 to return to its home position as shown in Figures 8F and 9F. A catch (not shown) engages a projection of the actuated arm 622 of the decoupling assembly actuator 620 and holds it in place, holding the decoupling assembly 500 in its release configuration.

[0065] Once one of the sensors 1700 detects that the actuating-assembly body 610 has reached the home position, the controller 1600 controls the motor 1100 to rotate the output shaft in the first drive direction. As explained above, this causes the rocker mover 420 to rotate about the tension-wheel rotational axis A oow in the tensioning direction T. As the rocker mover 420 rotates, the bearing point of the cam 424 against the cam-engaging finger 714 (i.e., the point of engagement between the finger-engaging surface 424s of the cam 424 that engages the camengaging finger 714) shifts from its apex 424s’ toward the trailing end 424te of the cam 424. The curved shape and the orientation of the finger-engaging surface 424s causes the tensioning assembly 400 to gradually lower from its strap-insertion position toward its tensioning position while the cam engages the cam-engaging finger 714, as shown in Figures 8F and 9F. Continued rotation of the rocker mover 420 eventually causes the cam to disengage the cam-engaging finger 714, at which point suitable biasing elements force the tensioning assembly 400 to complete the movement to its tensioning position and to move the cam-engaging assembly 700 back to itshome position, as shown in Figures 8G and 9G. Once the controller 1600 determines that the tensioning assembly 400 has reached its tensioning position (such as based on feedback from one of the sensors 1700), the controller 1600 controls the motor 1100 to stop rotating the output shaft.

[0066] The operator then actuates the first pushbutton actuator 1410, which (via a pivoting lever) causes the catch to disengage the projection of the actuated arm 622 of the decoupling assembly 620. As described above, this enables the decoupling assembly 500 to — via the biasing forces imparted by the expandable element 540 and the biasing element 620b — switch from its release configuration to its coupled configuration to enable the motor 1100 to operate to tension the strap S. Once one of the sensors 1700 detects the actuation of the first pushbutton actuator 1410, the controller 1600 initiates the strapping process by first carrying out a tensioning process. The controller 1600 controls 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 drive shaft 410 of the tensioning assembly 400 and rotates it in the tensioning direction T. This causes the first sun gear 410b to rotate about the tensionwheel rotational axis A400W in the tensioning direction T. The first sun gear 410b drives the first set of planet gears 414a-414c. Since the first set of planet gears 414a-414c are fixed in rotation about the tensioning-wheel axis A400W, they drive the rocker mover 420 to rotate about the tension-wheel rotational axis A400W in the tensioning direction T. Since the cam-engaging assembly 700 is in its home configuration, the cam-engaging finger 714 is not in the rotational path of the cams 424 and 426 of the rocker mover 420 and the tensioning assembly 400 does not pivot from its tensioning position.

[0067] The first sun gear 410b also drives the second set of planet gears 434a-434c. Since the decoupling assembly 500 is in its coupled configuration, it prevents the rollback ring gear 430 from rotating about the tension-wheel rotational axis A400W, and rotation of the second set of planet gears 434a-434c causes the carrier 432 — including the second sun gear 432b — to rotate about the tension-wheel rotational axis A400W in the tensioning direction T. The second sun gear 432b drives the third set of planet gears 436a-436c, which causes the tension wheel 400w to rotate about the tension-wheel rotational axis A400W in the tensioning direction T. Accordingly, the tensioning-assembly gearing operatively connects the motor 1100 and the transmission 1000to the tension wheel 400w to rotate the tension wheel 400w about the tension-wheel rotational axis A400W in the tensioning direction T.

[0068] As the tension wheel 400w rotates in the tensioning direction T, 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 1600 monitors the electrical 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 process, the controller 1600 stops the motor 1100, thereby terminating the tensioning process. At this point, the strap exerts a torque on the tension wheel 400w in the rollback direction TREV. The tension wheel 400w transmits this torque to the third set of planetary gears 436a-436c, which transmit this torque to the second sun gear 432b of the carrier 432. The second set of planetary gears 434a-434c transmit this torque to the first sun gear 410b of the driven shaft 410 and to the rollback ring gear 430. The tensioningassembly freewheel 412 prevents the driven shaft 410 from rotating in the rollback direction TREV. The decoupling assembly 500 is in its coupled configuration and prevents the rollback ring gear 430 from rotating in the rollback direction TREV. Accordingly, the torque the strap exerts on the tension wheel 400w is absorbed by components of the tensioning assembly 400 and the decoupling assembly 500, enabling the tension wheel 400w to hold tension in the strap without rotating in the rollback direction TREV.

[0069] After completion of the tensioning process, the controller 1600 automatically starts the sealing process 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 and oscillating the weld shoe 912 and pivot the weld arm 910 to its welding position. As the weld arm 910 reaches the welding position, the weld shoe 912 forces the overlapping upper and lower layers of strap against the weld plate 314 while the cutter 914 cuts the upper strap layer from the strap supply. The oscillating movement of the weld shoe 912 locally melts the portions of the upper and lower strap layers together. After a preset period of time or a preset quantity of rotations of the motor output shaft, the controller 1600 controls the motor 1100 to stop rotating the output shaft, completing the sealing process.

[0070] After the sealing process is complete, the operator again pulls the trigger 612, and in doing so moves the actuating-assembly body 610 from the home position to the actuated position. As this occurs, and as described above, the decoupling assembly actuator 620 switchesthe decoupling assembly 500 from the coupled configuration to the release configuration. After the sealing process is complete, the strap continues to exert the torque on the tension wheel 400w that acts in the rollback direction TREV. Switching the decoupling assembly 500 from the coupled configuration to the release configuration enables the tension wheel 400w to rotate in the rollback direction TREV to release that torque in a controlled manner.

[0071] Specifically, upon completion of the strapping process, the decoupling assembly 500 continues to prevent the rollback ring gear 430 of the tensioning-assembly gearing from rotating in the rollback direction TREV, which as explained above prevents the tension wheel 400w from rotating in the rollback direction TREV after tensioning so the tension wheel 400w can hold the tension in the strap. As the operator moves the actuating-assembly body 610 to its actuated position, the decoupling assembly actuator 620 begins rotating the sleeve 550 of the decoupling assembly 500 to its release position, and the inner diameter of the expandable element 540 of the decoupling assembly 500 begins expanding. Eventually, the torque the rollback ring gear 430 exerts on the decoupling-assembly shaft 510 of the decoupling assembly 500 (via the rollback intermediary gear 431) exceeds the compression force the expandable element 540 exerts on the first engageable element 520. When this occurs, the rollback ring gear 430 begins rotating in the rollback direction TREV about the tension-wheel rotational axis A400W, enabling the second set of planetary gears 434a-434c and the carrier 432 to rotate in the rollback direction TREV about the tension-wheel rotational axis A400w. This causes the tension wheel 400w to rotate in the rollback direction TREV about the tension-wheel rotational axis A400W to release the torque exerted by the tensioned strap.

[0072] The when one of the sensors 1700 detects that the actuating-assembly body 610 has reached the actuated position, the controller 1600 controls the motor 1100 to rotate the output shaft in the first drive direction to raise the tensioning assembly 400 to its strap-insertion position, as explained above. The operator then removes the strapping device 50 from the tensioned strap loop.

[0073] Although the sealing assembly of the above-described example embodiments of the strapping device is configured to form a friction-welded strap joint, the sealing assembly may comprise other sealing mechanisms (such as notching jaw assembly, a crimping jaw assembly, a sealless joint assembly, an ultrasonic welding assembly, or a hot-knife assembly) inother embodiments configured to seal any suitable type of strap (such as metal, plastic, or paper strap).

[0074] The above-described example embodiments 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.

[0075] 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.

[0076] 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.

Claims

Claims1. A strapping device comprising: tensioning-assembly gearing comprising a driven shaft and a first gear; a tension wheel drivable by the tensioning-assembly gearing; a decoupling assembly switchable between a coupled configuration and a release configuration, the decoupling assembly comprising: a decoupling-assembly shaft operably connected to the first gear; a first engageable element connected to and rotatable with the decouplingassembly shaft; a second engageable element; and an expandable element circumscribing at least part of the first engageable element and the second engageable element; and a locking device substantially preventing rotation of the second engageable element relative to the first engageable element, wherein when the decoupling assembly is in the coupled configuration, the expandable element frictionally engages the first and second engageable elements such that the first engageable element, the decoupling-assembly shaft, and the first gear are prevented from rotating relative to the second engageable element, wherein when the decoupling assembly is in the release configuration, the frictional engagement between the expandable element and the first engageable element is at least partially eliminated such that the first engageable element, the decoupling-assembly shaft, and the first gear are rotatable relative to the second engageable element.

2. The strapping device of claim 1, wherein the second engageable element comprises a body and a head, wherein the body is frictionally engaged by the expandable element.

3. The strapping device of claim 2, wherein the head comprises first and second fingers and a concavely curved surface extending between the first and second fingers.

4. The strapping device of claim 3, wherein the locking device comprises a fastener including a threaded body, a head connected to the body, and a flange extending around the head.

5. The strapping device of claim 4, further comprising a support, wherein the second engageable element is rotatably supported by the support, wherein the fastener is threadably received in the support and positioned such that the flange occupies the space between the first and second fingers and substantially prevents the second engageable element from rotating relative to the support and the first engageable element.

6. The strapping device of claim 5, wherein the flange engages the first and second fingers and the concavely curved surface.

7. The strapping device of claim 5, wherein the fastener is removable from the support to enable the second engageable element to rotate relative to the support.

8. The strapping device of claim 2, wherein the second engageable element defines a first opening, wherein the expandable element comprises a first end, a second end, and multiple windings between the first and second ends, wherein the first end is received in the first opening.

9. The strapping device of claim 8, wherein the decoupling assembly further comprises a rotatable sleeve comprising a body comprising external teeth and defining a second opening, wherein the second end of the expandable element is received in the second opening.

10. The strapping device of claim 9, further comprising a decoupling-assembly actuator movable from a home position to an actuated position and comprising a gear, wherein movement of the decoupling-assembly actuator from the home position to the actuated position causes the gear to mesh with the external teeth of the sleeve and drive the sleeve to rotate to cause the decoupling assembly to switch to the release configuration.11 . The strapping device of claim 10, wherein the rotation of the sleeve causes the second end of the expandable element rotates relative to the first end of the expandable element to expand one or more of the windings.

12. The strapping device of claim 11, wherein the head comprises first and second fingers and a concavely curved surface extending between the first and second fingers.

13. The strapping device of claim 12, wherein the locking device comprises a fastener include a threaded body, a head connected to the body, and a flange extending around the head.

14. The strapping device of claim 13, further comprising a support, wherein the second engageable element is rotatably supported by the support, wherein the fastener is threadably received in the support and positioned such that the flange occupies the space between the first and second fingers and substantially prevents the second engageable element from rotating relative to the support and the first engageable element.

15. The strapping device of claim 14, wherein the flange engages the first and second fingers and the concavely curved surface.

16. The strapping device of claim 14, wherein the fastener is removable from the support to enable the second engageable element to rotate relative to the support.

17. The strapping device of claim 1, further comprising a motor operably connected to the driven shaft and configured to drive the driven shaft, wherein when the decoupling assembly is in the coupled configuration, operation of the motor results in the tensioning-assembly gearing driving the tension wheel in a tensioning direction, wherein when the decoupling assembly is in the release configuration, the tension wheel is rotatable in a direction opposite the tensioning direction.

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