Strapping device with motor-driven rocker

Abstract

Various embodiments of the present disclosure provide a strapping device with a rocker movable from a tensioning position to a strap-insertion position to increase a distance between a tension wheel supported by the rocker and a tension plate on a support of the strapping device. The strapping device also includes a rotatable rocker mover, a movable cam-engaging finger, and a motor operably connected to the rocker mover and configured to rotate the rocker mover. The rocker mover includes a cam. When the cam-engaging finger is positioned to intersect a rotational path of the cam and the motor is operated to rotate the rocker mover, the cam bears against the cam-engaging finger to move the rocker from the tensioning position to the strap-insertion position.

Description

PRIORITY

[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 385,835, filed Dec. 2, 2022 and U.S. Provisional Patent Application No. 63 / 482,829, filed Feb. 2, 2023, the entire contents of both of which are 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 portions 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 portions of the strap to one another to form a tensioned strap loop around the load. Battery-powered strapping devices are one type of strapping device. 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 the leading end of the strap below another portion of the strap. The operator then introduces one or more (depending on the type of strapping device) of these overlapped strap portions into the strapping device and actuates one or more buttons to initiate: (1) a tensioning cycle during which a tensioning assembly tensions the strap around the load; and (2) after completion of the tensioning cycle, a sealing cycle during which a sealing assembly attaches the overlapped strap portions to one another (thereby forming a tensioned strap loop around the load) and cuts the strap from the strap supply.

[0004] Since strapping device operators can use handheld strapping devices hundreds of times each day, there is a continuing need to make the strapping devices as easy-to-use as possible (without sacrificing performance) and to reduce operator fatigue.SUMMARY

[0005] Various embodiments of the present disclosure provide a strapping device with a rocker movable from a tensioning position to a strap-insertion position to increase a distance between a tension wheel supported by the rocker and a tension plate on a support of the strapping device. The strapping device also includes a rotatable rocker mover, a movable cam-engaging finger, and a motor operably connected to the rocker mover and configured to rotate the rocker mover. The rocker mover includes a cam. When the cam-engaging finger is positioned such that it extends across a rotational path of the cam and the motor is operated to rotate the rocker mover, the cam bears against the cam-engaging finger to move the rocker from the tensioning position to the strap-insertion position.BRIEF DESCRIPTION OF THE FIGURES

[0006] FIGS. 1A and 1B are perspective views of one example embodiment of a strapping device of the present disclosure.

[0007] FIG. 1C is a block diagram of certain components of the strapping device of FIGS. 1A and 1B.

[0008] FIGS. 2A-2C are diagrammatic views of the strapping device of FIGS. 1A and 1B securing a load to a pallet.

[0009] FIG. 2D is a perspective view of a friction-weld strap joint formed by the strapping device of FIG. 1A to attach two overlapping portions of strap.

[0010] FIGS. 3A and 3B are perspective views of the working assembly of the strapping device of FIGS. 1A and 1B.

[0011] FIG. 4A is a perspective view of the tensioning assembly of the working assembly of FIGS. 3A and 3B.

[0012] FIG. 4B is an exploded perspective view of the tensioning assembly of FIG. 4A.

[0013] FIG. 4C is a cross-sectional perspective view of the tensioning assembly of FIG. 4A taken along line 4C-4C of FIG. 4A.

[0014] FIG. 4D is a front elevational view of the rocker mover of the tensioning assembly of FIG. 4A.

[0015] FIG. 5A is a perspective view of the decoupling assembly of the working assembly of FIGS. 3A and 3B.

[0016] FIG. 5B is an exploded perspective view of the decoupling assembly of FIG. 5A.

[0017] FIG. 5C is a cross-sectional perspective view of the decoupling assembly of FIG. 5A taken along line 5C-5C of FIG. 5A.

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

[0019] FIGS. 7A and 7B are perspective views of the cam-engaging assembly of the working assembly of FIGS. 3A and 3B with the cam engager in its home and actuated positions, respectively.

[0020] FIGS. 8A-8G are side views of part of one side of the working assembly of FIGS. 3A and 3B showing the tensioning assembly moving from its tensioning position to its strap-insertion position and back to its tensioning position. Certain components of the working assembly are not shown for clarity.

[0021] FIGS. 9A-9G are side views of part of the opposite side of working assembly of FIGS. 3A to 3B that correspond to FIGS. 8A-8G. Certain components of the working assembly are not shown for clarity.

[0022] FIGS. 10A-10D are side views similar to FIGS. 9A-9G showing a scenario in which a cam of the rocker mover of FIG. 4D is in the path of the cam-engaging finger of the cam-engaging assembly of FIGS. 7A and 7B.

[0023] FIGS. 11A and 11B are perspective and front elevational views, respectively, of another embodiment of the rocker mover.

[0024] FIGS. 12A and 12B are perspective views of another embodiment of the cam-engaging assembly.

[0025] FIGS. 12C and 12D are side views of the cam-engaging assembly of FIGS. 12A and 12B with the cam engager in its home and actuated positions, respectively.

[0026] FIGS. 13A-13C are side views of part of one side of the working assembly of another embodiment of the strapping device of the present disclosure including the rocker mover of FIGS. 11A and 11B and the cam-engaging assembly of FIGS. 12A-12D showing a scenario in which the cam-engaging finger of the cam-engaging assembly is in the rotational path of a cam of the rocker mover but does not extend across the rotational path.DETAILED DESCRIPTION

[0027] While the systems, devices, and methods described herein may be embodied in various forms, the drawings show and the specification describes certain exemplary and non-limiting 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.

[0028] FIGS. 1A-10D 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 FIGS. 2A-2C, 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 portion LP of the strap S (which includes the leading end of the strap S) is positioned below an upper portion UP of the strap S, as shown in FIG. 2A. The operator then introduces the overlapped upper and lower portions UP and LP of the strap S into the strapping device 50 and actuates one or more buttons to initiate the strapping cycle. As shown in FIG. 2B, 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 FIG. 2C, the motor drives a sealing assembly to carry out a sealing cycle during which the strapping device 50 connects the upper and lower portions UP and LP of the strap S to one another via friction welding to form a strap joint SJ, as shown in FIG. 2D, and cuts the strap S from the strap supply.

[0029] The strapping device 50 includes a housing 100 (FIGS. 1A and 1B), a working assembly 200 (FIGS. 3A and 3B), a cover 1300 (FIG. 1A), first and second pushbutton actuators 1410 and 1440 (FIGS. 1A and 1B), a display assembly 1490 (FIGS. 1A-2), a power supply 1500, a controller 1600 (FIG. 1C), and one or more sensors 1700 (FIG. 1C).

[0030] The housing 100, which is shown in FIGS. 1A and 1B, 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 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. The cover 1300 is attached to the front housing section 110 and covers part of the working assembly 200.

[0031] The working assembly 200, which is best shown in FIGS. 3A and 3B, includes the majority 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 portions 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 cam-engaging assembly 700, a sealing assembly 900, a transmission 1000, and a motor 1100.

[0032] The support 300, which is best shown in FIGS. 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 tension plate 312 below the tension wheel 400w of the tensioning assembly 400 (described below) and a weld plate 314 below the weld shoe 912 of the sealing assembly 900 (described below).

[0033] The tensioning assembly 400, which is best shown in FIGS. 4A-4D, is operable (with the motor 1100) to tension the strap around the load during the tensioning cycle and to move the tensioning assembly 400 relative to the support 300. 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.

[0034] The tensioning-assembly gearing includes: a driven shaft 410; a tensioning-assembly 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, 434c, and 434d; a third set of planet gears 436a, 436b, and 436c; and bearings 405b1, 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 A400w. The driven shaft 410 includes a shaft portion 410a having a driven end 410a1 and a first sun gear 410b at the end opposite the driven end 410a1. 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-434d are rotatably 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 A400w. The third set of planet gears 436a-436c are rotatably mounted to the rocker 400r (such as via respective bearings and mounting pins).

[0035] The rocker mover 420, which is best shown in FIG. 4D, includes a ring gear 421 having internal teeth 421it and supporting an annular cam support 422 that includes angularly spaced first, second, and third cams 424, 426, and 428. The first cam 424 has a leading end 4241e and a trailing end 424te connected by a convexly curved finger-engaging surface 424s. 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, and the trailing end 424te of the cam 424 is a distance Rmin from the center of the cam support 422. Rmax is greater than Rmin such that the apex 424s′ is further from the center of the cam support 422 than the trailing end 424te. 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 finger-engaging surface 424s and the center of the cam support 422 decreases moving from the apex 424s′ to the trailing end surface 424te. The second and third cams 426 and 428 are identical to the first cam 424 and are not separately described for brevity. Their components are identified herein with similar numbers as the components of the first cam 424, with the leading “424” being replaced with “426” and “428,” respectively. The first, second, and third cams 424, 426, and 428 are equally angularly spaced apart such that each cam is spaced apart from the others by the same angle α, which is 120 degrees in this example embodiment. While the rocker mover includes three cams in this example embodiment, it may include any suitable quantity of one or more cams in other embodiments.

[0036] 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 positioned within 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 421it of the ring gear 421 of the rocker mover 420. The bearing 405b1 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-434d. The second set of planet gears 434a-434d mesh with the internal teeth 430it 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).

[0037] The tensioning assembly 400 is movably mounted to the support 300 via the rocker 400r and a tensioning-assembly mounting shaft 395 (FIGS. 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 A400r between a tensioning position (FIGS. 8A-8C and 8G) and a strap-insertion position (FIGS. 8D-8F). When the tensioning assembly 400 is in the tensioning position, the tension wheel 400w is adjacent to the tension plate 312 of the support 300 (or the upper surface of the upper portion of the strap if the strap has been inserted into the strapping device 50). 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 portions of the strap to be inserted between the tension wheel 400w and 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 tensioning position.

[0038] 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 400r1 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 400r1 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.

[0039] The decoupling assembly 500, which is best shown in FIGS. 5A-5C, controls whether the rollback ring gear 430 can rotate about the tensioning-wheel axis A400w. Generally, 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 cycle 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 A400w 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, a threaded fastener 560, a spacer 570, and a gear 580.

[0040] 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 first support 514 extends from the first end 512a. The first engageable element 520 comprises a tubular bushing having a cylindrical outer surface and an interior surface having a perimeter that matches 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 and an annular flange 534 at one end of the body 532. An opening 534o is defined through the flange 534. 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.

[0041] As best shown in FIG. 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 A500. 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 decoupling-assembly 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 through the flange 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 gear 580 is mounted to the second end 512b of the body 512 of the decoupling-assembly shaft 510 such that the gear 580 is fixed in rotation with the decoupling-assembly shaft 510. The spacer 570 separates the first engageable element 520 and the gear 580.

[0042] As best shown in FIG. 5C, the decoupling assembly 500 is mounted to the frame 300f of the support 300 and operatively connected to the tensioning-assembly gearing. More specifically, the decoupling assembly 500 is mounted to the frame 300f via the fastener 560, which 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 flange 534 of the second engageable element 530—cannot rotate relative to the frame 300f about the decoupling-assembly rotational axis A500. The gear 580 operably connects the body 512 of the decoupling-assembly shaft 510 to rollback ring gear 430 of the tensioning-assembly gearing. Specifically, the teeth on the gear 580 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, there is no rollback intermediate gear, and the teeth of the gear of the decoupling assembly mesh directly with the external teeth of the rollback ring gear.

[0043] The decoupling assembly 500 has a coupled configuration and a release configuration. FIG. 5C shows the decoupling assembly 500 in the coupled configuration. When the 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 A500. 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—and thus the gear 580—is fixed in rotation relative to the frame 300f. Since the gear 580 meshes 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 A400r, which in turn prevents the rollback ring gear 430 from rotating about the tensioning-wheel axis A400w.

[0044] The decoupling assembly 500 is switchable (such as by the actuation 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 A500. 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 flange 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 A500 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).

[0045] The actuating assembly 600, which is best shown in FIGS. 6A and 6B, is operably connected to the decoupling assembly 500 to switch it between the coupled and release configurations. 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 rod 618 extending between the mounting ears 614a and 614b. Each mounting ear 614a and 614b defines a vertically extending slot therethrough. 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.

[0046] The first and second mounting ears 614a and 614b of the actuating-assembly body 610 are pivotably mounted to frame 300f via pivot pins (not labeled). The decoupling assembly actuator 620 is pivotably mounted to an actuator mounting pin 690 that extends through the slots defined through the first and second mounting ears 614a and 614b of the actuating-assembly body 610 and that is secured (such as via retaining rings) to the frame 300f. The actuated arm 622 of the decoupling assembly actuator 620 is positioned above the actuating rod 618.

[0047] The actuating-assembly body 610 is pivotable relative to the frame 300f about an actuating-assembly-body axis A610 between a home position (FIGS. 8A, 8F, and 8G) and an actuated position (FIGS. 8B-8E). A biasing element (not shown), such as a compression or torsion spring, biases the actuating-assembly body 610 to the home position. When the actuating-assembly body 610 is in the home position, the actuator mounting pin 690 is positioned at the top of the slots defined through the first and second mounting ears 614a and 614b of the actuating-assembly body 610. Conversely, when the actuating-assembly body 610 is in the actuated position, the actuator mounting pin 690 is positioned at the bottom of the slots. The actuator mounting pin 690 and the slots therefore define the range of (pivoting) movement of the actuating-assembly body 610.

[0048] The decoupling-assembly actuator 620 is pivotable relative to the frame 300f about an actuator axis A620 between a home position (FIG. 8A) and an actuated position (FIGS. 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 actuating-assembly body 610 moves from its home position toward its actuated position, the actuating rod 618 engages the actuated arm 622 of the decoupling-assembly actuator 620 and forces it to pivot about the actuator axis A620 until it (and the actuating-assembly body 610) reaches its actuated position.

[0049] 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 FIG. 8A, the decoupling 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 FIG. 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.

[0050] The cam-engaging assembly 700, which is best shown in FIGS. 7A and 7B, 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 tensioning 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 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. The actuating-assembly engager 720 is pivotably connected to the cam engager 710 such that the actuating-assembly engager 720 and the cam engager 710 can pivot relative to one another about a cam-engaging-assembly rotational axis A700. FIG. 7A 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 actuator-engaging finger 724 of the actuating-assembly engager 720. FIG. 7B 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 actuator-engaging finger 724. 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, at which the cam engager 710 engages the stop 726, which prevents further rotation.

[0051] As best shown in FIGS. 9A-10D, 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 the rocker axis A400r relative to the support 300 between a home configuration (FIGS. 9A, 9G, and 10A); a cam-engaging configuration (FIGS. 9B and 10D); and a stop configuration (FIGS. 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 actuating-assembly 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, second, and third cams 424, 426, and 428 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 cam-engaging finger 714 is in the cam-engaging position, the cam-engaging finger 714 extends across the rotational path of the first, second, and third cams 424, 426, and 428 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 cam-engaging finger 714 is in the cam-engaging position, the cam-engaging finger 714 extends across the rotational path of the first, second, and third cams 424, 426, and 428 of the rocker mover 420 such that rotation of the rocker mover 420 results in one of the cams engaging and forcing the cam-engaging finger 714 toward the stop position.

[0052] The sealing assembly 900, which is best shown in FIG. 3A, 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 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 (FIG. 3A) in which the weld shoe 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.

[0053] The transmission 1000, which is best shown in FIGS. 3A 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 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 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 1012 meshes with the driven gear.

[0054] The transmission gearing 1010 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 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 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 1022 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 1010 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 1012 in this example embodiment).

[0055] 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.

[0056] The motor 1100, which is best shown in FIGS. 3A 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.

[0057] The display assembly 1490, which is shown in FIGS. 1A-IC, 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.

[0058] 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.

[0059] The controller 1600, which is shown in FIG. 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 special-purpose processor, a digital-signal processor, one or more microprocessors, one or more microprocessors in association with a digital-signal processor core, one or more application-specific 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 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.

[0060] 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 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 cycle 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 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).

[0061] 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 tensioning position and / or its strap-insertion position; one or more trigger-position sensors configured to detect when the actuating-assembly body 610 is in its home position and / or its actuated position; and one or more actuating assembly sensors configured to detect actuation of the first and second pushbutton actuators 1410 and 1440.

[0062] 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.

[0063] Use of the strapping device 50 to form a tensioned strap loop around a load is described below. Initially, the tensioning assembly 400 is in its tensioning 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 FIGS. 8A and 9A. The strapping device 50 is in the automatic mode for the purposes of this example.

[0064] 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 portion of the strap to form upper and lower portions 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 actuated position, as shown in FIGS. 8B and 9B. As this occurs, and as described above, the decoupling-assembly 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 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.

[0065] 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 tension-wheel 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. Eventually, the leading end of one of the cams 424, 426, and 428—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 cam-engaging assembly 700 to its stop configuration, as shown in FIGS. 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 A400r toward its strap-insertion position.

[0066] The first sun gear 410b also drives the second set of planet gears 434a-434d. 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-434d 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 in FIGS. 8D and 9D, the controller 1600 controls the motor 1100 to stop rotating the output shaft. 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 cam-engaging 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 strap-insertion 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 tensioning position to its strap-insertion position.

[0067] 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 portions 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 FIGS. 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 FIGS. 8F and 9F. A catch (not shown) engages the projection 622a 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.

[0068] Once one of the sensors 1700 detects that the actuating-assembly body 610 has reached the home position (or has left the actuated position, depending on the embodiment), 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 A400w 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 cam-engaging 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 424se 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 FIGS. 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 strap-tensioning position and to move the cam-engaging assembly 700 back to its home position, as shown in FIGS. 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.

[0069] The operator then actuates the first pushbutton actuator 1410, which (via a pivoting lever) causes the catch to disengage the projection 622a 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 cycle. 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 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 tension-wheel 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, 426, and 428 of the rocker mover 420 and the tensioning assembly 400 does not pivot from its tensioning position.

[0070] The first sun gear 410b also drives the second set of planet gears 434a-434d. 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-434d 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 1000 to the tension wheel 400w to rotate the tension wheel 400w about the tension-wheel rotational axis A400w in the tensioning direction T.

[0071] As the tension wheel 400w rotates in the tensioning direction T, it pulls the upper portion of the strap S over the lower portion 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. 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-434d transmit this torque to the first sun gear 410b of the driven shaft 410 and to the rollback ring gear 430. The tensioning-assembly 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.

[0072] 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 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 cycle.

[0073] After the sealing cycle 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 switches the decoupling assembly 500 from the coupled configuration to the release configuration. After the sealing cycle 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.

[0074] 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 and the gear 580 of the of the decoupling assembly 500) 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-434d 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.

[0075] Once 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.

[0076] FIGS. 10A-10D show a scenario in which a cam of the rocker mover 420 is in the path of the cam-engaging finger 714 of the cam-engaging assembly 700 and preventing the cam-engaging finger 714 from moving to its cam-engaging configuration when the actuating-assembly body 610 moves to its actuated position. Initially, as shown in FIG. 10A, the actuating-assembly body 610 is in its home position and cam-engaging assembly 700 is in its home configuration. The operator begins pulling the trigger 612 and in doing so moving the actuating-assembly body 610 from the home position toward the actuated position, as shown in FIG. 10B. As this occurs, as also shown in FIG. 10B, the cam-engaging-assembly actuator 616 engages the actuator-engaging finger 724 and begins forcing the cam-engaging assembly 700 to move toward its cam-engaging configuration. Eventually, as also shown in FIG. 10B, the cam-engaging finger 714 contacts the finger-engaging surface 424s of one of the cams (here, the cam 424) of the rocker mover 420, which prevents the cam-engaging finger 714 from rotating any further. As the operator continues pulling the trigger 612 and in doing so continues moving the actuating-assembly body 610 from the home position toward the actuated position, the cam-engaging-assembly actuator 616b begins forcing the actuating-assembly engager 720 to pivot relative to the cam engager 710 against the biasing force of the biasing element 730, thereby beginning to move the cam engager 710 relative to the actuating-assembly engager from its home position to its actuated position. This continues until the actuating-assembly body 610 and the cam engager 710 reach their respective actuated positions, as shown in FIG. 10C. Once one of the sensors 1700 detects that the actuating-assembly body 610 has reached its actuated position, the controller 1600 controls the motor 1100 to rotate the output shaft in the first drive direction. As described above, this causes the rocker mover 420 and the cams thereon to begin rotating. Eventually, the cam 424 rotates out of engagement with the cam-engaging finger 714, and the appropriate biasing elements force the cam engager 710 back to its home position and the cam-engaging assembly 700 to its cam-engaging configuration in which the cam-engaging finger 714 extends across the rotational path of the cams, as shown in FIG. 10D Continued rotation of the rocker mover 420 causes the leading end 426le of the next cam 426 to engage the cam-engaging finger 714 and, eventually, move the tensioning assembly 400 to the strap-insertion position, as explained above. Accordingly, the ability of the cam engager 710 to pivot relative to the actuating-assembly engager 720 enables the operator to move the actuating-assembly body 610 from its home position to its actuated position without interference even if a cam of the rocker mover 420 is in the path of the cam-engaging finger 714.

[0077] In certain embodiments, the controller is not configured to operate the motor to move the tensioning assembly back to its tensioning position when the operator releases the trigger. This means that the tensioning assembly remains in its strap-insertion position when the operator releases the trigger. This enables the operator to introduce the overlapping upper and lower portions of the strap between the tension wheel and the tension plate and between the weld shoe and the weld plate without continually holding the trigger. In these embodiments, when the operator actuates the first pushbutton actuator (causing the catch to disengage the projection of the actuated arm of the decoupling assembly and enabling the decoupling assembly to switch from its release configuration to its coupled configuration, as described above), one of the sensors detects the actuation of the first pushbutton actuator, and in response the controller initiates the strapping cycle. The controller starts the tensioning cycle by controlling the motor to rotate the output shaft in the first drive direction. As explained above, the transmission transmits this rotational movement of the output shaft to the drive shaft of the tensioning assembly and rotates it in the tensioning direction. This causes the first sun gear to rotate about the tension-wheel rotational axis in the tensioning direction. The first sun gear drives the first set of planet gears. Since the first set of planet gears are fixed in rotation about the tensioning-wheel axis, they drive the rocker mover to rotate about the tension-wheel rotational axis in the tensioning direction. As the rocker mover rotates, the bearing point of the cam against the cam-engaging finger (i.e., the point of engagement between the finger-engaging surface of the cam that engages the cam-engaging finger) shifts from its apex toward the trailing end of the cam. The curved shape and the orientation of the finger-engaging surface causes the tensioning assembly to gradually lower from its strap-insertion position toward its tensioning position while the cam engages the cam-engaging finger. Continued rotation of the rocker mover eventually causes the cam to disengage the cam-engaging finger, at which point suitable biasing elements force the tensioning assembly to complete the movement to its strap-tensioning position and to move the cam-engaging assembly back to its home position.

[0078] The first sun gear also drives the second set of planet gears. Since the decoupling assembly is in its coupled configuration, it prevents the rollback ring gear from rotating about the tension-wheel rotational axis, and rotation of the second set of planet gears causes the carrier—including the second sun gear—to rotate about the tension-wheel rotational axis in the tensioning direction. The second sun gear drives the third set of planet gears, which causes the tension wheel to rotate about the tension-wheel rotational axis in the tensioning direction. Accordingly, the tensioning-assembly gearing operatively connects the motor and the transmission to the tension wheel to rotate the tension wheel about the tension-wheel rotational axis in the tensioning direction. As the tension wheel rotates in the tensioning direction, it pulls the upper portion of the strap over the lower portion of the strap, thereby tensioning the strap around the load. Accordingly, in these embodiments, actuating the first pushbutton actuator causes the controller to operate the motor to both lower the tensioning assembly and drive the tensioning wheel.

[0079] FIGS. 11A-13C show certain assemblies and components of another embodiment of the strapping device of the present disclosure. This embodiment of the strapping device is the same as the strapping device 50 but with the rocker mover 420 replaced with an alternative rocker mover 2420 (best shown in FIGS. 11A and 11B) and the cam-engaging assembly 700 replaced with an alternative cam-engaging assembly 2700 (best shown in FIGS. 12A-12D). Other components of this embodiment of the strapping device that are the same as those of the strapping device 50 are not separately described for brevity and are identified below for clarity using the same element numbers as used above but with a “2” added to the beginning each element number.

[0080] The rocker mover 2420 includes a ring gear 2421 having internal teeth 2421it and supporting an annular cam support 2422 that includes angularly spaced, triangularly shaped first, second, and third cams 2424, 2426, and 2428. The first cam 2424 has a leading end 24241e and a trailing end 2424te connected by a convexly curved finger-engaging surface 424s and a concavely curved lower surface. The finger-engaging surface 2424s has an apex 2424s′ that corresponds to the point on the finger-engaging surface 2424s furthest from the center of the cam support 2422. The apex 2424s′ of the finger-engaging surface 2424s is a distance Rmax from the center of the cam support 2422, the leading end 24241e of the cam 2424 is a distance Rle from the center of the cam support 2422, and the trailing end 2424te of the cam 2424 is a distance Rte from the center of the cam support 2422. Rmax is greater than Rle and Rte such that the apex 2424s′ is further from the center of the cam support 2422 than the leading and trailing ends 24241e and 2424te. In this example embodiment, Rte is greater than Rle though the opposite may be true or they may be the same in other embodiments.

[0081] The portion of the finger-engaging surface 2424s extending between the leading end 24241e and the apex 2424s′ is generally planar such that the distance between the finger-engaging surface 2424s and the center of the cam support 2422 increases at a generally constant rate moving from the leading end 24241e to the apex 2424s′. The portion of the finger-engaging surface 2424s extending between the apex 2424s′ and the trailing end 2424te is curved such that the distance between the finger-engaging surface 2424s and the center of the cam support 2422 decreases moving from the apex 2424s′ to the trailing end 2424te. The second and third cams 2426 and 2428 are identical to the first cam 2424 and are not separately described for brevity. Their components are identified herein with similar numbers as the components of the first cam 2424, with the leading “2424” being replaced with “2426” and “2428,” respectively. The first, second, and third cams 2424, 2426, and 2428 are equally angularly spaced apart such that each cam is spaced apart from the others by the same angle α, which is 120 degrees in this example embodiment. While the rocker mover includes three cams in this example embodiment, it may include any suitable quantity of one or more cams in other embodiments.

[0082] The cam-engaging assembly 2700 is movable by the actuating assembly 2600 into a position to be engaged by one of the cams 2424, 2426, and 2428 of the rocker mover 2420 of the tensioning assembly 2400 to raise the tensioning assembly 2400 from its tensioning position to its strap-insertion position. The cam-engaging assembly 2700 includes a cam engager 2710, an actuating-assembly engager 2720, and a biasing element 2730. The cam engager 2710 includes a cam-engager body 2712 and a cam-engaging finger 2714 extending transversely from the cam-engager body 2712. The actuating-assembly engager 2720 includes an actuating-assembly-engager body 2722, an actuator-engaging finger 2724 extending from the actuating-assembly-engager body 2722, and a stop 2726 extending from the actuating-assembly-engager body 2722. The cam engager 2710 is pivotably connected to the actuating-assembly engager 2720 such that the cam engager 2710 and the actuating-assembly engager 2720 can pivot relative to one another about a cam-engager rotational axis A2710. FIG. 12C shows the cam-engaging assembly 2700 when the cam engager 2710 is in a home position relative to the actuating-assembly engager 2720 such that the cam-engaging finger 2714 of the cam actuator 2710 is spaced-apart from the actuating-assembly-engager body 2722 of the actuating-assembly engager 2720. FIG. 12D shows the cam-engaging assembly 2700 when the cam engager 2710 is in an actuated position relative to the actuating-assembly engager 2720 such that the cam-engaging finger 2714 is closer to (and in certain embodiments engaging) the actuating-assembly-engager body 2722. The biasing element 2730, which is a compression spring in this example embodiment but may be any other suitable biasing element, biases the cam engager 2710 to its home position, and the cam engager 2710 engages the stop 2726, which prevents further rotation.

[0083] The cam-engaging assembly 2700—and particularly the cam engager 2710 and the actuating-assembly engager 2720—are pivotably mounted to the tensioning-assembly mounting shaft 2395 and configured to pivot about a cam-engaging-assembly axis A2720 (which is coaxial with the rocker axis A2400r) relative to the support 2300 between a home configuration, a cam-engaging configuration, and a stop configuration to raise the tensioning assembly 2400 in a manner similar to that described above. The ability of the cam engager 2710 to pivot relative to the actuating-assembly engager 2720 enables the operator to move the actuating-assembly body 2610 from its home position to its actuated position without interference even if a cam of the rocker mover 2420 is in the path of the cam-engaging finger 2714 (similar to how this is described above for the cam-engaging assembly 700 with respect to FIGS. 10A-10D).

[0084] FIGS. 13A-13C show such scenario in which the cam-engaging finger 2714 of the cam engager 2710 of the cam-engaging assembly 2700 is in the rotational path of a cam of the rocker mover 2420 but does not extend across the rotational path. Initially, as shown in FIG. 13A, the rocker mover 2420 is rotating, and the actuating-assembly body 2610 is moved from its home position toward its actuated position, thereby causing the cam-engaging assembly 2700 to move from its home configuration toward its cam-engaging configuration. Before the cam-engaging finger 2714 reaches its cam-engaging position, the leading end 2424le of the first cam 2424 of the rocker moves 2420 engages the tip of the cam-engaging finger 2714. Since at this point the cam-engaging finger 2714 does not extend across the rotational path of the first cam 2424, continued rotation of the rocker mover 2420 results in the first cam 2424 forcing the cam-engager 710 to pivot relative to the actuating-assembly engager 2420 from its home position toward its actuated position, as shown in FIGS. 13B and 13C, rather than toward its stop position. Accordingly, if the cam engager 2710 is inadvertently moved into the rotational path of the cams of the rocker mover 2420 while the rocker mover 2420 is rotating and is contacted by one of the cams before extending across the rotational path, the configuration of the cam-engaging assembly 700 enables the rocker mover 2420 to move the cam engager 2710 out of the rotational path without measurably affecting the rotation of the rocker mover 2420.

[0085] 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) in other embodiments configured to seal any suitable type of strap (such as metal, plastic, or paper strap).

[0086] 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.

[0087] 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.

[0088] 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

1. A strapping device comprising:a support;a rocker movable relative to the support between a tensioning position and a strap-insertion position;a rotatable rocker mover comprising a cam;a cam-engaging finger movable from a first position in which the cam-engaging finger is removed from a rotational path of the cam to a second position in which the cam-engaging finger extends across the rotational path of the cam; anda motor operably connected to the rocker mover and configured to rotate the rocker mover.

2. The strapping device of claim 1, wherein the cam is positioned such that, when the cam-engaging finger is in the second position, rotation of the rocker mover causes the cam to engage the cam-engaging finger and thereby move the rocker from the tensioning position to the strap-insertion position.

3. The strapping device of claim 2, further comprising a stop positioned such that, when the cam-engaging finger is in the second position, rotation of the rocker mover causes the cam to engage the cam-engaging finger and force the cam-engaging finger against the stop, after which continued rotation of the rocker mover causes the cam to force the rocker to move to the strap-insertion position.

4. The strapping device of claim 3, wherein the cam comprises a finger-engaging surface that engages the cam-engaging finger, wherein the finger-engaging surface is shaped such that continued rotation of the rocker mover after the rocker has reached the strap-insertion position results in the rocker gradually moving back toward the tensioning position while the finger-engaging surface continues to engage the cam-engaging finger.

5. The strapping device of claim 3, further comprising a sensor and a controller communicatively connected to the sensor and operably connected to the motor and configured to control the motor, wherein the controller is configured to control the motor to rotate the rocker mover, and wherein the controller is further configured to control the motor to stop rotating the rocker mover responsive to feedback from the sensor such that, when the rocker mover stops rotating, the rocker is in the strap-insertion position.

6. The strapping device of claim 5, wherein the sensor comprises a position sensor configured to detect when the cam-engaging finger has reached the stop.

7. The strapping device of claim 3, further comprising an actuating assembly including a trigger actuatable to move the cam-engaging finger from the first position to the second position.

8. The strapping device of claim 7, wherein the actuating assembly includes a body comprising the trigger and an actuator, wherein the trigger is actuatable to move the actuator to force the cam-engaging finger to move from the first position to the second position.

9. The strapping device of claim 8, further comprising a cam-engaging assembly comprising the cam-engaging finger, an actuator-engaging finger movable relative to the cam-engaging finger, and a biasing element biasing the cam-engaging finger to a first position spaced from the actuator-engaging finger.

10. The strapping device of claim 9, wherein when the cam-engaging finger is in the first position and the cam is in a movement path of the cam-engaging finger, actuation of the trigger forces the cam-engaging finger to move into engagement with the cam and, thereafter, forces the actuator-engaging finger to move against the force of the biasing element toward the cam-engaging finger.

11. The strapping device of claim 10, wherein the cam is positioned such that rotation of the rocker mover after the cam-engaging finger engages the cam results in the cam moving out of engagement with the cam-engaging finger and the biasing element biasing the cam-engaging finger back to the first position.

12. The strapping device of claim 1, further comprising:tensioning-assembly gearing supported by the rocker and comprising the rocker mover; anda tension wheel drivable by the tensioning-assembly gearing.

13. The strapping device of claim 12, wherein the tensioning-assembly gearing comprises a driven shaft configured to drive the tension wheel and to rotate the rocker mover.

14. The strapping device of claim 13, wherein the rocker mover comprises a ring gear having internal teeth, wherein the tensioning-assembly gearing comprises a first set of planet gears drivingly engaged to the internal teeth of the ring gear of the rocker mover, wherein the driven shaft is drivingly engaged to the first set of planet gears such that rotation of the driven shaft drives the first set of planet gears, which in turn drive the rocker mover to rotate.

15. The strapping device of claim 14, wherein the first set of planet gears are supported by the rocker.

16. The strapping device of claim 14, wherein the ring gear of the rocker mover and the tensioning wheel are coaxial.

17. The strapping device of claim 16, wherein the rocker is pivotable about a rocker axis between the tensioning position and the strap-insertion position.

18. The strapping device of claim 17, wherein the cam-engaging finger is pivotable about a cam-engaging-finger axis between the first and second positions.

19. The strapping device of claim 18, wherein the rocker axis is parallel to the cam-engaging-finger axis.

Images