Adjustable Gap Bundling Tool for Variable Strap Thickness
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Solution Overview
Problem
Existing automatic bundling tools are limited in their ability to reliably tighten one-piece-ties with varying strap thicknesses, as they require precise gap widths between the tension gear and rollers, leading to either blockage or slippage, and are often specific to a narrow range of strap thicknesses.
Innovation Solution
An automatic bundling tool device with a tightening mechanism featuring a lever-adjustable gap between the tightening gear and rollers, allowing for precise adjustment of the gap width to accommodate different strap thicknesses, including the use of eccentric elements and stoppers for fine-tuning, ensuring a form-fit, pinch-free arrangement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the gap width between the tension gear and rollers is fixed, then the tightening mechanism can reliably tighten cable ties of a specific thickness, but it cannot accommodate cable ties with varying strap thicknesses
Solution Approach 1:
The patent applies the dynamics principle by making the gap width between the tension gear and rollers adjustable rather than fixed. The tension roller unit can be positioned at different distances from the tension gear through an adjustment mechanism, allowing the system to adapt to various strap thicknesses while maintaining the necessary form-fit engagement for reliable tightening
Solution Approach 2:
The patent implements parameter changes by allowing the gap width parameter to be modified according to the strap thickness. The adjustment mechanism enables changing the distance between the tension gear and rollers, thereby optimizing the engagement parameters for different cable tie specifications without compromising the precision of the tightening action
2Reliability
If the gap width is reduced to prevent slippage, then the tension gear can grip the strap more securely, but the strap may be blocked or ground into fine dust
Solution Approach 1:
The patent uses parameter changes to optimize the gap width between the tension gear and rollers. By adjusting this parameter to the optimal value specific to each strap thickness, the system achieves reliable form-fit engagement that prevents slippage while avoiding excessive compression that would cause grinding or dust generation
Solution Approach 2:
The patent replaces the spring-force-based mechanical contact system with a positioned gap system. Instead of relying on spring pressure that causes continuous contact and grinding, the tension gear engages the strap through a controlled gap that allows precise form-fit engagement without excessive mechanical stress
3Force
If spring force is used to push support rollers against the tension wheel, then the tension wheel can maintain grip on the cable tie strap, but grinding occurs and fine dust is generated
Solution Approach 1:
The patent extracts the spring force mechanism from the tightening system. By removing the spring-based continuous contact arrangement, the system eliminates the source of grinding and dust generation while maintaining effective grip through the adjusted gap width that enables proper form-fit engagement between the tension gear teeth and strap serrations
Solution Approach 2:
The patent substitutes the spring-force mechanical contact system with a positioned gap system. The grip force is maintained not by continuous spring pressure but by the geometric form-fit engagement between the tension gear teeth and strap serrations, achieved through precise positioning of the tension rollers at an optimized distance from the tension gear
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables reliable tightening of one-piece-ties across a range of strap thicknesses without grinding or slipping, allowing for versatile use with various types of cable ties, including those with different thicknesses in the same harness.
Implementation Method 1
The tightening roller unit (12) comprises a lever (12c) with the two tightening rollers (12a, 12b) being arranged on the lever (12c) in a first end section (12') of the lever (12c), a turning point (12d) in a middle section (12'') of the lever (12c), and an adjustment element (12e) being in mechanical contact to a second end section (12''') of the lever (12c)
Implementation Method 2
The adjustment element comprises an excentric shaft (12e*) which is in mechanical contact with the second end section (12''') of the lever (12c), where the adjustment element is configured to adjust a minimal and/or maximal distance of the tightening rollers (12a, 12b) to the tightening gear (11a) by a rotation of the excentric shaft (12e*)
Implementation Method 3
The tightening mechanism (10) comprises a spring element (16) which is in mechanical contact with the second end section (12''') of the lever (12c) and is configured to exert a spring force on the second end section (12''') for holding the tightening rollers (12a, 12b) close to the tightening gear (11a)
Data Source
AI summary
This publication describes automatic bundling tool devices capable of tightening one-piece-ties with increased tolerance with respect to the thickness of the one-piece-tie (OPT) strap. In an aspect, disclosed is a bundling tool device that includes a tightening mechanism with a tightening gear unit with a tightening gear, and with a tightening roller unit with two tightening rollers, forming a gap in between tightening gear and tightening rollers. The gap is configured to hold a strap of a respective OPT processed by the device. The tightening gear includes teeth which are configured to fit into a serration of the strap. The tightening roller unit includes a lever with the two tightening rollers being arranged on the lever in a first end section of the lever, a turning point of the lever being arranged in a middle section of the lever, and an adjustment element of the tightening roller unit.