Automatic Binding Tool for Accurate Strap Tensioning and Cutting
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Solution Overview
Problem
Current cable tie tools are inaccurate, cumbersome, and wasteful, with manual tools prone to over-tensioning and producing sharp edges, and automated tools often require large power sources, making them difficult to handle and expensive to manufacture.
Innovation Solution
An automatic hand-held binding tool with a pistol-shaped housing, a reel magazine for continuous strap, a feeder mechanism, a locking heads magazine, and a controller-actuated cut-off mechanism that uses electric motors to accurately tension and cut the strap to a desired length, minimizing waste and improving user safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated tools are used for cable tie installation, then productivity and accuracy are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The tool is divided into distinct functional modules: a magazine for holding multiple cable ties, a feeder mechanism for individual dispensing, a tensioning mechanism with spring-loaded anvil, and a cutting mechanism. Each module operates independently, simplifying the overall system while maintaining automation capabilities.
Solution Approach 2:
The tool automatically feeds cable ties from the magazine one at a time, automatically tensions them using spring force, and automatically cuts the excess tail after installation. This self-service automation eliminates complex control systems while maintaining high productivity.
2Ease of operation
If pre-dimensioned cable ties are used, then installation is simplified, but material waste increases
Solution Approach 1:
The excess cable tail is automatically cut and removed after installation by the cutting mechanism. This extracts only the necessary portion of the cable tie for the application, minimizing material waste while maintaining ease of operation.
Solution Approach 2:
The tool allows adjustment of cable tie lengths and tension parameters to match specific application requirements. This optimization reduces material waste by using only the necessary amount of cable tie material for each binding task.
3Device complexity
If manual tensioning is used, then device complexity is reduced, but measurement precision and reliability decrease
Solution Approach 1:
A spring-loaded anvil is pre-configured with calibrated spring force to provide consistent, predetermined tension to each cable tie during installation. This prior cushioning ensures accurate tension application without complex real-time measurement systems.
Solution Approach 2:
The tool uses simple, replaceable spring elements and mechanical components for tensioning rather than expensive electronic sensors and actuators. These mechanical components provide sufficient precision for the application while keeping the system simple and reliable.
4Power
If heavy-duty automated tools are used, then power and cutting capability are improved, but weight and ease of operation worsen
Solution Approach 1:
The tool uses a lightweight, spring-based tensioning mechanism that dynamically adapts to different cable tie sizes and materials. The spring-loaded system provides sufficient power for various applications without requiring heavy motors or actuators, keeping the tool lightweight and easy to handle.
Data Source
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AI summary
The present invention provides for an automatic tool for distributing, tensioning and severing a binding strap. The tool comprises a pistol-shaped housing, having a barrel portion extending between a distal housing end portion and a proximal housing end portion along a longitudinal axis, and a handle portion extending away from said barrel portion in a direction different to said longitudinal axis; a reel magazine assembly, configured to retainingly receive at least one strap reel and provide for a rotation of the at least one strap reel about a strap reel centre axis, wherein said rotation is directed so as to wind up a strap coiled up onto the at least one strap reel; a feeder mechanism, provided within said barrel portion and configured to receive an end portion of the strap from the at least one strap reel and move the strap in a direction along said longitudinal axis; a locking heads magazine assembly, provided within said barrel portion and configured to store a plurality of locking heads and supply one locking head at the time for use with the strap; a cut-off mechanism, provided within said barrel portion, configured to cut the strap and receive and move said one locking head from said locking heads magazine assembly into a loading position ready for engagement with the strap, and a drive unit, configured to drive said feeder mechanism so as to selectively move the strap towards said distal housing end portion or towards said reel magazine assembly, and actuate said cut-off mechanism at a predetermined condition.