Cable Tie Tensioning with Closed-Loop Load Cell Control
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Solution Overview
Problem
Existing cable tie tensioning tools lack accurate and consistent tension control, leading to inconsistent tensions, increased manual effort, and potential worker injury, discomfort, and inefficiency.
Innovation Solution
A cable tie tensioning device with a load cell and closed-loop control system for precise tensioning, featuring a motor-driven lead screw and inline strain gauge for real-time tension measurement, and a separate cutting mechanism triggered by the load cell to ensure accurate cutting at the desired tension.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual cable tie tensioning tools are used, then device complexity is reduced, but tension precision and consistency deteriorate
Solution Approach 1:
The patent replaces manual mechanical tensioning with an automated motor-driven system. The motor 124 drives a lead screw 154 that converts rotational motion to linear motion, automatically pulling the cable tie through the tensioning assembly 122. This mechanical substitution eliminates manual operation while achieving precise tension control through electronic actuation and feedback.
Solution Approach 2:
The patent implements a feedback control system using a load cell 138 to measure the actual tension applied to the cable tie during tensioning. The load cell signal is fed back to the controller, which adjusts the motor operation to maintain the desired target tension. This closed-loop feedback ensures consistent tension precision despite variations in manual operation or tool-to-tool differences.
2Ease of operation
If manual cable tie tensioning tools are used, then ease of operation is improved, but worker safety and efficiency deteriorate
Solution Approach 1:
The patent replaces manual mechanical tensioning with an automated motor-driven system. The motor 124 drives a lead screw 154 that converts rotational motion to linear motion, automatically pulling the cable tie through the tensioning assembly 122. This mechanical substitution eliminates manual operation while achieving precise tension control through electronic actuation and feedback.
Solution Approach 2:
The tensioning device performs self-adjustment through its feedback control system. The load cell 138 continuously monitors the tension applied, and the controller automatically adjusts the motor 124 operation to maintain the target tension without requiring manual intervention. This self-service capability ensures consistent results and eliminates the physical strain and safety risks associated with manual operation.
3Device complexity
If mechanical tensioning assembly is used without calibration, then device complexity is reduced, but tension consistency deteriorates
Solution Approach 1:
The patent implements a feedback control system using a load cell 138 to measure the actual tension applied to the cable tie during tensioning. The load cell signal is fed back to the controller, which adjusts the motor operation to maintain the desired target tension. This closed-loop feedback ensures consistent tension precision despite variations in manual operation or tool-to-tool differences.
Solution Approach 2:
The patent enables dynamic adjustment of the target tension parameter through the user interface 116. The rotatable bezel 120 allows users to select different target tension values, and the controller modifies the motor operation accordingly. This parameter change capability allows the same device to maintain consistent tension across different applications and cable tie sizes without requiring physical recalibration or complex reconfiguration.
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
The device provides consistent and precise cable tie tensioning with real-time feedback, reducing the risk of over-tightening or under-tightening, improving safety and efficiency, and ensuring tool-to-tool consistency.
Implementation Method 1
a lead screw drive that is configured to axially rotate a screw about the lead screw drive
Implementation Method 2
an inline strain gauge for real-time tension measurement
Data Source
AI summary
A cable tie tensioning device is provided. The cable tie tensioning device includes a tensioning assembly configured to at least partially receive a cable tie and apply tension to the cable tie. The cable tie tensioning device further includes an actuator in communication with the tensioning assembly for operating the tensioning assembly. The cable tie tensioning device further includes a user interface in communication with the tensioning assembly. The user interface includes an input means for input of a target tension to be applied by the tensioning assembly to the cable tie, and an output means for display of an actual tension being applied by the tensioning assembly to the cable tie during operation of the tensioning assembly.