Clip Applying Apparatus With Reciprocating Hammer And Lockout Lever
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Solution Overview
Problem
Manual connection of rebar in concrete reinforcement is labor-intensive, time-consuming, and prone to injuries due to repeated bending, with existing clip applicators not fully addressing the efficiency and safety concerns.
Innovation Solution
A clip applying apparatus featuring a barrel with a clip receiving cavity, alignment head, and a reciprocating hammer mechanism, along with safety and lockout features to guide and secure frangibly connected clips onto reinforcing bars, reducing manual labor and preventing injuries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual connection of rebar is used, then flexibility and simplicity are maintained, but labor intensity increases and injury risk rises
Solution Approach 1:
The clip applying apparatus is designed to be self-operating through automated mechanisms. The hammer automatically strikes the clip, the safety shield moves independently to lock the lever, and the frangibly connected clips are automatically advanced after each application. This self-service capability eliminates the need for continuous manual intervention while maintaining operational simplicity.
Solution Approach 2:
The patent replaces the manual mechanical bending and tying process with an automated mechanical system. The reciprocating hammer mechanism, triggered by moving the safety shield, automatically applies clips to connect rebar, substituting the labor-intensive manual operations with a controlled mechanical system that reduces physical strain on workers.
2Productivity
If clip applying apparatus is used, then productivity and safety are improved, but device complexity increases
Solution Approach 1:
The barrel assembly serves multiple functions: it houses the hammer mechanism, guides the frangibly connected clips, positions the clip for striking, and contains the lockout lever mechanism. The safety shield simultaneously acts as a protective barrier, a trigger mechanism for the hammer, and a locking device for the lever. This multi-functionality reduces the need for separate components, managing device complexity while maintaining productivity improvements.
Solution Approach 2:
The patent employs a nested structure where the hammer is received within the barrel, the clip receiving cavity is defined within the barrel, and the lockout lever is pivotally connected to the barrel. The safety shield moves within the confines of the barrel assembly. This nesting arrangement consolidates multiple components into a compact integrated unit, managing structural complexity while enabling automated operation.
3Reliability
If lockout lever mechanism is added, then safety is improved by preventing premature firing, but device complexity increases
Solution Approach 1:
The lockout lever is preliminarily positioned in a locked state by default, preventing the hammer from firing until the safety shield is deliberately moved. This preliminary locking action ensures that the apparatus cannot accidentally discharge, and the operator must consciously activate the mechanism by moving the safety shield, thereby preventing premature or accidental firing.
Solution Approach 2:
The safety shield acts as an intermediary between the operator's intent and the hammer firing mechanism. Moving the safety shield serves as the intermediate action that simultaneously triggers the hammer reciprocation and releases the lockout lever from its locked position. This intermediary mechanism ensures that firing only occurs when the safety shield is deliberately actuated, adding a safety layer without requiring a completely separate control system.
4Extent of automation
If frangibly connected clips are used, then automation is improved, but manufacturing complexity increases
Solution Approach 1:
The clips are segmented into a frangibly connected string, where individual clips are linked by a frangible connector that allows them to be fed sequentially through the apparatus. This segmentation enables automated feeding without requiring complex individual clip handling mechanisms, as the frangible string naturally advances one clip at a time after each is fired, simplifying the automation while managing manufacturing complexity.
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 apparatus significantly reduces the time and labor required for connecting rebar, minimizes the need for manual bending, and enhances safety by automating the clip application process, thereby improving efficiency and reducing worker exposure to injury.
Implementation Method 1
A hammer received in the barrel. A main drive connected to the hammer and configured to reciprocate the hammer within the barrel
Implementation Method 2
A lockout lever may be pivotally connected to the barrel to pivot outward when a clip is not fully received within the clip receiving cavity. When the lockout lever is pivoted outward, proximal motion of the safety shield will be prevented.
Implementation Method 3
The lobe member may include an inner face directed toward the barrel and configured to engage a string of frangibly connected clips and thereby force the lever outward away from the barrel when a clip is not fully received within the clip receiving cavity.
Implementation Method 4
The support face may prevent regressive movement of the clip string. For example, the string will be unable to fall out of the clip receiving cavity once a clip is fully received in the clip receiving cavity.
Data Source
AI summary
A clip applying apparatus is provided for connecting plastic clips to reinforcing bars. The clip applying apparatus will generally include a barrel, a hammer received in the barrel, and a main drive configured to reciprocate the hammer within the barrel. Other features may include a safety shield as well as a lockout lever which prevents proximal movement of the safety shield if a clip is not fully received within the barrel. Another feature which may be included is a clip door operably connected to a sliding-pivot channel defined in one of the barrel and the clip door. Still other features may include at least one guide slot disposed within the barrel to direct hammer movement, and a hammer bushing coaxial with the barrel to support the hammer.