Inline Load Cell Cable Tie Tensioning for Consistent Force 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 prolonged application time.
Innovation Solution
A cable tie tensioning device with a motor-driven lead screw system, a load cell for precise tension measurement, and a closed-loop control system, ensuring consistent and accurate tensioning and cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual cable tie tensioning tools are used, then device complexity is reduced, but manufacturing precision and reliability of tension application deteriorate
Solution Approach 1:
The patent replaces manual mechanical tensioning with an automated motor-driven lead screw system. The motor (224) mechanically couples to the lead screw drive (254) to automatically apply tension to the cable tie, eliminating the need for manual cranking while ensuring consistent tension through controlled mechanical motion. This substitution of manual mechanical operation with automated mechanical systems resolves the contradiction by improving tension consistency without requiring complex manual intervention.
Solution Approach 2:
The patent incorporates a load cell (256) disposed in line with the motor and lead screw drive to provide real-time feedback on the tension being applied. The load cell measures the actual tension force and feeds this information back to a controller, which can then adjust the motor operation to maintain the desired tension level. This feedback mechanism ensures manufacturing precision in tension application while keeping the overall device complexity manageable through automated control.
2Device complexity
If manual cable tie tensioning is performed, then device complexity remains low, but productivity and duration of action worsen due to significant user force requirements
Solution Approach 1:
The patent replaces manual mechanical tensioning with an automated motor-driven lead screw system. The motor (224) mechanically couples to the lead screw drive (254) to automatically apply tension to the cable tie, eliminating the need for manual cranking while ensuring consistent tension through controlled mechanical motion. This substitution of manual mechanical operation with automated mechanical systems resolves the contradiction by improving tension consistency without requiring complex manual intervention.
Solution Approach 2:
The device performs the tensioning operation autonomously through the motor-driven system. Once the operator positions the cable tie in the jaw (210), the motor automatically executes the tensioning sequence without requiring continuous user input or force application. The system serves itself by converting electrical energy to mechanical work, thereby improving productivity while maintaining manageable device complexity.
3Ease of manufacture
If mechanical tensioning assembly without calibration is used, then ease of manufacture is improved, but reliability of tension control deteriorates
Solution Approach 1:
The patent incorporates a load cell (256) disposed in line with the motor and lead screw drive to provide real-time feedback on the tension being applied. The load cell measures the actual tension force and feeds this information back to a controller, which can then adjust the motor operation to maintain the desired tension level. This feedback mechanism ensures manufacturing precision in tension application while keeping the overall device complexity manageable through automated control.
Solution Approach 2:
The patent replaces manual mechanical tensioning with an automated motor-driven lead screw system. The motor (224) mechanically couples to the lead screw drive (254) to automatically apply tension to the cable tie, eliminating the need for manual cranking while ensuring consistent tension through controlled mechanical motion. This substitution of manual mechanical operation with automated mechanical systems resolves the contradiction by improving tension consistency without requiring complex manual intervention.
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 precise, repeatable, and reproducible cable tie tensioning with real-time feedback, reducing the risk of over-tightening or under-tightening, enhancing safety and efficiency.
Implementation Method 1
a lead screw drive, and a pulling shaft mechanically coupled at a first end to the lead screw drive
Implementation Method 2
a sensor disposed in line with the motor and the lead screw drive... measuring a tension applied to the cable tie with the tie handling jaw with a sensor disposed in line with the motor and the lead screw drive
Data Source
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AI summary
A cable tie tensioning device is provided. The cable tie tensioning device includes a motor mechanically coupled to a lead screw drive, and a pulling shaft mechanically coupled at a first end to the lead screw drive. The cable tie tensioning device further includes a tie handling jaw mechanically coupled to a second end of the lead screw drive. The tie handling jaw is configured to at least partially receive a cable tie for tensioning of the cable tie during operation of the motor. The cable tie tensioning device further includes a sensor disposed in line with the motor and the lead screw drive.