Powered Banding Device Torque Control and Folding Mechanism
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing band clamping tools are not fully automatic, requiring manual intervention for tasks like locking and folding the band clamp after tightening, which lacks precision and efficiency.
Innovation Solution
A powered banding device with a housing, gears, and an electric motor that automatically tightens and locks a band clamp by calculating torque using motor current, and includes a buckle clamp and cutter blade for precise tensioning and cutting, with an actuator for sequential operation of the buckle clamp, roller pin, and cutter blade.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual operation is used to lock and fold the band clamp after tightening, then the tool structure can be simpler, but the automation level is reduced and precision is compromised
Solution Approach 1:
The patent combines multiple functions (tightening, locking, and folding operations) into a single integrated powered tool. The electric motor drives gears that simultaneously control the gripping rollers for tightening and the buckle clamp for locking, while the roller pin performs folding. This merging of functions into one automated device achieves high automation level without proportionally increasing overall tool complexity.
Solution Approach 2:
The electric motor serves multiple purposes: it drives the gears for tightening operations, controls the buckle clamp for locking, and enables the roller pin for folding. This multi-functionality allows a single power source to control all critical operations, achieving full automation while avoiding the need for separate actuators for each function.
2Productivity
If manual intervention is required for locking and folding operations, then the device can be simpler to manufacture, but productivity and precision are reduced
Solution Approach 1:
The roller pin is pre-positioned in the housing to engage the band tail end immediately after tightening. The buckle clamp is pre-configured to automatically lock the buckle once the band is tensioned. These preliminary positioning arrangements ensure that locking and folding actions follow seamlessly after tightening, eliminating manual intervention and improving productivity.
Solution Approach 2:
The device performs self-locking through the buckle clamp that automatically engages the buckle, and self-folding through the roller pin that automatically folds the band tail end. This self-service capability eliminates the need for manual operations, significantly improving productivity while the integrated design keeps complexity manageable.
3Manufacturing precision
If torque monitoring and control circuitry are added to calculate band tension, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The control circuitry continuously monitors motor current during tightening operations and uses this feedback to calculate real-time torque and band tension. When the predetermined tension is reached, the system automatically stops the motor. This feedback mechanism ensures precise band tension control while using relatively simple current sensing and calculation logic.
Solution Approach 2:
The patent replaces complex mechanical tensioning measurement systems with an electrical sensing approach. By monitoring motor current and calculating torque electrically, the system achieves precise band tension control without requiring mechanical load cells or complex mechanical feedback mechanisms, thereby improving precision while keeping the control system relatively simple.
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 fully automatic and precise tightening, locking, and folding of band clamps, ensuring consistent tension and eliminating the need for manual operation in securing bands around objects.
Implementation Method 1
an electric motor coupled to and configured to cause rotation of the plurality of gears to pull the band therebetween
Implementation Method 2
torque monitoring, sensing, and control circuitry coupled to the electric motor and configured to calculate a torque and thus the band tension or loop force using a motor current of the electric motor
Implementation Method 3
the plurality of gears drive diamond knurled gripping rollers that grip the tail end of the band
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A powered banding device (100) includes a housing and a plurality of gripping rollers (133, 137) within the housing (112) that are configured to pull a tail end of a band through a feed slot (124) as the gripping rollers (133, 137) rotate. The device (100) also includes torque circuitry coupled to an electric motor (104) driving the plurality of gripping rollers (133, 137), which the torque circuitry is configured to calculate a torque on the band using a motor current to determine when to stop pulling. A roller pin (126) is configured to move through a roller slot (130) after the electric motor (104) stops pulling to form a fold in the band as the roller pin (126) moves to an end of a downward curved portion of the roller slot (130). A cutter blade (156) behind the roller pin (126) follows the roller pin (126) and cuts the band above the roller pin (126) and flattens a cut end over a buckle (152) of the band.