Battery Powered Strap Tensioner with Sensor Control
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Solution Overview
Problem
Existing strap tensioning tools, both manual and automatic, face limitations such as labor-intensive manual operation and dependence on compressed air sources, making them inefficient and impractical for use in various locations without access to air supply.
Innovation Solution
A portable, battery-powered strap tensioner with a motor-driven tension wheel, a nosepiece, and a controller that includes sensors and switches for automatic tensioning, allowing operation in both manual and automatic modes, and enabling use without compressed air.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual tensioners are used, then the device is simple and portable, but the operation is labor-intensive and fatiguing
Solution Approach 1:
The patent replaces the manual mechanical operation with an automated motor-driven system. The motor is connected to the tension wheel through a drive train that includes a speed reduction gear set, automatically drawing tension in the strap without requiring manual lever operation.
Solution Approach 2:
The tensioner incorporates sensors (strap sensor, home position switch) that automatically detect strap presence and nosepiece position, enabling the system to self-regulate the tensioning cycle without continuous operator intervention.
2Extent of automation
If pneumatic automatic tensioners are used, then the tensioning is automated, but the tool requires compressed air source
Solution Approach 1:
The patent substitutes the pneumatic system with an electric motor system. The motor is operably connected to the tension wheel through a drive train, providing automated tensioning without requiring compressed air infrastructure.
Solution Approach 2:
The battery-powered motor system provides universal operation in any location without requiring infrastructure support. The tensioner can function anywhere a battery can be charged, greatly increasing adaptability compared to pneumatic systems.
3Power
If speed reduction gear set is added, then the motor can effectively drive the tension wheel, but the device complexity increases
Solution Approach 1:
The patent uses a planetary gear set within the drive train to provide speed reduction and torque multiplication. This compact gear mechanism efficiently transmits motor power to the tension wheel while maintaining manageable device dimensions.
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 efficient and ergonomic strap tensioning with reduced operator fatigue and increased portability, enabling operation anywhere with a battery-powered solution that automatically manages tensioning cycles.
Implementation Method 1
a motor, where the tension wheel is positioned in the tension head and is operably connected to the motor
Implementation Method 2
The drive train can include a speed reduction gear set, such as a planetary gear set
Implementation Method 3
The nosepiece includes a pinch element, for example, a pinch wheel and is mounted to bias the pinch wheel toward the tension wheel
Data Source
AI summary
A tensioner for strap includes a housing, a battery, a motor, a tension head having a tension wheel operably connected to the motor and a nosepiece having a pinch element. The nosepiece is mounted to the tension head for movement relative thereto. An actuator handle is mounted to the nosepiece to move the pinch element toward and away from the tension wheel. A strap sensor is operably connected to a controller and senses the presence or absence of strap between the tension wheel and the pinch element. A home position switch senses pinch wheel proximity to the tension wheel. The nosepiece is moved away from the tension head to introduce strap to the tool and the home position switch changes state to signal the controller to permit actuation of the motor when the strap sensor senses the presence of strap between the pinch element and the tension wheel.