CONDUIT BENDER

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application No. 63/657,260, filed Jun. 7, 2024, the entire contents of which are incorporated by reference herein.

FIELD OF THE INVENTION

The present disclosure relates to a tool for bending conduit. Conduit may include pipes, electrical metallic tubing (EMT), intermediate metal conduit (IMC), rigid metal conduit (RMC), rigid non-metallic conduit (RNC), solid stock, rebar, or any other elongate material.

SUMMARY

In one example, the disclosure provides a bending system including a bender head for bending conduit, a bend shoe, and a backformer. The bender head includes a housing; a motor contained within the housing; and an output shaft driven by the motor to rotate about a bending axis. The bend shoe is coupled to the output shaft for rotation therewith and for engaging the conduit. The backformer is slidably mounted in a first channel of the housing for movement to a set of positions, the backformer including a roller configured to engage the conduit and press the conduit against the bend shoe.

In another example, which is combinable with any other example, the housing includes a second channel, and the backformer is alternately mountable in the first channel and the second channel.

In another example, which is combinable with any other example, a bender stand supports the bender head above a ground surface, and the bender stand is moveable between an extended position and a collapsed position.

In another example, which is combinable with any other example, the bender stand is removably attached to the bender head.

In another example, which is combinable with any other example, the bend shoe includes a hub and a sector body extending from the hub, wherein the hub includes a socket positioned on a rear face of the hub, and wherein the socket includes a non-circular inner profile configured to transmit rotation from the output shaft to rotate the bend shoe.

In another example, which is combinable with any other example, the socket includes notches positioned opposite one another, and the notches serve as an alignment feature when coupling the bend shoe to the bender head.

In another example, which is combinable with any other example, the backformer includes a backformer arm supporting the roller.

In another example, which is combinable with any other example, the bender head includes a gear train housed within a gear case, the output shaft is coupled to the gear train and at least partially extends from the gear case, and the backformer is coupled to the gear case.

In another example, which is combinable with any other example, the backformer arm is slidably mounted within the first channel such that the backformer arm is movable between set positions correlated to different sizes of the bend shoe.

In another example, which is combinable with any other example, a fixing assembly includes an actuator configured to selectively release the backformer arm and allow movement of the backformer arm between the set positions.

In another example, which is combinable with any other example, the backformer arm is positioned within the first channel such that a ratio of roller distance to bend radius is between 0.75 and 1.

In another example, which is combinable with any other example, a bending system for bending conduit includes a bender head including a housing and an output shaft, the output shaft extending from the housing and for being driven to rotate relative to the housing about a bending axis; a bend shoe coupled to the output shaft for rotation therewith and for engaging the conduit; and a stand to support the bender head above a surface, the stand including a center column to couple to the bender head, and a set of legs coupled to the center column and to engage the surface. The set of legs are unevenly circumferentially spaced about the center column.

In another example, which is combinable with any other example, the stand is movable between an expanded position and a collapsed position.

In another example, which is combinable with any other example, the set of legs includes a first leg extending from the center column and a pair of second legs extending from the center column, and the first leg is spaced from each of the pair of second legs by a first spacing, and the pair of second legs are spaced by a second spacing that is different than the first spacing.

In another example, which is combinable with any other example, the first leg includes a base and the pair of second legs include respective bases, and the base of the first leg is wider than the respective bases of the pair of second legs.

In another example, which is combinable with any other example, the base of the first leg includes a T-shaped bar.

In another example, which is combinable with any other example, the stand includes a collar assembly slidably coupled to the center column, and the collar assembly is coupled to the set of legs via struts that are pivotably coupled to the collar assembly and to the set of legs.

In another example, which is combinable with any other example, the collar assembly includes a tube body and a handle, the tube body for receiving the center column.

In another example, which is combinable with any other example, the collar assembly includes a bushing positioned within the tube body between the center column and the tube body.

In another example, which is combinable with any other example, the collar assembly includes a locking system, the locking system for selectively locking the set of legs in an expanded position and a collapsed position.

In another example, which is combinable with any other example, the center column includes a first aperture and a second aperture, and the locking system includes a detent pin that selectively engages the first aperture and the second aperture to lock the set of legs in the expanded position and the collapsed position, respectively.

In another example, which is combinable with any other example, the handle includes an actuator coupled to the detent pin to selectively disengage the detent pin from the first aperture and the second aperture.

In another example, which is combinable with any other example, a bender head for bending conduit includes a housing; a motor contained within the housing; an output shaft driven by the motor to rotate about a bending axis; a bend shoe coupled to the output shaft for rotation therewith and for engaging the conduit; a backformer including a roller for engaging the conduit and pressing the conduit against the bend shoe; a sensor for detecting an orientation of the bend shoe; and a controller coupled to the sensor.

In another example, which is combinable with any other example, the controller is operable to: receive one or more selected from a group consisting of a target bend angle, a conduit size, and a conduit type, and determine a spring back adjustment based on the group.

In another example, which is combinable with any other example, the controller is operable to determine a calibrated clamp position for a bending operation by receiving, from the sensor, an angle of the bend shoe, and storing the angle of the bend shoe in an internal memory of the controller as a calibrated clamp position.

In another example, which is combinable with any other example, the sensor is an angle sensor, and the bender head further includes a current sensor configured to measure current draw of the motor. The controller is operable to: determine if the current draw monitored by the current sensor exceeds a predetermined threshold, and deactivate the motor in response to the current draw exceeding the predetermined threshold.

In another example, which is combinable with any other example, the controller is operable to monitor the current draw as a rolling average.

In another example, which is combinable with any other example, the controller is operable to: activate the motor to rotate the bend shoe to a starting position, lock the bend shoe in the starting position, analyze signals received by the sensor to determine that the bend shoe is locked, and set an angle position to zero.

In another example, which is combinable with any other example, the controller is operable to: detect a starting position of the bend shoe based on data from the sensor, thereafter, compare the starting position to a pre-programmed lock position, and thereafter, activate the motor to rotate the bend shoe to the pre-programmed lock position.

In another example, which is combinable with any other example, the bender head further includes a drive system and a motor braking system, the motor braking system including a brake to act on the drive system and to be activated by the controller when a bending operation is at least partially finished.

The features identified above may be used in any combination or individually. Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a bending system including a bender head, a bend shoe, and a bender stand.

FIG. 2 is a front view of the bend shoe for use with the bender head of FIG. 1.

FIG. 3 is a rear view of a portion of the bend shoe of FIG. 2.

FIG. 4 is a perspective view of the bender head of FIG. 1 detached from the bender stand.

FIG. 5 is a cross-sectional view of a drive system of the bender head of FIG. 4.

FIG. 6 is an assembly view of a mounting assembly for connecting the bender head and the bender stand of FIG. 1.

FIG. 7 is a first side view of the bender head of FIG. 4.

FIG. 8 is a second side view of the bender head of FIG. 4.

FIG. 9 is a front view of the bender head of FIG. 4.

FIG. 10 is another perspective view of the bender head of FIG. 4 and illustrates a backformer extending from a gear case.

FIG. 11 is a side view of the bender head of FIG. 10 illustrating the backformer unassembled from the gear case and including an alternate position of the backformer.

FIG. 12 is a lower perspective view of the bender head of FIG. 10 with the backformer disassembled from the gear case.

FIG. 13A is a perspective view showing a bender head in an upper configuration.

FIG. 13B is a perspective view showing the bender head in a lower configuration.

FIG. 14 is a side view of the bender head and the bend shoe of the bending system of FIG. 1.

FIG. 15 illustrates an exemplary user interface for use with the bending system of FIG. 1.

FIG. 16 illustrates the bender stand of FIG. 1 detached from the bender head and in an expanded position.

FIG. 17 illustrates the bender stand of FIG. 16 in a collapsed position.

FIG. 18 is a top view of the bender stand of FIG. 16.

FIG. 19 is a perspective view of a collar assembly of the bender stand of FIG. 16.

FIG. 20 is an assembly view of portions of the collar assembly of FIG. 19.

FIG. 21 is a perspective view of the collar assembly of FIG. 19 with a handle housing in phantom.

FIG. 22 is a perspective view of a portion of the bender stand of FIG. 16 including the collar assembly positioned between a first position and a second position.

FIG. 23A illustrates the collar assembly of FIG. 19 with a locking system in a first position.

FIG. 23B illustrates the collar assembly of FIG. 23A with the locking system in a second position.

FIG. 24 is an assembly view of a joint between the collar assembly of FIG. 19 and a strut.

FIG. 25 is a cross-sectional view of the joint of FIG. 24.

FIG. 26 is a block diagram of a control system of the bending system of FIG. 1.

FIG. 27 is a first flowchart describing operation of a controller of the control system of FIG. 26 using angle sensors.

FIG. 28 is a second flowchart describing operation of a controller of the control system of FIG. 26 using a spring-back function.

FIG. 29 is a third flowchart describing operation of a controller of the control system of FIG. 26 using a dynamic current calibration process.

FIG. 30 is a fourth flowchart describing operation of a controller of the control system of FIG. 26 using a safety stop process.

FIG. 31 illustrates a double bend shoe usable in the bending system of FIG. 1.

FIG. 32 illustrates a double headed hand conduit bender.

FIG. 33 illustrates a bend shoe usable in the bending system of FIG. 1 and including an alignment feature.

FIG. 34 illustrates the bend shoe of FIG. 33 in operation.

FIG. 35 illustrates a first bend alignment subassembly for use in the bending system of FIG. 1 including a laser module mounted on the bend shoe.

FIG. 36 illustrates a second bend alignment subassembly for use in the bending system of FIG. 1 including a laser module mounted on the bender head.

FIG. 37 illustrates a third bend alignment subassembly for use in the bending system of FIG. 1 including a laser module mounted on a support arm.

FIG. 38 illustrates a first accessory bend alignment laser module configured to couple to an end of conduit.

FIG. 39 illustrates a second accessory bend alignment laser module configured to couple to a length of conduit.

FIG. 40 illustrates the first accessory bend alignment laser module of FIG. 38 in use with a bend shoe including an indicator line.

FIG. 41 illustrates an accessory bend alignment laser module in use with a hand bender.

FIG. 42 illustrates an alternate bend alignment subassembly including a light projector.

Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.

It should also be noted that certain features are described in reference to certain embodiments but are not limited to application in that embodiment and may be incorporated into other embodiments, both explicitly disclosed and not disclosed.

DETAILED DESCRIPTION

Pipes or conduit are used in a variety of use cases that can require different configurations and shapes be created. A conduit bender is typically used to form the pipes into the desired shape. Conduit benders or conduit bending tools can be used to bend conduit including pipes, electrical metallic tubing (EMT), intermediate metal conduit (IMC), rigid metal conduit (RMC), rigid non-metallic conduit (RNC), solid stock, rebar, or any other elongate material. Conduit benders typically use a bend shoe that includes an arc-shaped outer rim defining a bend radius. The conduit is pressed against the outer rim to create a bend in the conduit having a radius corresponding to the bend radius of the bend shoe. The figures and disclose provide various aspects of conduit benders and bending systems. Unless otherwise stated, any of the features discussed can be implemented with or without any of the other features disclosed and any combination of features is included in this disclosure.

FIG. 1 illustrates a powered conduit bending tool 10 also referred to herein as a bending system 10. The bending system 10 includes a bender head 14, a bender stand 18 supporting the bender head 14 above a ground surface, and a bend shoe 300 removably coupled to the bender head 14. FIG. 1 illustrates the bending system 10 in an active configuration. In the active configuration, the bender head 14 is supported on the bender stand 18, and the bender stand 18 is expanded and engages the ground surface to provide a stable base. The bend shoe 300 is coupled to the bender head 14 to receive conduit. FIG. 1 illustrates a length of conduit C loaded into the bend shoe 300 and ready to be bent by the conduit bending system 10. The bending system 10 is also movable to a storage or transport configuration in which the bender head 14 is detached from the bender stand 18 (FIG. 4) and the bender stand 18 is in a collapsed position (FIG. 17). The bend shoe 300 may remain attached to the bender head 14 during transport or may be removed and stored separately. The bend shoe 300 may be one of a set of bend shoes 300 that are alternately couplable to the bender head 14. The set of bend shoes 300 may include bend shoes 300 of varying sizes (e.g., with different bend radii, with varying channel widths, etc.). To successfully bend most types of commonly used conduit an operator uses one of three bend shoes 300: a first bend shoe (e.g., for bending ½″ EMT), a second bend shoe (e.g., for bending ¾″ EMT and ½″ RMC), and a third bend shoe (e.g., for bending 1″ EMT and ¾″ RMC). Therefore, in some embodiments, the bending system 10 includes a set of three bend shoes 300 substantially similar but scaled to different sizes.

With reference to FIGS. 2 and 3, the illustrated bend shoe 300 includes a hub 304 and a sector body 308 extending from the hub 304. The hub 304 includes a socket 312 (FIG. 3) that couples to the bender head 14 and defines a rotation axis R (FIG. 14). In the illustrated embodiment, the socket 312 is positioned on a rear face of the hub 304 and includes a non-circular inner profile 316 capable of transmitting rotation to rotate the bend shoe 300 about the rotation axis R. In other embodiments, the bend shoe 300 may include a socket positioned on an outer surface of the hub 304 to engage a pole or other powered bending system. As discussed further below, in some embodiments, the socket 312 may be separately formed and coupled to the hub 304. In other embodiments, the socket 312 is integrally formed in the hub 304. In the illustrated embodiment, the non-circular inner profile 316 includes a set of similar teeth 320 and a pair of notches 324 positioned opposite each other about the rotation axis R. The notches 324 may serve as an alignment feature when coupling the bend shoe 300 to the bender head 14. In other embodiments, the inner profile 316 may be shaped differently (e.g., square, D-shaped, splined, oblong, etc.).

With continued reference to FIGS. 2 and 3, the body 308 of the bend shoe 300 is designed to reduce the weight of the bend shoe 300. Operators may be required to carry multiple bend shoes 300 to a jobsite to perform the needed bending operations. To minimize the weight of the overall bending system 10, the bend shoes 300 are designed to be light weight compared to traditional bending shoes. The body 308 includes an outer edge 328 following a bend radius measured from the rotation axis R. The outer edge 328 defines a channel 332 for receiving conduit C. The body 308 further includes a hook 336 positioned on the opposite side of the channel 332 and outward from the outer edge 328. The conduit C may be installed in the bend shoe 300 by positioning the conduit C in a front portion of the channel 332 between the outer edge 328 and the hook 336. In a bending operation, force may be applied to the portion of conduit extending above the outer edge 328 to press the conduit C into the channel 332 and form the conduit C to the bend radius.

The outer edge 328 is supported by a spur supports 340 extending between the hub 304 and the outer edge 328. The spur supports 340 may extend radially from the hub 304 and may be angularly spaced by an angle A. In the illustrated embodiment, the body 308 includes three spur supports 340 spaced by approximately 60 degrees. In other embodiments, other configurations may be used. Openings 344 are defined between the spur supports 340. The openings 344 decrease the amount of material used in the body 308 and therefore decrease the weight of the bend shoe 300. In some examples, the bend shoe 300 is mostly formed from aluminum which is relatively light weight compared to other materials used to form bend shoes, e.g., steel. The bend shoe 300 may include a steel internal structure 348 (FIG. 3) that interfaces with and receives torque from the bender head 14. The steel internal structure 348 may surround and include the socket 312. In some embodiments, the steel internal structure 348 extends within portions of the body 308 such as within one or more of the spur supports 340. The steel internal structure 348 reinforces the aluminum bend shoe 300 and provides the needed support while minimizing the added weight. In some embodiments, the steel internal structure 348 may be a removable insert coupled to the hub 304. Due to the application of large amounts of torque, the interface between the socket 312 and the bender head 14 can be subject to wear. Thus, the steel insert may be removed and replaced in the event of damage to the socket 312 and inner profile 316.

Turning to FIG. 4, the bender head 14 is shown detached from the bender stand 18. The illustrated bender head 14 includes a housing 26, a drive system 30 at least partially disposed within the housing 26, a roll cage 34 coupled to the housing 26, and a user interface 38 for controlling the bender head 14. The housing 26 may be formed from plastic and may generally surround a portion of the drive system 30 as well as electronic components used in operating the bending system 10. As discussed above, the bending system 10 is a powered system. The bending system 10 includes a battery 101 (FIG. 26) electrically coupled to the drive system 30. In the illustrated embodiment, the battery 101 is mechanically supported on the housing 26 of the bender head 14 by a battery mount 100, or battery receptacle, (FIG. 9) in a battery receiving area 40. In other embodiments, the battery 101 may be supported on the bender stand 18 (e.g., adjacent a lower end of a center column thereof, on a leg thereof, etc.) and the bender stand 18 may electrically couple to the bender head 14 to transmit power to the drive system 30. In still other embodiments, the battery 101 may be otherwise positioned or the bending system 10 may be include an electrical cord configured to connect the bender head 14 to power.

With reference to FIG. 5, the drive system 30 includes a motor 42, a gear train 46 coupled to the motor 42, and an output shaft 50 coupled to the gear train 46. The motor 42 drives the output shaft 50 to rotate about a bend axis B through the gear train 46. The gear train 46 is not limited to the arrangement illustrated in FIG. 4, numerous other gear train 46 configurations exist. The motor 42, the gear train 46, and at least a portion of the output shaft 50 are positioned within a gear case 58. The gear case 58 may be formed from metal or another rigid material. The gear case 58 is at least partially positioned in the housing 26. In the illustrated embodiment, the drive system 30 has an aligned configuration meaning the motor 42 and the output shaft 50 are coaxial. In other embodiments, the drive system 30 may have an offset configuration where an axis of the motor 42 and the bend axis B of the output shaft 50 are parallel but spaced. In still other embodiments, the drive system 30 may have an angled configuration where the axis of the motor 42 and the bend axis B of the output shaft 50 are at an angle with respect to each other.

As seen best in FIG. 4, a portion of the gear case 58 may extend from a side of the housing 26. The output shaft 50 extends from the portion of the gear case 58 along the bend axis B. The output shaft 50 includes an end portion 62 with a splined outer profile that generally corresponds to the inner profile 316 of the bend shoe 300 to rotatably couple the bend shoe 300 to the output shaft 50. The illustrated profiles include a toothed circumference and opposed notches. In some embodiments, the profiles may include square profiles or any other noncircular profiles capable of transmitting rotation therebetween. The bend shoe 300 may include a retaining feature (not shown) and/or quick-connect feature (not shown) to selectively secure the bend shoe 300 to the output shaft 50 by preventing movement along the bend axis B. In other embodiments, the bend shoe 300 may be permanently coupled to the output shaft 50. For example, the bend shoe 300 may be integrally formed or machined as a single piece with the output shaft 50.

With reference to FIG. 4, the bender head 14 includes a backformer arm 70 extending from the gear case 58. The backformer arm 70 includes a roller 72 that cooperates with the bend shoe 300 to secure conduit C in the bender head 14. For example, the roller 72 is rotatably mounted on a shaft and rotates with respect to the shaft relative to the backformer arm 70. In other embodiments, the roller 72 may be omitted. In such embodiments, the backformer arm 70 may include, for example, a force reactionary member, or projection, that is stationary (i.e., non-rotatable). When the motor 42 is activated, the bend shoe 300 is rotated about the bend axis B by the drive system 30 and the conduit C is pressed by the roller 72 of the backformer arm 70 against the outer edge 328 of the bend shoe 300 creating a bend in the conduit C.

Turning to FIG. 6, the bender head 14 is removably coupled to the bender stand 18 by a mounting assembly 74. In the illustrated embodiment, the mounting assembly 74 includes a mounting bracket 78 that secures to the gear case 58. In other embodiments, the mounting bracket 78 may be part of the housing 26 or otherwise secured to the bender head 14. The mounting bracket 78 defines a central channel 80 that receives an upper post 86 of the bender stand 18. The mounting bracket 78 includes a first opening 82a and the upper post 86 includes a second opening 82b. When the mounting bracket 78 is fitted over the upper post 86, the first opening 82a and second opening 82b may be aligned. In the illustrated embodiment, the first opening 82a is one of a pair of first openings 82a and the second opening 82b is one of a pair of second openings 82b. A detent pin 88 is coupled to the mounting bracket 78 and is biased by a spring 90 to extend through the aligned openings 82a, 82b. The detent pin 88 secures the mounting bracket 78 on the upper post 86 thereby coupling the bender head 14 to the bender stand 18. The position of the second opening 82b on the upper post 86 limits the orientation of the bender head 14 with respect to the bender stand 18 and acts as an alignment feature. In other embodiments, the bender head 14 may be removably coupled to the bender stand 18 in other ways.

With reference to FIGS. 4 and 7-10, the roll cage 34 provides structural support in the event the bender head 14 is impacted or dropped. The roll cage 34 at least partially surrounds the housing 26 and is formed from, for example, metal or sturdy plastic to protect the housing 26 (formed from a lighter plastic) and electronic components contained therein. In the illustrated embodiment, the roll cage 34 includes a plurality of rails including a pair of side rails 94a, 94b and a plurality of cross rails 98. The side rails 94a, 94b are coupled together by the cross rails 98 extending perpendicularly therebetween. The roll cage 34 is coupled to the housing 26 so the side rails 94a, 94b are positioned on either side of the housing 26. In some embodiments, the roll cage 34 may couple to the gear case 58 and be configured to react the force of an impact or drop through the gear case 58 to protect the housing 26. As seen best in FIGS. 7-8, in the illustrated embodiment, the side rails 94a, 94b are different shapes and connect to the housing 26 at multiple points and at least one cross rail 98 couples to the housing 26. In other embodiments, the side rails 94a, 94b may be the same shape and the roll cage 34 may couple to the housing using a different combination of cross rails and side rails. With reference to FIGS. 7-9 especially, the roll cage 34 is disposed further outboard of the housing 26 in all directions. Thus, if the bender head 14 is dropped onto a surface, the roll cage 34 is positioned to contact the surface before the housing 26 and absorb the impact. The side rails 94a, 94b each define a gap creating an access channel allowing the operator to access the user interface 38 while still protecting the housing 26. As seen best in FIG. 9, the gear case 58 extends past the side rail 98a such that the end portion 62 of the output shaft 50 is positioned beyond the roll cage 34. The bend shoe 300 is coupled to the output shaft 50 to define a bending plane P that does not intersect the roll cage 34. Therefore, the roll cage 34 does not inhibit the bending operations. In some embodiments, the roll cage 34 is fixed to the housing 26. In some embodiments, the roll cage 34 is removably coupled to the housing 26 to allow for easy replacement if the roll cage 34 is damaged.

In addition to protecting the housing 26 from impact, the roll cage 34 also provides a number of grab points, allowing the operator to easily support the bender head 14. For example, the operator may grab any of the cross rails 98 or side rails 94a, 94b in order to lift the bender head 14 and position the channel 82 of the mounting bracket 78 about the upper post 86 of the bender stand 18. Additionally, in the transport configuration the grab points defined by the roll cage 34 provide a handle for the operator to carry the bender head 14. In some embodiments, one or more of the grab points may include a grip surface that is shaped or textured to provide a specific handle portion. The roll cage 34 may also be used to secure the bender head 14 during storage and prevent theft, for example, by winding a chain through the roll cage 34 and coupling the chain to a fixed or secure structure. In some embodiments, the roll cage 34 may also enable the operator to support the bender head 14 on a hook or otherwise hang the bender head 14 during storage.

Turning to FIG. 10, the backformer arm 70 of the bender head 14 is movably coupled to the gear case 58. The backformer arm 70 may be movable between set positions correlated to different sizes of bend shoe 300. As discussed in further detail below, the positions may be specifically selected based on a spacing between the roller 72 and the edge of the bend shoe 300 to maximize the efficiency of the bending system 10 for each size bend shoe 300. In the illustrated embodiment, the backformer arm 70 is slidably mounted in a channel 102 and is held in position by a fixing assembly including an actuator 106 (FIG. 11) to selectively release the backformer arm 70 and allow movement of the backformer arm 70 between the positions. The backformer arm 70 may include markings or indicia to assist the operator in determining the correct position for the backformer arm 70 based on the bend shoe 300 being used. In the illustrated embodiment, the fixing assembly engages the backformer arm 70 to selectively secure the backformer arm 70 in one of three positions. In other embodiments, more or less positions may be included to correspond with the bend shoes 300 of varied sizes used in the bending system 10.

With reference to FIGS. 11, 12, and 13A-13B, in some embodiments, the backformer 70 may be removably coupled to the gear case 58 and may be assembled to the bender head 14 in multiple configurations. In these embodiments, the channel 102 is a first channel 102a and the gear case 58 includes a second channel 102b. The backformer arm 70 is alternately coupled to the gear case 58 in an upper configuration (FIG. 13A) and a lower configuration (FIG. 13B). In the upper configuration, the backformer arm 70 is slidably received in the first channel 102a with the roller 72 positioned above the housing 26. The bend shoe 300 is coupled to the bender head 14 as seen in FIG. 13A, and conduit C can be positioned between the bend shoe 300 and the backformer arm 70. Conduit bent with the backformer arm in the upper configuration is moved by the bend shoe 300 such that an end of the conduit C extending rearwardly from the bender head 14 is moved down toward the ground during the bending operation. In the lower configuration, the backformer arm 70 is slidably coupled to the second channel 102b with the roller 72 positioned below the housing 26. The bend shoe 300 is coupled to the bender head 14 in a position rotated 180 degrees opposite from the position shown in FIG. 13A. Conduit C is positioned between the bend shoe 300 and the backformer arm 70 and is bent so that an end of the conduit C extending forwardly from the bender head 14 is moved up away from the ground during the bending operation. In the illustrated embodiments, the first channel 102a and the second channel 102b are parallel and the upper configuration and the lower configuration are spaced apart by 180 degrees. In other embodiments, the configurations may be spaced by other set angles and the channels 102a, 20b may extend at an angle with respect to each other. The two assembly configurations of the backformer arm 70 and bend shoe 300 allow the operator to assess the surrounding environment and select how the conduit will move. Additionally, in the upper configuration the conduit C is near eye level to assist the operator in aligning multiple bends in the same plane.

Turning to FIG. 14 and as discussed above, the backformer 70 may be lockable in each of a set of positions by the fixing assembly (e.g., the detent feature) and the positions each correspond to a size of bend shoe 300. The positions are selected to place the roller 72 in the right location with respect to the bend shoe 300 to properly bend the conduit C without damaging it. The roller 72 should be close to the bend shoe 300 in order to properly form the conduit C to the outer edge 328 of the bend shoe 300. However, if the roller 72 is too close to the bend shoe 300 then the roller 72 can apply excessive force to a sidewall of the conduit C which can deform the shape of the conduit C (e.g., denting the diameter, flattening a circular shape into an ovaloid shape, etc.). Similarly, the lateral distance between the bend shoe 300 and the roller 72 can impact the amount of force applied to conduit C especially during the beginning of a bending operation. The fixing assembly limits the backformer 70 to the set positions that provide the highest force from the roller 72 without damaging the conduit C and maintaining the torque applied to the bend shoe 300. The preselection of the set positions saves the operator from needing to waste material by doing a test bend and from needing to manually fine tune the position of the backformer 70.

With continued reference to FIG. 14, when the conduit C is first clamped between the bend shoe 300 and the backformer 70, the channel 332 of the bend shoe 300 engages the conduit C at a tangent point 331. Force is therefore applied to the conduit C in three locations to lock the conduit C relative to the bend shoe 300: adjacent the roller 72, at the tangent point 331 in the channel 332, and at the hook 336. The pressing force (F) applied to the sidewall of the conduit C by the roller 72 is a function of the bend radius (R) of the bend shoe 300, the distance (x) between the roller 72 and the tangent point 331, and the torque (T) output by the output shaft 50 as represented in the equation below.

F = T x + μ ⁢ R

The coefficient μ is a coefficient of friction between the roller 72 and a portion of the backformer arm 70 on which the roller 72 is mounted. In some embodiments, μ may be between 0.05 and 0.25. In one exemplary embodiment, the portion of the backformer arm 70 is formed from steel and the bend shoe is formed from a thermoplastic material (e.g., polyoxymethylene), and thus the coefficient μ is 0.15. As illustrated by the equation, increasing the distance between the roller 72 and the tangent point 331 reduces the force applied to the conduit C without reducing the torque applied to the bend shoe 300. Additionally, the bend shoe 300 may be constrained (e.g., by the notches 324 in the inner profile 316) to mount to the output shaft 50 in a specific orientation to correctly position the distance between the roller 72 and the tangent point 331 for the beginning of a bending operation.

Thus, the higher the ratio between the roller distance and the bend radius, the less potential flattening damage to the conduit C. As discussed above, in one example the bending system 10 includes three bend shoes 300: a first bend shoe, a second bend shoe, and a third bend shoe. The backformer 70 may be movable within the channel 102 to a first position corresponding to the first bend shoe. In the first position, the backformer 70 may be positioned such that the ratio of roller distance to bend radius is between 0.95 and 1.00. In the illustrated embodiment the ratio in the first position may be approximately 0.96. The backformer 70 may be movable within the channel 102 to a second position corresponding to the second bend shoe. In the second position, the backformer 70 may be positioned such that the ratio of roller distance to bend radius is between 0.85 and 0.95. In the illustrated embodiment the ratio in the second position may be approximately 0.90. Finally, the backformer 70 may be movable within the channel 102 to a third position corresponding to the third bend shoe. In the third position, the backformer 70 may be positioned such that the ratio of roller distance to bend radius is between 0.75 and 0.85. In the illustrated embodiment the ratio in the third position may be approximately 0.78. The ratios are further illustrated in the included table below. As seen in the table, the bend shoes including smaller bend radii include more advantageous ratios as they are intended for bending narrower conduit that can be more susceptible to damage.

With reference back to FIGS. 4 and 10, the bending system 10 is controlled by the user interface 38 positioned on the housing 26. In the illustrated embodiment, the user interface 38 is supported on the housing 26 adjacent a front area of the bender head 14 and on an upper surface. The user interface 38 is positioned above the battery receiving area 40. In other embodiments, the user interface 38 may be positioned elsewhere on the housing 26 and/or may span multiple portions of the bender head 14 and bender stand 18.

The bender head 14 may include a controller 114 (FIG. 10) positioned in the housing 26 and coupled to the battery mount 100, the motor 42, and the user interface 38 among other things. The controller 114 is configured to electrically connect the battery 101 (via the battery mount 100) and the motor 42 based on input received via the user interface 38. The user interface 38 may be used to program the controller 114 to perform a bending operation with specific parameters. For example, the operator may input information regarding the desired bend angle, the diameter of the conduit, the wall thickness of the conduit, the configuration of the backformer, the size of the bend shoe 300, the material of the conduit, and any information regarding spring back adjustments, multiple bends, etc. The controller 114 may include a memory storing additional information that may be used in combination with the received input. Additionally, the bender head 14 may include one or more sensors coupled to the controller 114 to provide additional input regarding the location of the backformer, the location of the bend shoe 300, the status of the bend operation, the motor current, the applied torque, the rotation speed, the angular position of components of the drive system 30, etc. In addition to receiving input, the user interface 38 allows the controller 114 to communicate information to the operator including bend status, failure or errors, battery status, etc.

An exemplary embodiment of the user interface 38 is illustrated in FIG. 15, however, other variations exist and are covered by the scope of this disclosure. The user interface 38 includes various control components (e.g., actuators, switches, LEDs, buttons, displays, joysticks, speakers, etc.) used by the operator to control the bending system 10. Specifically, the illustrated user interface 38 includes a display 404, a power button 408, a button dial selector 412, and a set of button controls 416. The display 404 may communicate the current settings to an operator and provide feedback during both the set up and bending operation. In the illustrated embodiment, the display 404 includes an LCD screen. In other embodiments, the display 404 may alternately or additionally include a touch screen, LEDs, buzzers, or other indicators to communicate with the operator. The power button 408 may connect the controller 114 with the battery 101 or may wake up the controller 114 when pressed. The power button 408 is illustrated as a push button but may alternately include other types of controls (e.g., rocker switch, etc.). The power button 408 may also communicate to the controller 114 to activate the display 404 and the rest of the user interface 38 to allow the operator to begin setting up a bend operation. The button dial selector 412 and button controls 416 allow the operator to provide the controller 114 with the required information. The button dial selector 412 can be used to easily scroll through and select menu options or set/alter a bend angle. The button dial selector 412 may rotate in both directions without limits and may also be used as a push button. The button dial selector 412 offers the advantage of easily making large adjustments to values, such as the bend angle, especially in comparison with +/− or ▴ ▾ buttons that require many repeated button pushes to make large changes. The set of button controls 416 further includes a pair of selector buttons as +/− buttons 440 allowing for micro adjustments of the bend angle if needed after the dial selector 412 is used. The set of button controls 416 may be used to quickly indicate to the controller which information is being received. The set of button controls 416 includes a lock conduit button 420, also referred to herein as a clamp button 420, that engages a clamp assembly (not shown) to lock the conduit in place, a release button 424 to release the clamp assembly and thus the conduit, and a bend button 428 to start the bending operation. In some embodiments, the bend button 428 may be a press button and the controller 114 may be programmed to automatically complete the bend operation after receiving instructions to begin. In other embodiments, the bend button 428 may be a ‘dead-man switch’ control that must stay actuated to keep the motor 42 running and the bend operation occurring. The set of button controls 416 also includes a material diameter button 432 and a material type button 436 that can be used to set the input information. As discussed above, the user interface 38 may incorporate additional control elements not disclosed herein. For example, the user interface 38 may include a remote controller wirelessly coupled to the controller 114 in the tool. The user interface 38 may utilize any combination of buttons, encoders, voice prompts, etc. for the operator to provide input and receive information.

Turning to FIGS. 16-17, the bender stand 18 is movable between an expanded or open position (FIG. 16) and a collapsed or storage position (FIG. 17). In the open position, the bender stand 18 may couple to the bender head 14 to provide stable support in the active configuration of the bending system 10. In the collapsed position, the bender stand 18 may be transported and stored in the transport configuration of the bending system 10. In the illustrated embodiment, the bender stand 18 is a tripod style support and includes a center column 118, a plurality of legs 122 each pivotally coupled to the center column 118, and the upper post 86 which interfaces with the mounting assembly 74 to secure the bender head 14 to the bender stand 18.

As seen best in FIG. 18, in the illustrated embodiment, the legs 122 are unevenly circumferentially spaced about the center column 118. The legs 122 include a first leg 122a and a pair of second legs 122b. The first leg 122a is spaced from each second leg 122b by a first angle A1. The second legs 122b are spaced from each other by a second angle A2. In the illustrated embodiment, the first angle A1 is smaller than the second angle A2. Specifically, the first angle A1 may be approximately 115 degrees and the second angle A2 may be approximately 130 degrees. In other embodiments, other spacings may be used. In the illustrated embodiment, the first leg 122a includes a first foot 126a and each second leg 122b includes a second foot 126b. The first foot 126a is different than the second foot 126b. The first foot 126a may include a T-shaped bar extending at an angle to the radial extension direction of the leg 122a. The foot 126a may be oriented so the T-shaped bar extends tangentially with respect to the circle defined by the legs 122. The first foot 126a includes a wider base to increase stability of the stand 18. Each second foot 126b includes an inclined bar that extends radially outward with respect to the circle defined by the legs 122. In other embodiments, the first foot 126a and the second food 126b may be substantially the same. The alignment features of the mounting assembly 74 orients the bender head 14 such that the bend plane P in which the bend shoe 300 rotates does not intersect any of the legs 122. Therefore, bending operations can be performed by the bend system 10 without impacting the stability of the bender stand 18 or the integrity of the bend operation. In the illustrated embodiment, the first leg 122a may extend generally parallel to the bend plane and the first foot 126a helps to increase stability during the bend operations.

Returning to FIGS. 16 and 17, the stand 18 includes a collar assembly 130 slidably coupled to the center column 118. The collar assembly 130 is coupled to the legs 122 via struts 132 which pivotally couple to the collar assembly 130 and the legs 122. As seen best in FIGS. 19-20, the collar assembly 130 includes a sliding collar 134 and a handle 138 coupled to the sliding collar 134. The sliding collar 134 includes a tube body 142 having an inner channel 146, a bushing 150 mounted in the inner channel 146, and a set of mounting brackets 154 positioned around the tube body 142. The handle 138 includes a plastic outer housing 158 and a reinforcement beam 162 coupled to the tube body 142. In some embodiments, the reinforcement beam 162 is integrally formed with the tube body 142. In other embodiments, the reinforcement beam 162 is fixedly secured to the tube body 142. The reinforcement beam 162 is generally J-shaped and at least partially extends within a portion of the plastic outer housing 158. The plastic outer housing 158 is formed from two halves that are coupled together around the reinforcement beam 162 to create a D-shaped handle defining a receiving area for the operator's hand. As seen in FIG. 21, the reinforcement beam 162 extends around a majority of the D-shaped plastic outer housing 158 to reinforce the lower and outer portions of the handle 138. The reinforcement beam 162 provides additional strength and integrity to the handle 138 in the event the stand 18 is dropped and/or the handle 138 is impacted. The handle 138 may be used in the transport configuration to carry the stand 18 across a worksite. Additionally, as seen in FIG. 22, the handle 138 may be used to move the collar assembly 130 along the center column 118. Movement of the collar assembly 130 along the center column 118 moves the stand 18 between the expanded and collapsed positions and pulls the legs 122 toward the center column 118.

With continued reference to FIGS. 19, 20, and 22, the bushing 150 decreases the friction between the center column 118 and the collar assembly 130 allowing for easier movement of the stand 18 between the expanded and collapsed positions. In the illustrated embodiment, the bushing 150 is formed from a low-friction material (e.g., brass, nylon, etc.) and is press fit into the inner channel 146 of the tube body 142. An inner diameter of the bushing 150 may be sized to match an outer diameter of the center column 118 to constrain the collar assembly 130 to move along the center column 118. The contact between the bushing 150 and the center column 118 allows for smooth sliding of the collar assembly 130. In some embodiments, the tube body 142 may include a low-friction coating or lining in the inner channel 146 instead of a separate bushing. The decrease in friction provides an easier transition and thus a better experience for the operator moving the stand 18 between the expanded and collapsed positions. In addition, the bushing 150 prevents damage to the center column 118 or damage to the collar assembly 130 that can result from forcing the collar assembly 130 along the center column 118 through sticking points with high friction. In some embodiments, the bushing 150 may be formed from a wearable material and may be designed to be replaced as needed to maintain the frictionless movement of the collar assembly 130.

The collar assembly 130 is movable along the center column 118 between a first or lower position (FIG. 16), corresponding to the expanded position of the stand 18, and a second or upper position (FIG. 17), corresponding to the collapsed position of the stand 18. The collar assembly 130 may be selectively locked in the lower position or upper position by a locking system 166 included in the handle 138 and seen in FIGS. 20-23B. The locking system 166 includes a detent pin 170 that engages first and second apertures 174 (FIG. 22) on the center column 118. The detent pin 170 is slidably mounted in the handle 138 of the collar assembly 130. A first of the apertures 174 is positioned on the center column 118 adjacent a lower end of the center column 118. The second of the apertures 174 is positioned between an upper and a lower end of the center column 118. The detent pin 170 is biased toward the center column 118 by a spring 182. In the illustrated embodiment, the detent pin 170 extends through openings 178 in the side of the tube body 142 and the bushing 150. In other embodiments, the detent pin 170 may be supported above or below the tube body 142. The detent pin 170 and spring 182 are supported in the handle 138. The handle 138 further includes an actuator 186 coupled to the detent pin 170 to release the locking system 166. The actuator 186 is slidable in a direction generally parallel to the center column 118 and angle with respect to the movement of the detent pin 170. The actuator 186 moves between a neutral position (FIG. 23A) in which the detent pin 170 engages the center column 118, and a depressed position (FIG. 23B) in which the detent pin 170 is pulled away from the center column 118. The actuator 186 includes an angled slot 190 that interfaces with a post on the detent pin 170 to convert movement of the actuator 186 in one direction (e.g., generally vertical) to movement of the pin 170 in another direction (e.g., generally horizontal). The actuator 186 is therefore ergonomically positioned at a top of the handle 138 to be easily depressed by the operator gripping the handle 138. The actuator 186 also serves as a visual and tactile indicator of the status of the locking system 166.

When the collar assembly 130 is positioned in the lower position the detent pin 170 is biased by the spring 182 toward the center column 118 and extends through the first of the apertures 174 adjacent the lower end of the center column 118. The stand 18 is therefore locked in the expanded position with the legs 122 rotated away from the center column 118. The operator pushes the actuator 186 to release the locking system 166 and pulls upward on the handle 138 to move the collar assembly 130 along the center column 118. The operator can release the actuator 186 which is held in the depressed position by the retracted detent pin 170. When the collar assembly 130 aligns with the second of the apertures 174, the spring 182 biases the detent pin 170 to extend through the aperture 174 and engage the center column 118 to lock the collar assembly 130 in the upper position. The movement of the detent pin 170 returns the actuator 186 to the released position, indicating to the user that the locking system 166 is engaged and the stand 18 is locked in the collapsed position. The locking system 166 prevents inadvertent movement between the expanded and collapsed positions of the stand 18. This is advantageous in the expanded position to add stability to the stand 18 during bending operations. Additionally, during transport this prevents the legs 122 from pivoting away from the center column 118, for example due to gravity, and being damaged.

Turning to FIGS. 24 and 25, the mounting brackets 154 are positioned around the tube body 142, and each mounting bracket 154 pivotally couples to one of the struts 132 extending between the collar assembly 130 and the legs 122. The mounting brackets 154 each include a through bore 194 extending along a pivot axis of the struts 132. The struts 132 each include a pair of links 198 having apertures 200 positioned adjacent the end thereof. The links 198 are pivotally coupled to the mounting brackets 154 by a fastener. In the illustrated embodiment, the fastener includes a head 202, a shaft 204, and a nut 206. The shaft 204 is positioned through the aperture 200 of one of the links 198, the through bore 194, and the aperture 200 of the other link 198. The nut 206 is threaded onto the end of the shaft 204 and tightened to secure the links 198. To avoid unnecessary stresses due to overtightening that would prevent easy pivoting of the links 198, the collar assembly 130 includes a spacer 208 positioned in the through bore 194 of the mounting brackets 154. The spacer 208 is wider than the mounting bracket 154 such that when the fastener is tightened, the links 198 are held in contact with ends of the spacer 208 and a gap is left between the links 198 and the mounting bracket 154. The links 198 are therefore free to rotate with respect to the mounting bracket 154 without friction between the inner faces of the links 198 and the outer faces of the mounting bracket 154. While described as a bolt and nut, the fastener may take other forms. In the illustrated embodiment, the spacer 208 is slidable and rotatable within the through bore 194. In some embodiments, the spacer 208 may instead be press fit into the through bore 194.

Turning back to FIG. 19, the mounting brackets 154 of the collar assembly 130 include a curved seat 212 on an outer surface thereof. In the collapsed position of the stand 18 shown in FIG. 17, the legs 122 are pivoted inward toward the center column 118, and an outer diameter of the legs 122 engages the seat 212. The curved profile of the seat 212 increases the contact area between the legs 122 and the mounting brackets 154. In the event the stand 18 is dropped or otherwise impacted while in the collapsed position the forces applied to the legs 122 are transmitted to the tube body 142 through a larger surface area. Distributing the forces across the larger area reduces damage to the legs 122 that can occur when force is transmitted through a single point or line of contact. The curved seat 212 also allows the legs 122 to pivot closer to the center column 118, creating a smaller footprint of the stand 18 when in the collapsed position.

The stand 18 therefore offers a stable support for the bender head 14 that accommodates the specific needs of the bending operations.

FIG. 26 illustrates a block diagram of a control system 500. As discussed above, the bending system 10 includes a controller 114 coupled to the user interface 38 and used to program and operate the bending system 10. The controller 114 is powered by the battery 101, which is mounted to the bending system 10 via the battery mount 100. The controller 114 may be part of the control system 500. The control system 500 may include the user interface 38 and one or more sensors positioned in or on the bender head 14. For example, the control system 500 may include one or more angle sensors 504, and one or more current sensors 508. The angle sensor 504 detects the position of a rotating component such as the output shaft 50, the motor 42, another portion of the drive system 30, etc. The angle sensor 504 sends a signal to the controller 114 indicating the position of the rotating component. The signal may be used to infer the bend angle of the bend shoe 300 and the installed conduit C. In some embodiments, the angle sensor 504 may include a set of hall sensors positioned to surround a portion of the motor 42 and detect the rotational position of the motor 42 based on which hall sensor is activated. In some embodiments, the angle sensor 504 includes switches positioned along the path of a rotationally moving component such as the output shaft 50 or the bend shoe 300 to communicate a specific angle reached by the component. The switches may be mechanical or may be electronic such as hall switches. In some embodiments, the angle sensor 504 may include an inductive position sensor to sense the angular position of a rotatable component. In some embodiments, the angle sensor 504 may include an absolute or incremental rotary encoder used to sense the angular position of a rotatable component. In some embodiments, the angle sensor 504 may include an inclinometer or tilt sensor positioned on the rotatable component to infer a position thereof. In some embodiments, the angle sensor 504 may include a potentiometer used to infer the angular position of a rotatable component. In some embodiments, the control system 500 may include a combination of sensors and may include multiple angle sensors 504 associated with the same or different rotatable components. The controller 114 is able to track the status of the bend operation and determine a current bend angle based on the input from the angle sensor 504.

With reference to FIG. 27, the controller 114 and control system 500 may be programmed to follow a logic sequence described by the flow chart 520. The operator may turn on the bending system 10 (e.g., by pressing the power button 408). The operator may engage the user interface 38 to input information about the conduit and bend operation including the target bend angle. The controller 114 may wait in a ready state until the operator initiates the bend (e.g., by pressing the bend button 428). Upon receiving the signal from the user interface 38, the controller 114 activates the motor 42 thereby beginning the bending operation. In embodiments where the bend button is a ‘dead-man switch’ the controller 114 may continually check to see if the bend button is depressed and the bend signal is being received. Additionally, the controller 114 may receive input from the angle sensor 504 and compare the measured angle to the target angle. If no change in input is detected and the measured angle is less than the target angle, the motor 42 continues to operate. If at any point the input changes or the measured angle has reached the target angle, the controller 114 deactivates the motor 42, ceasing the bend operation. The included logic sequence is one exemplary method of integrating input from angle sensors 504. In other embodiments the controller 114 may be programmed differently based on the type or position of the angle sensors 504.

As mentioned briefly above, the input received by the user interface 38 may include information about spring back adjustments. Spring back occurs when the natural resilience of the conduit (e.g., due to the material, size, etc.) restores the conduit after the bending operation, resulting in a bend that is less than the desired bend angle. To address this, the conduit C can be overbent by an offset angle. By over-bending, or bending the conduit to an angle greater than the desired bend angle, the conduit naturally springs back, resulting in a bend of the correct angle. In some embodiments, the offset may be manually accounted for by the operator entering a higher bend angle then the desired bend angle. In some embodiments, the operator inputs the desired bend angle and the needed offset angle using the user interface 38. However, since the needed offset angle can vary widely based on the conduit specifications, it can be difficult to calculate the correct offset angle for each bend. The control system 500 may include a memory that includes calculations or lookup tables that allow the controller 114 to calculate the needed offset angle based on the desired final angle and the other user input regarding the specifications of the conduit C (e.g., material, diameter, thickness, etc.).

With reference to FIG. 28, the controller 114 may be programmed to follow a logic sequence described by the flow chart 530. The operator may turn on the bending system 10 (e.g., by pressing the power button 408). The operator may engage the user interface 38 to input information about the conduit and bend operation including the target bend angle, the conduit size, the conduit type. The controller 114 may use these inputs to determine a spring back prediction function to find an adjusted target bend angle. The controller 114 may wait in a ready state until the operator initiates the bend (e.g., by pressing the bend button 428). Upon receiving the signal from the user interface 38, the controller 114 activates the motor 42 thereby beginning the bending operation. In embodiments where the bend button 428 is a ‘dead-man switch’ the controller 114 may continually check to see if the bend button is depressed and the bend signal is being received. Additionally, the controller 114 may receive input from the angle sensor 504 and compare the measured angle to the adjusted target angle determined by the spring back prediction function. If no change in input is detected and the measured angle is less than the adjusted target angle, the motor 42 continues to operate. If at any point the input changes or the measured angle has reached the adjusted target angle, the controller 114 deactivates the motor 42, ceasing the bend operation. The included logic sequence is one exemplary method of integrating spring back prediction and input from angle sensors 504. In other embodiments the controller 114 may be programmed differently.

As discussed above, in some embodiments, the control system 500 includes angle sensors 504 which may be electronic or mechanical devices positioned adjacent rotating components to determine the position thereof. In some embodiments, the control system 500 may recalibrate the position of rotating components using dynamic current calibration. Specifically, the bend shoe 300 may be moved to a starting position and locked and the controller 114 may analyze the signals received by the current sensor 508 to determine that the bend shoe 300 is locked and set the angle position to zero.

With reference to FIG. 29, the controller 114 may be programmed to follow a logic sequence described by the flow chart 540. The operator may turn on the bending system 10 (e.g., by pressing the power button 408). The operator may engage the user interface 38 to input information about the conduit and bend operation including the target bend angle, the conduit size, and the conduit type. The controller 114 may continually monitor to detect signals from the user interface 38 regarding clamping calibration. For example, the controller 114 may monitor to detect if an operator has pressed the clamp button 420 on the user interface 38. In some embodiments, a similar logic sequence may be used to calibrate the bend angle without requiring user input. The controller 114 first determines and stores the starting position of the bend shoe 300 at the moment the clamp button 420 is pressed. The controller 114 then determines whether calibration is engaged depending on the starting position of the bend shoe 300 as determined by the angle sensor 504.

If the clamp button 420 has been pressed, but calibration is not engaged, the controller 114 activates the motor 42 to rotate the bend shoe 300. The controller 114 compares the detected starting position from the angle sensor 504 to a pre-programmed lock position and activates the motor 42 to move the bend shoe 300 to the lock position. Once the lock position has been reached the motor 42 is deactivated and the controller 114 waits in a ready state until the operator provides further input such as initiating the bend (e.g., by pressing the bend button 428) or pressing the clamp button 420 again.

If the clamp button 420 has been pressed and calibration is engaged, the controller 114 may activate the motor 42. The controller 114 may monitor the current draw via the current sensor 508. Specifically, the controller 114 may calculate an average ‘no-load current’ for a set duration of time. After that set duration of time, the controller 114 iterates through a rolling average (e.g., an average of the sensed current over the last 5 milliseconds). The initial ‘no load current’ average is compared to the rolling average at intervals of time (e.g., every millisecond). As the motor 42 rotates the bend shoe 300, the conduit C comes into contact with the roller 72 which applies a torque to the bend shoe 300 and thus increases the current use of the motor 42. The monitoring continues until the rolling average surpasses a certain threshold indicating that clamping has been achieved (e.g., that the conduit C is pressed against the roller 72). At that point the controller 114 deactivates the motor 42. The controller 114 receives a signal from the angle sensor 504 corresponding to an angle of the system (e.g., an angle of the bend shoe 300) and the received angle is stored or saved to the internal memory as a calibrated clamp position or a zero position for the bending operation. The controller 114 may then await further input from the user interface 38 to initiate the bend. The included logic sequence is one exemplary method of using current sensing to calibrate an angular position detected by angle sensors 504. In other embodiments the controller 114 may be programmed differently.

The bending system 10 also includes a safety stop. The current sensors 508 may also be used to detect unsafe operation conditions and protect the motor 42. In some operating scenarios, the motor 42 may attempt to apply a large amount of bending torque. This may happen when the bend shoe 300 or conduit C is prevented from rotating and pushes backward on the output shaft 50. The motor 42 therefore increases the torque in order to maintain the position of the bend shoe 300 and try to move the bend shoe 300 against the blockage. The safety stop prevents this from occurring by stopping the bending operation when unsafe levels of torque are being applied.

With reference to FIG. 30, the controller 114 may be programmed to follow a logic sequence described by the flow chart 550. The operator may turn on the bending system 10 (e.g., by pressing the power button 408). The operator may engage the user interface 38 to input information about the conduit and bend operation including the target bend angle, the conduit size, and the conduit type. The controller 114 may wait in a ready state until the operator initiates the bend (e.g., by pressing the bend button 428). Upon receiving the signal from the user interface 38, the controller 114 activates the motor 42 thereby beginning the bending operation. The controller 114 may monitor the load on the motor 42 using the current sensor 508. If the sensed current exceeds a predetermined threshold or is high in comparison with previously measured current levels, the controller 114 deactivates the motor 42. The controller 114 then indicates the error/fail status to the user for example using the display of the user interface 38. The controller 114 may then await additional input from the user interface 38. By shutting off the motor when the load exceeds a safe amount, the mechanical components of the bending system 10 especially the components of the drive system 30 and the bend shoe 300 are protected from damage due to excessive torque. The included logic sequence is one exemplary method of using current sensing to prevent overload. In other embodiments the controller 114 may be programmed differently.

Similarly, to protect the components of the drive system 30, the bender head 14 includes a motor braking system. The motor braking system includes a brake actuated by the controller 114. The brake may be electrical or mechanical and may be applied to the drive system 30 once the bend operation is partly or completely finished. The brake fights against the torque being applied by the bent conduit C and inhibits gear backlash or back driving of the system. The motor brake may be used alongside the safety stop when excessive torque is applied to the drive system 30.

Turning now to FIG. 31, an alternate embodiment of a bend shoe 300′ is disclosed. In the illustrated embodiment, the bend shoe 300′ includes a hub 304′, a first body 308a extending from the hub 304′, and a second body 308b extending from the hub 304′ generally opposite the first body 308a. The first body 308a includes a first outer edge 328a extending to a first radius R1. The second body 308b includes a second outer edge 328b extending to a second radius R2. The bend shoe 300′ therefore provides multiple bending geometries in a single head, reducing the number of bend shoes required by an operator and reducing the overall weight of the system 10 compared with a system including separate bend shoes. The first body 308a and the second body 308b may be rotated 180 degrees from each other and may utilize alignment features in the socket to align one of the bodies 308a, 308b with the bender head 14 and backformer 70.

With reference to FIG. 32, the lightweight bend shoe design may be integrated into a hand bender 800 having a handle post 804. In some embodiments, the hand bender may include a first bending shoe 300a coupled to a first end 808 of the handle post 804 and a second bending shoe 300b to a second end 812 of the handle post 804. Similar to the double bend shoe 300′ of FIG. 31, the double headed hand bender 800 of FIG. 32 decreases the number of components an operator must keep track of. In some embodiments, the bend shoes 300a, 300b may be interchangeably used with the hand bender 800 and the powered bending system 10. Specifically, the bend shoes 300a, 300b may be one of the set of bend shoes 300 of the bending system 10 and may be removably coupled to the handle post 804 such that the bend shoes 300a, 300b may be uncoupled from the handle post 804 and coupled to the bender head 14 of the bending system 10.

Turning to FIGS. 33 and 34, in some embodiments, the bend shoe 300 may include an alignment feature 358. In some bending operations a single piece of conduit C may be bent multiple times to create a shape lying in the bending plane P (FIG. 34). Thus, the conduit C needs to be maintained in the bend plane P while setting up for a subsequent bend. As seen best in FIG. 34, the alignment feature 358 allows a user to visually confirm the conduit C extends within the bending plane P. In some embodiments, the alignment feature 358 may include indicia that allow a user to align the conduit C at a specific angle relative to the bend plane P according to the desired bend configuration. The alignment feature 358 may be a ‘gun-sight’ style feature and include a notch positioned on the bend shoe 300. The operator may rotate the conduit C relative to the plane P until the conduit C lines up with the alignment feature 358.

With reference to FIGS. 35-41, in some embodiments, the bending system 10 may further include a bend alignment subassembly 900 including a laser module 904. The laser module 904 includes one or more light sources that generate a laser line 908 within an alignment plane 912. In some embodiments, such as those shown in FIGS. 35-37, the laser module 904 may be positioned on or adjacent the bender head 14. In other embodiments, such as those shown in FIGS. 38 and 39, the laser module 904 may be an accessory that couples to the conduit C. The laser line 908 provides a visual guide that an operator can use to position the previously bent segments of the conduit C in the alignment plane 912. In some embodiments, the alignment plane 912 may be aligned with the bending plane P in which the bend shoe 300 rotates. In some embodiments, the laser module 904 may include multiple light sources configured to generate multiple laser lines 908 in multiple alignment planes. The laser lines 908 may be alternately illuminated or may be simultaneously illuminated to allow for alignment in multiple planes.

In FIG. 35, the laser module 904 is illustrated as mounted to the bend shoe 300 adjacent the hub 304 and projects the alignment plane 912 parallel and co-planar with the bending plane. The laser module 904 may include multiple light sources to generate a laser line 908 on either side of the bend shoe 300. The laser module 904 may be removably coupled to the bend shoe 300. In some embodiments, the laser module 904 may be programmable to project the laser line 908 in a plane different from the bending plane.

In FIG. 36, the laser module 904 is illustrated as rotatably mounted to the roll cage 34 for rotation with respect to the bender head 14. The laser module 904 may generate the laser line 908 extending in one direction from a front of the laser module 904. The laser module 904 may be rotated between first and second positions to project the laser line 908 in first and second directions with the alignment plane 912 coplanar to the bend plane. In the first position, the laser line 908 may be advantageously positioned to align with 90-degree bends having the already bent conduit C extend toward the ground. In the second position, the laser line 908 may be advantageously positioned to align with 90-degree bends having the already bent conduit C extend upward away from the ground. The laser module 904 may be removably coupled to the roll cage 34.

In FIG. 37, the laser module 904 is coupled on a support arm 916 extending from the gear case 58 opposite the backformer arm 70. The laser module 904 is rotatable with respect to the support arm 916 to move the laser line 908 along the bend plane. The laser module 904 may be removably coupled to the support arm 916.

In FIG. 38, the laser module 904 is an accessory that can be removably coupled to the conduit C. FIG. 38 illustrates the laser module 904 coupled to an end of the conduit, past the previous bend. The laser module 904 may couple to the conduit using a clamping structure 920. In the illustrated embodiment, the clamping structure 920 includes a rotatable screw. The laser module 904 may include an adjustment actuator 924 that can be rotated to move the laser line 908 within the alignment plane 912 to overlap the conduit positioned in the bend shoe.

FIG. 39 illustrates another accessory style laser module 904 including a clamping structure 920. In this embodiment, the clamping structure is configured to mount along the length of a conduit C, between ends of the conduit C, and on either side of the previous bend. The laser module 904 emits light in two directions to create an extended laser line 908. The laser module 904 may be moved and removed as needed for aligning multiple bends.

Turning to FIG. 40, in some embodiments, using an accessory style laser module 904, the bend shoe 300 includes an alignment feature such as an indicator line 930 that can be used to align the laser line 908 and thus the conduit C. The laser module 904 can also be used to create multiple bends that are not inline. Once the laser module 904 has been mounted to the conduit to align with the indicator line 930 on the shoe 300, the conduit C may be rotated within the shoe 300 such that the laser line 908 is projected toward the bender head 14 or bender stand 18 in an alignment plane 912 that is angled with respect to the bend plane. The laser line 908 may then be aligned with features on the bender head 14 or bender stand 18 corresponding with different angles to offset the subsequent bend from the previous bend.

As seen in FIG. 41, the laser modules 904 discussed above may be removably coupled to the powered bending system 10 and may be interchangeably used with a hand bender 950.

With reference to FIGS. 42, in some embodiments, the bending system 10 may include a bend alignment subassembly 900 including a light projector 970 instead of or in addition to a laser module 904. The light projector 970 may be an accessory coupled to the conduit or may be coupled to the bender head 14 or bender stand 18. The light projector 970 may cast light toward the bend shoe 300 and/or the conduit C and may include an obstruction that casts a shadow line 978. The shadow line 978 may be used to align the conduit in a similar way to the laser line 908 of the previous embodiments.

The embodiments described above and illustrated in the figures are presented by way of example only and are not intended as a limitation upon the concepts and principles of the present subject matter. As such, it will be appreciated that variations and modifications to the elements and their configuration and/or arrangement exist within the spirit and scope of the one or more independent aspects as described.

Various features and advantages of the invention are set forth in the following claims.