HAND HELD STRAPPING TOOL

Description

INTRODUCTION

Devices can be used to secure straps around objects. The straps can be secured to one another.

SUMMARY

At least one aspect is directed to a strapping device. The strapping device can include a tensioner assembly that is pivotally coupled to a mount of the device via a lever. The lever can be coupled with a crank assembly via a linkage. The crank assembly can include a crank that is rotatably coupled to a crank mount and configured to rotate about a crank axis. The linkage can include a first linkage end coupled with a lobe of the crank. The linkage can include a second linkage end coupled with an axle of the lever, where the axle is received by a resilient member positioned in an opening of the second linkage end of the linkage. As the crank rotates, the linkage can move downwards to lower the lever and the feed wheel of the tensioner assembly toward a strap supported by a base of the device. The resilient member through which the axle of the lever is received can deform in response to downward movement of the linkage as the feed wheel is positioned against the strap. The deformation of the resilient member can cause the feed wheel to apply a downward (e.g., compressive) force against the strap. When the feed wheel is positioned against the strap and is applying said downward force against the strap, the gear train can be actuated by a motor to cause rotation of the feed wheel and cause the strap to be under tension. A one-way bearing of a gear can operatively engage with the feed wheel to prevent back-rotation of the feed wheel and hold tension in the strap until a welding or crimping operation is complete or until the feed wheel moves away from the strap via rotation of the lever.

At least one aspect is directed to a strapping device. The strapping device can include: a base; a mount coupled with the base; a tensioner assembly pivotally coupled with the mount, the tensioner assembly including a feed wheel, the feed wheel and the base collectively defining an opening to receive a strap; a lever coupled with the tensioner assembly to pivot the tensioner assembly relative to the base, the lever including an axle; a crank assembly including a crank, the crank coupled with an actuator to rotate the crank about a crank axis; a linkage including a first linkage end and a second linkage end, the first linkage end pivotally coupled with the crank at a position offset from the crank axis, the second linkage end including a first opening having a sidewall; a resilient member defining a second opening, the resilient member coupled with the second linkage end and positioned at least partially within the first opening of the second linkage end, the axle of the lever coupled with the resilient member and positioned at least partially within the second opening; and the axle to move relative to the sidewall of the first opening with the feed wheel positioned against a strap.

At least one aspect is directed to a strapping device. The strapping device can include: a base; a mount coupled with the base; a motor coupled with the base; a gear train, including: a pulley operatively coupled with the motor; a first gear coupled with the pulley, the first gear to counter rotate relative to the pulley; a second gear coupled with the first gear, the second gear to counter rotate relative to the first gear; a tensioner assembly pivotally coupled with the mount, the tensioner assembly including a feed wheel, the feed wheel and the base collectively defining an opening to receive a strap; a lever coupled with the tensioner assembly to pivot the tensioner assembly relative to the base, the lever including an axle and a tension holding gear, the tension holding gear to permit rotation in a first direction and prevent rotation in a second direction, the tension holding gear to selectively couple with the second gear of the gear train; a crank assembly including a crank, the crank coupled with an actuator to rotate the crank about a crank axis; and a linkage including a first linkage end and a second linkage end, the first linkage end pivotally coupled with the crank at a position offset from the crank axis, the second linkage end coupled with the axle of the lever.

At least one aspect is directed to a method of operating a tool. The can include: providing a strap between a feed wheel and a base; rotating a crank about a crank axis in a first direction from a first position to a second position, the crank to position a first linkage axis of a linkage below a crank axis and position the feed wheel against the strap with the crank in the second position, the linkage coupled to the feed wheel via an axle of a lever, wherein the axle is positioned a second distance relative to a sidewall of the lever with the crank in the second position; and rotating the feed wheel to apply tension to the strap.

At least one aspect is directed to a method of providing a strapping device. The strapping device can include: a base; a mount coupled with the base; a tensioner assembly pivotally coupled with the mount, the tensioner assembly including a feed wheel, the feed wheel and the base collectively defining an opening to receive a strap; a lever coupled with the tensioner assembly to pivot the tensioner assembly relative to the base, the lever including an axle; a crank assembly including a crank, the crank coupled with an actuator to rotate the crank about a crank axis; a linkage including a first linkage end and a second linkage end, the first linkage end pivotally coupled with the crank at a position offset from the crank axis, the second linkage end including a first opening having a sidewall; a resilient member defining a second opening, the resilient member coupled with the second linkage end and positioned at least partially within the first opening of the second linkage end, the axle of the lever coupled with the resilient member and positioned at least partially within the second opening; and the axle to move relative to the sidewall of the first opening with the feed wheel positioned against a strap.

These and other aspects and implementations are discussed in detail below. The foregoing information and the following detailed description include illustrative examples of various aspects and implementations, and provide an overview or framework for understanding the nature and character of the claimed aspects and implementations. The drawings provide illustration and a further understanding of the various aspects and implementations, and are incorporated in and constitute a part of this specification.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are not intended to be drawn to scale. Like reference numbers and designations in the various drawings indicate like elements. For purposes of clarity, not every component may be labeled in every drawing. In the drawings:

FIG. 1 is a block diagram of a strapping device, in accordance with some aspects.

FIG. 2 is a partial first side view of a strapping device, in accordance with some aspects.

FIG. 3 is a partial perspective view of a strapping device with a lever in a first position, in accordance with some aspects.

FIG. 4 is a partial side view of the strapping device of FIG. 3, in accordance with some aspects.

FIG. 5 is a partial perspective view of a strapping device with a lever in a second position, in accordance with some aspects.

FIG. 6 is a partial side view of the strapping device of FIG. 5, in accordance with some aspects.

FIG. 7 is a partial perspective view of a strapping device with a lever in a third position, in accordance with some aspects.

FIG. 8 is a partial side view of the strapping device of FIG. 7, in accordance with some aspects.

FIG. 9A is a detail view of a crank assembly of a strapping device with a crank in a first position, in accordance with some aspects.

FIG. 9B is a detail view of a crank assembly of a strapping device with a crank in a second position, in accordance with some aspects.

FIG. 9C is a detail view of a crank assembly of a strapping device with a crank in a third position, in accordance with some aspects.

FIG. 10 is a partial perspective view of a drive assembly of a strapping device, in accordance with some aspects.

FIG. 11 is a partial side view of a drive assembly of a strapping device, in accordance with some aspects.

FIG. 12 is a partial side view of a drive assembly of a strapping device, in accordance with some aspects.

FIG. 13 is a partial side view of a drive assembly of a strapping device, in accordance with some aspects.

FIG. 14 is a partial side view of a drive assembly of a strapping device, in accordance with some aspects.

FIG. 15 is a detail view of a drive assembly of a strapping device, in accordance with some aspects.

FIG. 16 is a detail view of a drive assembly of a strapping device, in accordance with some aspects.

FIG. 17 is a flow chart of an example method of crimping a strap with a strapping device, in accordance with some aspects.

FIG. 18 is a flow chart of an example method of providing a strapping device, in accordance with some aspects.

DETAILED DESCRIPTION

Following below are more detailed descriptions of various concepts related to, and implementations of strapping devices (e.g., tools) having angled handles. Strapping devices can fix a strap to a package, such as a box. The strap can be made from various materials, such as steel, nylon, polypropylene, and polyester. The various concepts introduced above and discussed in greater detail below can be implemented in any of numerous ways.

A strapping device can include a tensioner assembly that is pivotally coupled to a mount of the device via a lever. The lever can be coupled with a crank assembly via a linkage. The tensioner assembly can include a feed wheel that is driven by a gear train of a drive assembly such that rotation of a gear of the gear train can cause the feed wheel to rotate. The crank assembly can include a crank that is rotatably coupled to a crank mount and configured to rotate in response to actuation of a pivot actuator. The pivot actuator can pivot the crank about a crank axis. The linkage can include a first linkage end coupled with the crank in a position located away from the crank axis and a second linkage end coupled with the lever. The lever can include a second end having an axle that is received by a resilient member positioned in an opening of the second linkage end of the linkage. Rotation of the crank about the crank axis can cause at least partially vertical movement of the linkage, which can in turn cause vertical movement of the second linkage end of the linkage and ultimately pivotal motion of the lever and the tensioner assembly. As the crank rotates, the linkage can move downwards to lower the lever and the feed wheel of the tensioner assembly toward a strap supported by a base of the device. The resilient member through which the axle of the lever is received can deform in response to downward movement of the linkage as the feed wheel is positioned against the strap. The deformation of the resilient member can act to cause the feed wheel to apply a desired downward force against the strap. When the feed wheel is positioned against the strap and is applying said downward force against the strap, the gear train can be actuated by a motor to cause rotation of the feed wheel and cause the strap to be under tension. A one-way bearing of a gear can operatively engage with the feed wheel to prevent back-rotation of the feed wheel and hold tension in the strap until a welding or crimping operation is complete or until the feed wheel moves away from the strap via rotation of the lever.

FIG. 1 depicts a block diagram of a strapping device 100 (e.g., a strapping tool 100, a strapping machine 100). The strapping device 100 can be handheld. For example, the strapping device 100 can have a mass less than a threshold mass (e.g., less than 5 pounds; less than 10 pounds; less than 25 pounds; less than or 50 pounds), to enable the strapping device 100 to be manipulated with a single hand of a user. The strapping device 100 can receive a strap (e.g., two straps on top of one another, two ends or portions of the same strap), apply tension to the strap and secure the strap to a remote component (e.g., a box), and can weld the strap together (e.g., weld together ethe two straps that are on top of one another together) via a welding device such that the portions of the strap are coupled (e.g., welded, bonded, fused, joined, or otherwise coupled together).

The strapping device 100 can include at least one handle 105. The handle 105 can be shaped to be held by a hand of a user. The handle 105 can include a grip 110 extending at least partially on the handle 105. The grip 110 can be shaped to receive the hand of the user. The grip 110 can include a relatively high friction surface (e.g., greater friction than a remainder of a surface of the handle 105).

The handle 105 can be coupled with a body 115 of the strapping device 100. For example, the handle 105 can extend between surface portions of the body 115. The handle 105 can allow a user to support the handle 105 to support a mass of the strapping device 100. The handle 105 can extend from an end attached to the body 115. Various components of the strapping device 100 can be disposed in or attached to the body 115. The body 115 can be made at least partially of a plastic material, a composite material, a resilient (e.g., elastomeric, rubberized, or some other elastic or deformable material), or some combination thereof, among others.

The body 115 can include at least one base 125 and at least one tensioner assembly 120 coupled with a drive assembly 130. The drive assembly 130 can include at least one motor 135, at least one gear train 140 having multiple gears, at least one pivot actuator 145 (e.g., a servo motor 145). The body 115 can define an opening 210 between the base 125 and the tensioner assembly 120. The strapping device 100 can receive a strap in the opening between the base 125 and the tensioner assembly 120.

The strapping device 100 can include at least one processing circuit 150. The processing circuit 150 includes a processor 155 and memory 160. The processing circuit 150 can be implemented using a circuit board. Processor 155 can be a general purpose or specific purpose processor, an application specific integrated circuit (ASIC), one or more field programmable gate arrays (FPGAs), a group of processing components, or other suitable processing components. Processor 155 can execute computer code or instructions stored in memory 160 or received from other computer readable media (e.g., CDROM, network storage, a remote server, etc.).

Memory 160 can include one or more devices (e.g., memory units, memory devices, storage devices, etc.) for storing data or computer code for completing or facilitating the various processes described in the present disclosure. Memory 160 can include random access memory (RAM), read-only memory (ROM), hard drive storage, temporary storage, non-volatile memory, flash memory, optical memory, or any other suitable memory for storing software objects or computer instructions. Memory 160 can include database components, object code components, script components, or any other type of information structure for supporting the various activities and information structures described in the present disclosure. Memory 160 can be communicably connected to processor 155 via processing circuit 150 and may include computer code for executing (e.g., by processor 132) one or more processes described herein. When processor 155 executes instructions stored in memory 160, processor 155 generally configures the processing circuit 150 to complete such activities.

The strapping device 100 can include at least one user interface 165. The user interface 165 can receive user input and present information regarding operation of the strapping device 100. The user interface 165 may include one or more user input devices 170, such as buttons, dials, sliders, keys, or a touch interface (e.g., touch screen) to receive input from a user. The user interface 165 may include one or more display devices 175 (e.g., OLED, LED, LCD, CRT displays), speakers, tactile feedback devices, or other output devices to provide information to a user. The user interface 165 can output information regarding the strapping device 100, such as feedback regarding tensioning or welding operations being performed by the strapping device 100.

The strapping device 100 can include at least one communications circuit 180. The communications circuit 180 can include wired or wireless interfaces (e.g., jacks, antennas, transmitters, receivers, transceivers, wire terminals) for conducting data communications with various systems, devices, or networks. For example, the communications circuit 180 can include an Ethernet card and port for sending and receiving data via an Ethernet-based communications network. The communications circuit 180 can include a WiFi transceiver for communicating via a wireless communications network. The communications circuit 180 can communicate via local area networks (e.g., a building LAN), wide area networks (e.g., the Internet, a cellular network), or conduct direct communications (e.g., NFC, Bluetooth). The communications circuit 180 can conduct wired or wireless communications. For example, the communications circuit 180 can include one or more wireless transceivers (e.g., a Wi-Fi transceiver, a Bluetooth transceiver, a NFC transceiver, a cellular transceiver). The processing circuit 150 can communicate with a remote network (e.g., an internet protocol network) using the communications circuit 180. The communications circuit 180 can output information regarding the strapping device 100 to a remote device, such as a portable electronic device. For example, the processing circuit 150 can cause the communications circuit 180 to output information such as status information regarding the strapping device 100, such as if the strapping device needs to be cleaned, if a welding or crimping operation was successful, if tension was applied by the strapping device successfully (e.g., if tension was maintained beyond some threshold), or some other information. The communications circuit 180 can receive operational information that can be used to control operation of the tensioner assembly 120 or the welder 185, such as settings associated with tension to be applied to the strap or a duration of time for which to performing welding.

The strapping device 100 can include at least one input device (e.g., trigger, lever, button, switch) 112 coupled with the handle 105. Responsive to being actuated, the trigger 112 can output an actuation signal to the drive assembly 130 to cause operation of the drive assembly 130, such as to adjust a position of the tensioner assembly 120. The trigger 112 can be coupled with a switch that outputs the actuation signal responsive to operation of the trigger 112. The trigger 112 can output the actuation signal directly to the drive assembly 130. The trigger 112 can output the actuation signal to the drive assembly 130 via the processing circuit 150. The trigger 112 can output the actuation signal to cause the pivot actuator 145 of the drive assembly 130 to move the tensioner assembly 120, such as to lift the tensioner assembly 120 away from the base 125 to allow the strap to be received between the tensioner assembly 120 and the base 125 (e.g., prior to applying tension to the strap) or release the strap from between the tensioner assembly 120 and the base 125 (e.g., subsequent to applying tension to the strap).

The strapping device 100 can include or be coupled with at least one energy source 190. The energy source 190 can include a battery, which can be removably coupled with the strapping device 100. For example, the energy source 190 can be removed to allow the energy source 190 to be recharged, or to replace the energy source 190 with a replacement energy source 190. The strapping device 100 can be coupled with the energy source 190 via an energy interface 195, which may allow the strapping device 100 to connect to various energy sources (e.g., a battery, a wall outlet, or some energy source). The energy source 190 can provide power to various components of the strapping device 100, including the processing circuit 150. The processing circuit 150 can detect a charge level of the energy source 190 and cause the user interface 165 to output an indication of the charge level, for example.

The strapping device 100 can include a welder 185 (e.g., a crimping mechanism 185). The welder 185 can be driven by operation of the drive assembly 130 to cause friction with the strap, enabling multiple straps (e.g., two straps adjacent to one another) to be welded together. For example, the drive assembly 130 can receive a weld command from the processing circuit 150 and drive the welder 185 responsive to receiving the weld command, such as to cause the welder 185 to at least one of vibrate and oscillate. As the welder 185 vibrates or oscillates, a weld can be created between the straps using friction. In other examples, the welder 185 can be a laser welder or some other welder that is used to mechanically join two portions of a strap (or a portion of two different straps) together.

As depicted in FIG. 2, among others, the strapping device 100 is configured to receive at least one strap 200 between the base 125 and the tensioner assembly of the strapping device 100. For example, the strap 200 can be inserted at least partially into the strapping device 100 along a strap axis 205 and within an opening 210 (e.g., a space 210, a gap 210). The opening 210 can be defined by an upper surface or portion of the base 125 and a lower surface or portion of the tensioner assembly 120. For example, the base 125 can define an at least partially horizontal surface or platform upon which the strap 200 can be placed. In this way, the base 125 can support the strap 200. The tensioner assembly 120 can be movably positioned vertically above the strap 200 with the strap supported by the base 125. For example, as is discussed in detail below, the tensioner assembly 120 can be pivotable so that the tensioner assembly 120 can be selectively brought into or out of contact with an upper surface of the strap 200. The strap 200 can be disposed at least partially between the base 125 and the tensioner assembly 120 such that the tensioner assembly 120 can contact the strap 200 to apply a tension force to the strap 200 (e.g., to cause the strap 200 to be under tension), which can permit the welder 185 of the strapping device 100 to successfully weld the strap 200.

As depicted in FIGS. 3-9C, among others, the drive assembly 130 can include the pivot actuator 145 to cause the tensioner assembly 120 to move towards or away from the base 125. For example, the drive assembly 130, such as by actuating the pivot actuator 145 to actuate a lever 335 and cause the lever 335 to apply a force against a strap 200 via the tensioner assembly 120 after the strapping device 100 receives the strap. For example, the pivot actuator 145 can be coupled to a crank (e.g., a crank assembly 370) or a linkage (e.g., a linkage 360) to cause the tensioner assembly 120 to move (e.g., pivot, rotate, or otherwise move). The

As depicted in FIGS. 3-16, among others, the drive assembly 130 can include the motor 135 (depicted in FIGS. 10-16) the and the gear train 140 to actuate the tensioner assembly 120 and cause the tensioner assembly 120 to apply a force against the strap when the strapping device 100 receives the strap, where the force can cause the strap to be under tension and substantially without slack. The tensioner assembly 120 can include at least one tension feed wheel 300 (e.g., a gripper wheel) configured to rotate about a feed wheel axis 305. The tensioner assembly 120 can include a housing 310 positioned at least partially around the feed wheel 300. The feed wheel 300 can at least partially extend from the housing 310 or be at least partially accessible from below with the housing 310 positioned at least partially around the feed wheel 300. For example, the tensioner assembly 120 can include the feed wheel 300 defining a lower-most portion or surface of the tensioner assembly 120 such that the feed wheel 300 can contact an object positioned beneath the tensioner assembly 120. In this way, the feed wheel 300 and the base 125 of the strapping device 100 can collectively define the opening 210 to receive the strap 200.

The strapping device 100 can include at least one mount 320 coupled with the base 125. The housing 310 can be coupled to the mount 320. The mount 320 can be a structure or chassis element of the strapping device 100 to which various components (e.g., the welder 185, the motor 135 of the drive assembly 130, and the tensioner assembly 120) can be coupled. For example, the mount 320 can be coupled with the base 125, and the tensioner assembly 120 can be coupled with the mount 320. The strapping device 100 can include the tensioner assembly 120 pivotally coupled with the mount 320 of the strapping device 100. For example, the housing 310 of the tensioner assembly 120 can include a mounting portion 315 (e.g., a boss or other region) that defines an opening. The opening of mounting portion 315 of the housing 310 can receive an axle 325. The axle 325 can be further coupled with an opening of the mount 320. The axle 325 can extend at least partially along a pivot axis 330. For example, the axle 325 can be fixed relative to one of the mount 320 or the mounting portion 315 of the housing 310, but rotatable relative to the other of the mount 320 or the mounting portion 315 so as to permit rotation of the housing 310 (and thus the feed wheel 300 of the tensioner assembly 120) relative to the mount 320 about the pivot axis 330. In other examples, both the mount 320 and the mounting portion 315 can be rotatably coupled to the axle and can both rotate relative to the axle 325 and relative to each other.

The tensioner assembly 120 can be driven by the drive assembly 130. For example, the feed wheel 300 can be coupled to the gear train 140, and the motor 135 of the drive assembly 130 can cause the gear train 140 to rotate the feed wheel 300. The feed wheel 300 of the tensioner assembly 120 can include frictional elements (e.g., ridges, roughened surfaces) to grip the strap 200 such that movement of the feed wheel 300 with the feed wheel 300 positioned against the strap 200 can cause the strap 200 to move or be subject to a force (e.g., a tension force) that is applied by the feed wheel 300. For example, the drive assembly 130 can rotate the feed wheel 300 of the tensioner assembly 120, while the tensioner assembly 120 grips the strap 200, causing the strap 200 to be translated by the tensioner assembly 120.

The strapping device 100 can include at least one lever 335 coupled with the tensioner assembly 120 to pivot the tensioner assembly 120 relative to the base. For example, the strapping device 100 can include the lever 335 coupled with the housing 310 of the tensioner assembly 120 and further coupled to the mount 320 of the strapping device 100. The lever 335 can include a first end 340, a second end 345, and at least one axle 350 (e.g., a pin 350, a shaft 350). The first end 340 of the lever 335 can be coupled with the axle 325 and can be pivotable about the pivot axis 330 via the axle 325. For example, the first end 340 of the lever 335 can define an opening (e.g., an aperture, a through-hole, a bore) that can receive the axle 325. Each of the mount 320, the mounting portion 315 of the tensioner assembly 120, and the first end 340 of the lever 335 can be coupled with the axle 325 and pivotable about the pivot axis 330. The second end 345 of the lever 335 can define an opening that can receive the axle 350. For example, the second end 345 of the lever 335 can include the axle 350 positioned at least partially within an opening of the second end 345, where one or both of the axle 350 and the opening of the second end 345 define an axis 355.

The lever 335 can include a generally arcuate shape such that, with the first end 340 coupled with the mount 320, the second end 345 is positioned vertically lower than the first end 340 and a mid portion (e.g., a portion under which the housing 310 of the tensioner assembly 120 resides) is vertically higher than both the first end 340 and the second end 345 to accommodate the tensioner assembly 120, for example. The lever 335 can be coupled with the tensioner assembly 120 such that the tensioner assembly 120 moves with the lever 335 as the lever 335 moves. For example, as the lever 335 pivots about the pivot axis 330, the tensioner assembly 120 can move in a corresponding fashion. The lever 335 can be coupled with a gear of the gear train 140, as is discussed below with reference to FIGS. 10-16. The lever 335 can be coupled with a gear of the gear train 140, where the gear of the gear train 140 is rotatable about an axis 337.

The strapping device 100 can include at least one crank assembly 370. The crank assembly 370 can include or be coupled with at least one motor. For example, the crank assembly 370 can be coupled with the pivot actuator 145 of the drive assembly 130. The pivot actuator 145 of the drive assembly 130 can be configured to cause the crank assembly 370 or a portion thereof to move in response to an actuation signal (e.g., an electrical signal) provided to the pivot actuator 145. The crank assembly 370 can include at least one crank mount 375 to support at least one crank 385. For example, the crank assembly 370 can include the crank 385 rotatably supported by the crank mount 375 such that the crank 385 can rotate about a crank axis 380 with the crank 385 supported by the crank mount 375. For example, the crank 385 can be rotatably coupled with the crank mount 375 via at least one bearing assembly or some other friction reducing element. The crank mount 375 can be coupled with the base 125 or a portion thereof. The crank axis 380 can be positioned vertically above the base 125 at a distance from a surface of the base 125 sufficient to allow the crank 385 to rotate a full 360° about the crank axis 380 without colliding with the base 125, the crank mount 375, or some other component. For example, the crank 385 can include a lobe 390 that extends radially from a coupling portion of the crank 385. The coupling portion of the crank 385 can be coupled with the crank mount 375 and positioned at least partially around the crank axis 380, while the lobe 390 of the crank 385 can extends radially therefrom. The crank 385 can rotate about the crank axis 380 to various positions, including at least three positions detailed below with respect to FIGS. 9A-9C, among others.

As depicted in FIGS. 3-9C, among others, the strapping device 100 can include at least one linkage 360. The linkage 360 can be coupled with the crank 385 of the crank assembly 370. For example, the linkage 360 can be coupled with the lobe 390 of the crank 385 of the crank assembly 370. The linkage 360 can be further coupled with the lever 335. For example, the linkage 360 can be coupled with the second end 345 of the lever 335. The linkage 360 can be or include a rigid or non-elastic material such that a distance between the first linkage end 910 and the second linkage end 361 can remain substantially consistent despite the presence of a load or force applied to the linkage (e.g., a compressive or tensile force). The strapping device 100 can include the linkage 360 having at least one linkage end 910 (e.g., a first linkage end 910) and at least one linkage end 361 (e.g., a second linkage end 361). As depicted in FIGS. 9A-9C, among others, the first linkage end 910 can be pivotally coupled with the crank 385 of the crank assembly 370 at a position offset from the crank axis 380. For example, the lobe 390 of the crank 385 can include or define a shaft 900 (e.g., a protrusion, a projection, a pin, a rod) that extends outwardly from the lobe 390 in a direction that is substantially parallel (e.g., ±15° from parallel) with the crank axis 380. The shaft 900 can define an axis 905 (e.g., a first linkage axis 905, a shaft axis 905) that can be substantially parallel (e.g., ±15° from parallel) with the crank axis 380. The first linkage end 910 of the linkage 360 can be pivotally (e.g., rotatably) coupled with the shaft 900 of the lobe 390 such that the first linkage end 910 can pivot with respect to the shaft 900. For example, the first linkage end 910 can be rotatably coupled with the shaft 900 via at least one bearing assembly or some other friction reducing element.

The strapping device 100 can include the second linkage end 361 including an opening 362 (e.g., a first opening 362) having a sidewall 930, as shown in FIGS. 9A-9C. For example, the second linkage end 361 can include the opening 362 that extends at least partially or entirely through a portion of the second linkage end 361 and defines a bore or recess. The opening 362 can be a generally circular opening as depicted in FIGS. 9A-9C. In other examples, the opening 362 can have some other shape or form factor, such as a star-shaped profile, an oval profile, a rectangular profile, a symmetrical profile, an asymmetrical profile, or some other profile.

The strapping device 100 can include at least one resilient member 365. The resilient member 365 can be coupled with the second linkage end 361 of the linkage 360. For example, the resilient member 365 can be positioned at least partially within the opening 362 of the second linkage end 361. The resilient member 365 can include an overall (e.g., outer) shape, profile, or dimension that approximates or resembles a shape, profile, or dimension of the opening 362 of the second linkage end 361. For example, if the opening 362 of the second linkage end 361 includes a generally circular cross-sectional shape, the resilient member 365 can include an outer shape that is generally circular and of a similar dimension to the opening 362 such that the resilient member 365 can be positioned at least partially within the opening 362. The resilient member 365 can be or include a resilient material, such as an elastomeric or rubber material, that can be compressed or stretched and substantially return to its original shape. For example, if the resilient member 365 is subject to some compression, the resilient member 365 can exert a reaction force in an opposite direction. In this way, the resilient member 365 can at least partially absorb energy when subject to an applied force, and then at least partially release said energy when the applied force is removed. Although elastomeric or rubber materials are listed as examples, it is understood that the resilient member 365 can be or include some other material that has similarly resilient properties so as to absorb and release energy, for example.

The resilient member 365 can define an opening (e.g., a second opening). For example, the resilient member 365 can include an opening that extends through the resilient member 365 to form a bore or other opening. The opening of the resilient member can be a generally circular opening such that the opening can receive a generally circular object (e.g., the axle 350). In other examples, the opening of the resilient member 365 can have some other shape or form factor, such as a star-shaped profile, an oval profile, a rectangular profile, a symmetrical profile, an asymmetrical profile, or some other profile. For example, the resilient member 365 can include the opening having a shape or profile that resembles an outer shape or profile of the resilient member. With the opening generally centered on the resilient member 365, a wall thickness (e.g., a dimension from an outer edge of the opening to an outer edge of the resilient member itself) can be substantially consistent (e.g., consistent ±15%).

The strapping device 100 can include the axle 350 of the lever 335 coupled with the linkage 360. For example, the strapping device 100 can include the axle 350 of the lever 335 at least partially received by the opening of the resilient member 365 with the resilient member 365 positioned at least partially within the opening 362 of the second linkage end 361. As noted above, the axle 350 can be positioned within an opening of the second end 345 of the lever 335. In addition, the axle 350 can be coupled with the resilient member 365, which can itself be coupled with the second linkage end 361 of the linkage 360. In this way, the second end 345 of the lever 335 can be coupled with the second linkage end 361 via the axle 350 and the resilient member 365. By virtue of the coupling of the second linkage end 361 with the second end 345 of the lever, the linkage 360 can cause a movement of the lever 335 and vice versa. For example, the lever 335 can pivot about the pivot axis 330 such that the second end 345 of the lever 335 moves at least partially upwards. Such a movement of the lever 335 can cause the linkage 360 to move at least partially upwards as well, for example. The strapping device 100 can include the axle 350 positioned at least partially within the opening of the resilient member 365 and configured to move relative to the sidewall 930 of the opening 362 of the second linkage end 361. For example, as noted above, the resilient member 365 can be or include a resilient material that can deform with application of a load or force. Such a force can be applied directly or indirectly by the axle 350. For example, as the axle 350 applies a force to the resilient member 365—which can result from movement of the linkage 360 relative to the lever 335, movement of the crank 385, or some other movement—the axle 350 can apply a force (e.g., a compressive force) to the resilient member 365. The portion of the resilient member 365 to which the force is applied can deform (e.g., compress) between the axle 350 and the sidewall 930 of the opening 362 of the second linkage end 361. Because the resilient member 365 deforms between the sidewall 930 of the opening 362 and the axle 350, the position of the axle 350—and thus the position of the axis 355—can move relative to the sidewall 930 of the linkage 360 and relative to the linkage 360 more generally, as is discussed in greater detail below.

The strapping device 100 can include the pivot actuator 145 to rotate the crank 385 of the crank assembly 370. For example, the pivot actuator 145 can be directly or indirectly coupled with the crank 385 of the crank assembly 370 such that, when actuated, the pivot actuator 145 can cause rotation of the crank 385 about the crank axis 380. For example, the pivot actuator 145 can receive a signal (e.g., an input signal, an electrical signal, or some other signal) that causes an output shaft or other component of the pivot actuator 145 to move. The movement of the pivot actuator 145 or a component thereof can cause the crank 385 to rotate about the crank axis 380. For example, a gear, pulley, chain, pusher, rod, or other element coupled with the pivot actuator 145 can move (e.g., spin, rotate, translate, slide, pivot, or otherwise move) as the pivot actuator 145 is actuated. Movement of the gear, pulley, chain, pusher, rod, or other element can cause the crank 385 of the crank assembly 370 to rotate about the crank axis 380, which can further cause movement of the linkage 360 by virtue of the coupling of the first linkage end 910 with the lobe 390 of the crank 385, for example. For example, the pivot actuator 145 can cause movement of a pusher 395, where the pusher 395 can be engaged with the crank 385 such that movement of the pusher 395 causes movement of the crank 385. In one example, the pusher 395 moves linearly to cause rotational movement of the crank 385 about the crank axis 380 (e.g., due to the lobed shape of the lobe 390 or a lobed shape of another component coupled, for example).

The tensioner assembly 120 can be movable relative to the base 125 of the strapping device 100 so that the tensioner assembly 120 can selectively approach the base 125 to contact the strap 200 and apply tension to the strap 200 (e.g., via rotation of the feed wheel 300). The drive assembly 130 the strapping device 100 can include the pivot actuator 145 to cause the tensioner assembly 120 to move (e.g., pivot) towards or away from the base 125. The drive assembly 130 of the strapping device 100 can include the motor 135 and the gear train 140 to cause the feed wheel 300 of the tensioner assembly 120 to rotate. As such, the drive assembly 130 can drive the tensioner assembly 120 to apply a driving force against the strap 200, increasing tension of the strap 200 relative to a package or other body to which the strap 200 is to be secured. The drive assembly 130 can drive the tensioner assembly 120 towards or away from the strap 200 to contact the feed wheel 300 of the tensioner assembly 120 to the strap 200 (and increase a force applied by the feed wheel 300 of the tensioner assembly 120 to the strap 200).

The strapping device 100 can include the lever 335 to move relative to the pivot axis 330. For example, the strapping device 100 can include the lever 335 to pivot about the pivot axis 330 with the first end 340 of the lever 335 coupled with the mount 320 via the axle 325. The lever 335 can move from a first position to a second position or from a second position to a third position, among other positions. For example, the lever 335 can move from a first position 399 in which the lever 335 is in a lowered position such that the feed wheel 300 of the tensioner assembly 120 is positioned against or proximate to the base 125 of the strapping device 100, as depicted in FIGS. 3 and 4, among others. In this first position 399, which can be regarded as an initial or home position of the lever 335, no strap 200 is inserted between the feed wheel 300 and the base 125. The linkage 360 and the crank 385 can be in a generally lowered position. For example, the first linkage end 910 and the lobe 390 of the crank 385 to which the first linkage end 910 is coupled can be positioned at least partially vertically below the crank axis 380 (e.g., as depicted in FIG. 9B).

As depicted in FIGS. 5 and 6, among others, the strapping device 100 can include the lever 335 to move to a second position 500 in which the lever 335 elevated to lift the feed wheel 300 of the tensioner assembly 120 away from the base 125 to create the opening 210 to receive the strap 200. In this second position 500, the feed wheel 300 is elevated from the base 125, and a strap 200 can be inserted between the feed wheel 300 and the base 125 in preparation for a crimping or welding operation. The linkage 360 and the crank 385 can be in a generally raised position. For example, the first linkage end 910 and the lobe 390 of the crank 385 to which the first linkage end 910 is coupled can be positioned at least partially vertically above the crank axis 380 (e.g., as depicted in FIG. 9A).

The strapping device 100 can include the lever 335 to move to a third position 700 in which the lever 335 is positioned in an intermediate position between the first position and the second position, as depicted in FIGS. 7 and 8, among others. For example, the lever 335 can move to a third position in which the second end 345 of the lever 335 is positioned vertically above a position of the second end 345 of the lever 335 when the lever 335 is in the above-described first position 399 (e.g., FIGS. 3 and 4, among others) and vertically below a position of the second end 345 of the lever 335 when the lever 335 is in the above described second position 500 (e.g., FIGS. 5 and 6, among others). With the lever 335 in the third position 700, the feed wheel 300 is positioned vertically above a position of feed wheel 300 when the lever 335 is in the above-described first position 399 (e.g., FIGS. 3 and 4, among others) and vertically below a position of the feed wheel 300 when the lever 335 is in the above-described second position 500 (e.g., FIGS. 5 and 6, among others). For example, with the lever 335 in the third position 700, the feed wheel 300 can be positioned against a strap 200 that is supported by the base 125. Because the strap is supported by the base 125, the feed wheel 300 cannot be lowered further (e.g., to the base 125 or to the position of the feed wheel 300 when the lever 335 is in the first position). For example, the strap 200 has some thickness (e.g., 17 thousandths of an inch, 35 thousandths of an inch, 55 thousandths of an inch, 110 thousandths of an inch, or some other thickness), the feed wheel 300 can be positioned a distance from the base 125 that is approximately equivalent to the thickness of the strap 200 with the feed wheel 300 positioned against the strap 200. The feed wheel 300 can be positioned against the strap 200 with the lever 335 in the third position 700. As discussed below, the feed wheel 300 can apply a force (e.g., a compressive force) to the strap 200 with the lever 335 in the third position 700.

The feed wheel 300 can apply a force (e.g., a compressive force) to the strap 200 with the lever 335 in the third position as shown in FIGS. 7 and 8. For example, the feed wheel 300 can apply a compressive force to the strap 200 with the strap 200 supported by the base 125 and positioned between the base 125 and the feed wheel 300. For example, the linkage 360 can apply a downward force to the axle 350 of the second end 345 of the lever 335, which can cause the lever 335 to in turn apply a downward force to the tensioner assembly 120 coupled with the lever 335, which can in turn cause the feed wheel 300 of the lever 335 to apply a downward (e.g., compressive force) to the strap 200 positioned between the feed wheel 300 and the base 125. The second linkage end 361 of the linkage 360 can apply a downward force to the axle 350 as the crank 385 of the crank assembly 370 applies a force to the first linkage end 910 of the linkage 360. For example, as the crank 385 rotates about the crank axis 380, the lobe 390 of the crank can move, which can cause the first linkage end 910 of the linkage 360 to experience a downward force as applied by the shaft 900 of the lobe 390 (depending on a vertical position of the lobe 390 relative to the crank axis 380).

As depicted in FIGS. 9A-9C, among others, the strapping device 100 can include the crank 385 of the crank assembly 370 to move from a first position 915 to a second position 920, from the second position 920 to a third position 925, from the third position 925 to the second position 920, from the second position 920 to the first position 915, or to some other position. As noted above, the crank 385 of the crank assembly 370 is rotatably coupled with the crank mount 375 and can rotate about the crank axis 380 in response to actuation of the pivot actuator 145. Accordingly, actuation of the pivot actuator 145 can cause the crank 385 to move from a first position 915 to a second position 920, from the second position 920 to a third position 925, from the third position 925 to the second position 920, from the second position 920 to the first position 915, or to some other position, where each of the first position 915, the second position 920, and the third position 925, among other positions, are radial positions of the crank 385 about the crank axis 380. In particular, each of the first position 915, the second position 920, and the third position 925 can be associated with radial positions of the lobe 390 of the crank 385.

As depicted in FIG. 9A, the strapping device can include the crank 385 to be positioned in the first position 915 (e.g., a first radial position 915) in which the first linkage end 910 is positioned at least partially vertically above the crank axis 380. For example, the axis 905 can be positioned vertically above the crank axis 380 with the crank 385 in the first position 915. Because the first linkage end 910 is positioned at least partially vertically above the crank axis 380, the second linkage end 361 can be further positioned vertically above the crank axis 380. Because the second linkage end 361 is in an elevated position with the crank 385 in the first position 915, so too is the second end 345 of the lever 335, which can further position the feed wheel 300 of the tensioner assembly 120 away from the base 125 of the strapping device 100. Accordingly, the lever 335 can be in the above described second position 500 when the crank 385 is in the first position 915. As noted above, the tensioner assembly 120 is not applying tension to the strap 200 via the feed wheel 300. Accordingly, the linkage 360 (e.g., the resilient member 365 coupled with the second linkage end 361 of the linkage) is not applying a force to the axle 350, and the axle is in turn not applying any force to compress the resilient member 365 between the axle 350 and the sidewall 930 of the opening 362 of the second linkage end 361. Because the resilient member 365 is not being compressed between the sidewall 930 and the axle 350, the axle 350 and the axis 355 are positioned a first distance from the sidewall 930 of the opening 362.

As depicted in FIG. 9B, the strapping device 100 can include the crank 385 to be positioned in the second position 920 (e.g., a second radial position 920) in which the first linkage end 910 is positioned at least partially vertically below the crank axis 380. For example, the axis 905 can be positioned vertically below the crank axis 380 with the crank 385 in the second position 920. Because the first linkage end 910 is positioned at least partially below above the crank axis 380, the second linkage end 361 is vertically lower with the crank 385 in the second position 920 than with the crank 385 in the first position 915. For example, the second linkage end 361 is positioned closer to the crank axis 380 when the crank 385 is in the second position 920 than when the crank 385 is in the first position 915. Because the second linkage end 361 is vertically lower with the crank 385 in the second position 920, so too is the second end 345 of the lever 335, which can further position the feed wheel 300 of the tensioner assembly 120 closer to the base 125 of the strapping device 100. For example, when the crank 385 is in the second position 920, the lever 335 can be in the third position 700 such that the feed wheel 300 of the tensioner assembly 120 can be positioned against the strap 200 and can be applying a compressive force against the strap 200. The feed wheel 300 can be positioned against the strap 300 with the crank 385 in the second position 920. Put another way, the lever 335 can reach a lower limit (e.g., a lowest vertical position possible) when the feed wheel 300 contacts the strap 200, which can prevent the feed wheel 300 and the second end 345 of the lever arm 335 from moving further downwards.

However, because the second linkage end 361 of the linkage 360 is coupled to the second end 345 of the lever 335 via the axle 350 and the resilient member 365, the linkage 360 can continue to move in a vertically downward direction as the crank 385 moves from the first position 915 to the second position 920 (and from the second position 920 to the third position 925). For example, even though the lever 335 cannot move in a downwards direction because the feed wheel 300 is positioned against the strap 200, the linkage 360 can continue to move downwards because the resilient member 365 can be compressed between the axle 350 and the sidewall 930 of the opening 362. For example, the axis 355 of the axle 350 be positioned the first distance (e.g., 3-8 mm, more than 8 mm, less than 3 mm, or some other distance) from the sidewall 930 of the opening 362 with the crank 385 in the first position 915, but the axis 355 can be a second distance (e.g., 1.5-4 mm, less than 1.5 mm, more than 4 mm, or some other distance) from the sidewall 930 of the opening 362 with the crank 385 in the second position 920. The axis 355 of the axle 350 can be positioned the second distance from the sidewall 930 of the opening 362 because the resilient member 365 can be compressed between the axle 350 and the sidewall 930 of the opening as the linkage 360 continues to move with the rotation of the crank 385 about the crank axis 380 even as the feed wheel 300 contacts the strap 200. More particularly, the downward movement of the linkage 360 via the movement of the crank 385 from the first position 915 to the second position 920 can cause the linkage to apply a downward force to the axle 350 of the lever 335, but because the lever 335 is at a lower limit (e.g., positioned against the strap), the lever 335 does not move downward with the movement of the linkage 360. Instead, the lever 335 remains generally stationary as the resilient member 365 is compressed between the axle 350 and the sidewall 930 of the opening 362. During this compression, the resilient member 365 can absorb the force applied by its compression between the axle 350 and the sidewall 930 of the opening 362. Movement of the linkage 360 via movement of the crank 385 from the first position 915 to the second position 920 can cause the lever 335 to apply a force against the strap 200 via the feed wheel 300 of the tensioning assembly 120, where the force applied against the strap 200 can keep the strap 200 in tension to facilitate a welding operation, for example.

As depicted in FIG. 9C, the strapping device 100 can include the crank 385 to be positioned in the third position 925 (e.g., a third radial position 925) in which the first linkage end 910 is positioned at least partially vertically below the crank axis 380. For example, the axis 905 can be positioned vertically below the crank axis 380 with the crank 385 in the third position 925. Because the first linkage end 910 is positioned at least partially below above the crank axis 380, the second linkage end 361 is vertically lower with the crank 385 in the third position 925 than with the crank 385 in the first position 915. In the third position 925, the axle 350 of the lever 335 can be positioned a third distance from the sidewall 930 of the opening 362, and the welder 185 can be engaged with the strap 200 to perform a welding or crimping operation, for example. The axis 355 of the axle 350 be positioned the first distance (e.g., 3-8 mm, more than 8 mm, less than 3 mm, or some other distance) from the sidewall 930 of the opening 362 with the crank 385 in the first position 915, but the axis 355 can be a third distance (e.g., 1.5-4 mm, less than 1.5 mm, more than 4 mm, or some other distance) from the sidewall 930 of the opening 362 with the crank 385 in the third position 925.

For example, the third distance between the axis 355 and the sidewall 930 (or between the axle 350 and the sidewall 930) can be similar to the second distance between the axis 355 and the sidewall 930 (or between the axle 350 and the sidewall 930) discussed above with reference to the second position 920. The axis 355 of the axle 350 can be positioned the third distance from the sidewall 930 of the opening 362 because the resilient member 365 can be compressed between the axle 350 and the sidewall 930 of the opening 362 as the linkage 360 continues to move with the rotation of the crank 385 about the crank axis 380 even as the feed wheel 300 contacts the strap 200. More particularly, the continued movement of the linkage 360 via the movement of the crank 385 from the first position 915 to the second position 920 and from the second position 920 to the third position 925 can cause the linkage 360 to apply a downward force to the axle 350 of the lever 335. Because the lever 335 is at a lower limit (e.g., positioned against the strap), however, the lever 335 does not move downward with the movement of the linkage 360. Instead, the lever 335 remains generally stationary as the resilient member 365 is compressed between the axle 350 and the sidewall 930 of the opening 362. During this compression, the resilient member 365 can continue to absorb and can retain the force applied by its compression between the axle 350 and the sidewall 930 of the opening 362. Movement of the linkage 360 via movement of the crank 385 from the second position 920 to the third position 925 can continue to cause the lever 335 to apply a force against the strap 200 via the feed wheel 300 of the tensioning assembly 120, where the force applied against the strap 200 can permit the feed wheel 300 to effectively apply tension to the strap 200 (e.g., by rotating against the strap 200) and holding the strap 200 in tension to facilitate a welding operation via the welder 185, for example.

The resilient member 365 coupled with the linkage 360 can exert a force on the axle 350 of the lever 335 to which the second linkage end 361 is coupled, where the force exerted on the axle 350 can in turn cause the feed wheel 300 of the tensioner assembly 120 to exert a compressive (e.g., a downward) force against the strap 200 that is positioned between the feed wheel 300 and the base 125 of the strapping device 100. In this way, the movement of the crank 385 (e.g., via actuation of the pivot actuator 145) can cause the feed wheel 300 of the tensioner assembly 120 to both apply a force to the strap 200 to allow the rotation of the feed wheel 300 put the strap 200 in tension along the strap axis 205, as well as hold the strap 200 under tension as a welding operation occurs via the welder 185, for example.

When the resilient member 365 is compressed between the axle 350 and the sidewall 930 of the opening 362, the resilient member 365 is deformed. For example, as noted above, the resilient member 365 can be or include an elastic or deformable member that can be deformed under some load (e.g., a compressive force or a tensile force) and then, upon removal of said load, substantially return to its original position. In the case of the resilient member 365, the opening of the resilient member 365 includes an original shape, profile, or dimension within the resilient member 365 is not subject to any loading (e.g., a compressive load) or when the resilient member 365 is in its initial or first state. However, upon application of a load (e.g., a compressive load), the opening of the resilient member 365 can deform such that the opening takes a different shape, profile, or dimension than the original shape, profile or dimension. For example, the opening of the resilient member 365 can be circular in an original state, but can deform to resemble an oval or some other shape as the resilient member 365 is deformed during operation of the strapping device 100.

As depicted in FIGS. 10-16, among others, the drive assembly 130 of the strapping device is shown in greater detail. The drive assembly 130 can include the motor 135 operatively coupled with the gear train 140. For example, the motor 135 can include an output member 1005 (e.g., an output shaft 1005, an output pulley 1005) that is coupled to the gear train 140 via a belt 1000 (e.g., a strap 1000). Actuation of the motor 135 can cause the output member 1005 of the motor 135 to rotate. Rotation of the output member 1005 can cause the output member 1005 to move the belt 1000. For example, when viewed from the perspective of FIG. 11, rotation of the output member 1005 in a clockwise direction (e.g., in a direction 1110) can cause the output member 1005 to move the belt 1000 toward the output member 1005 in a right-hand direction to cause the general movement of the belt 1000 in the clockwise direction around the output member 1005.

The strapping device 100 can include the output member 1005 operatively coupled with a first gear 1010 of the gear train 140. For example, the drive assembly 130 of the strapping device 100 can include the first gear 1010 coupled with the output member 1005 of the motor via the belt 1000. Movement of the belt 1000 can cause movement (e.g., rotation) of the first gear 1010. For example, the first gear can include a first portion that defines multiple gear teeth arranged around a periphery of the first gear 1010 and a second portion that defines a surface or channel within which the belt 1000 is received. The first gear 1010 can rotate in the same direction as the output member 1005 of the motor 135. For example, rotation of the output member 1005 of the motor 135 in a direction 1110 (e.g., a first direction 1110 as depicted in FIG. 11) can cause a similar rotation of the first gear 1010 in the direction 1110.

The strapping device 100 can include the first gear 1010 operatively coupled with a second gear 1015 of the gear train 140. For example, the drive assembly 130 of the strapping device 100 can include the second gear 1015 at least partially meshed with the first gear 1010. With the first gear 1010 and the second gear 1015 at least partially meshed, a movement (e.g., a rotation) of the first gear 1010 can cause a movement (e.g., a rotation) of the second gear 1015. For example, the second gear 1015 can counter rotate relative to the first gear 1010. Accordingly, a rotation of the first gear 1010 in the direction 1110 can cause a rotation of the second gear 1015 in the direction 1115, which is opposite the direction 1110. The second gear 1015 can rotate about the pivot axis 330. For example, the second gear 1015 can be rotatably coupled with the axle 325 or can be otherwise positioned along the pivot axis 330 so as to rotate about the pivot axis 330.

The strapping device 100 can include the second gear 1015 operatively coupled with a third gear 1020 of the gear train 140. For example, the drive assembly 130 of the strapping device 100 can include the third gear 1020 at least partially meshed with the second gear 1015. With the second gear 1015 and the third gear 1020 at least partially meshed, a movement (e.g., a rotation) of the second gear 1015 can cause a movement (e.g., a rotation) of the third gear 1020. For example, the third gear 1020 can counter rotate relative to the second gear 1015 and can rotate in the same direction as the first gear 1010. Accordingly, a rotation of the second gear 1015 in the direction 1115 can cause a rotation of the third gear 1020 in the direction 1110, which is opposite the direction 1115.

The third gear 1020 can rotate about the feed wheel axis 305 about which the feed wheel 300 of the tensioner assembly 120 rotates. For example, the third gear 1020 can be operatively coupled with the feed wheel 300 of the tensioner assembly such that rotation of the third gear 1020 about the feed wheel axis 305 can cause a rotation of the feed wheel 300 about the feed wheel axis 305. In this way, the movement of the third gear 1020 can cause the movement of the feed wheel 300. As discussed above, rotational movement of the feed wheel 300 with the feed wheel 300 positioned against the strap 200 can cause the feed wheel 300 to tension the strap 200 (e.g., subject the strap 200 to a tensile force along the strap axis 205). Accordingly, movement of the third gear 1020 via actuation of the motor 135 can cause the feed wheel 300 of the tensioner assembly 120 to place the strap 200 in tension, which is of particular importance to fostering a successful or efficacious welding or crimping operation. For example, actuation of the motor 135 can cause the output member 1005 of the motor to rotate in the direction 1110, which can cause the belt 1000 to move and rotate the first gear 1010 in the same direction 1110. Rotation of the first gear 1010 in the direction 1110 can cause the second gear 1015 to rotate in the direction 1115 by virtue of the meshed relationship between the first gear 1010 and the second gear 1015. Rotation of the second gear 1015 in the direction 1115 can cause the rotation of the third gear 1020 in the direction 1110 by virtue of the meshed relationship between the second gear 1015 and the third gear 1020. Rotation of the third gear 1020 in the direction 1115 can cause a rotation of the feed wheel 300 in the direction 1115. Rotation of the feed wheel 300 when the feed wheel 300 is positioned against the strap 200 (e.g., when the lever arm is in the third position 700 and when the crank is in the second position 920) can cause the feed wheel 300 to grip the strap 200 and cause tension in the strap 200, for example.

The strapping device 100 can include third gear 1020 operatively coupled with a fourth gear 1025 (e.g., a tension holding gear 1025) of the gear train 140. For example, the drive assembly 130 of the strapping device 100 can include the fourth gear 1025 at least partially meshed with the third gear 1020. With the third gear 1020 and the fourth gear 1025 at least partially meshed, a movement (e.g., a rotation) of the third gear 1020 can cause a movement (e.g., a rotation) of the fourth gear 1025. For example, the fourth gear 1025 can counter rotate relative to the third gear 1020 and can rotate in the same direction as the second gear 1015. Accordingly, a rotation of the third gear 1020 in the direction 1110 can cause a rotation of the fourth gear 1025 in the direction 1115, which is opposite the direction 1115.

The fourth gear 1025 can be coupled with the lever 335. For example, the lever 335 can include the fourth gear 1025 rotatably coupled to the lever and rotatable about the axis 337 of the lever 335. The fourth gear 1025 can be rotatably coupled with the lever 335 via a bracket 1030. The fourth gear 1025 can be or include a one-way bearing (e.g., a ratchet assembly, a backstop clutch, a sprag clutch, or some other uni-directional rotational device) that can permit rotation of the fourth gear 1025 in one direction (e.g., the direction 1115) and substantially prohibit rotation of the fourth gear 1025 in the opposite direction (e.g., the direction 1110). For example, the third gear 1020 can rotate in the direction 1110 and cause a corresponding rotation of the fourth gear 1025 in the direction 1115. When the rotation of the third gear 1020 ceases, the one-way bearing of the fourth gear 1025 can prevent any back-rotation of the fourth gear 1025 or the third gear 1020. For example, the one-way bearing of the fourth gear 1025 can prevent any rotation of the fourth gear 1025 in the direction 1110 and can prevent any rotation of the third gear 1020 in the direction 1115. In this way, the one-way bearing of the fourth gear 1025 can hold the third gear 1020 in place (e.g., prevent any rotation of the third gear 1020 in the direction 1115). For example, as depicted in FIG. 12, the third gear 1020 cannot rotate in the direction 1115 and the fourth gear 1025 cannot rotate in the direction 1110. Holding the third gear 1020 in place and preventing any associated back-rotation can cause the feed wheel 300 of the tensioner assembly 120 to hold tension in the strap 200. For example, as discussed above, the feed wheel 300 can rotate to apply a force to the strap 200 that places the strap 200 in tension along the strap axis 205. However, such tension is released (e.g., slack is introduced in the strap) if the feed wheel 300 back rotates (e.g., rotates in the direction 1115) or otherwise loses grip of the strap 200. To prevent back rotation and potential loss of tension, which could adversely cause a poor or suboptimal weld or crimp operation, the fourth gear 1025 remains meshed with the third gear 1020 while the one-way bearing of the fourth gear 1025 prevents back-rotation of the third gear 1020. Accordingly, the fourth gear 1025 and its uni-directional rotation can operate to permit the third gear 1020 to apply tension to the strap 200 (via the feed wheel 300) and can operate to maintain the tension within the strap 200 by holding the third gear 1020 in place so that a successful welding operation can be performed.

A reaction force associated with the engagement of the fourth gear 1025 with the third gear 1020, particularly when the third gear 1020 is applying or holding tension within the strap 200 via the feed wheel 300 can be directed toward the pivot axis 330. For example, as depicted in FIG. 13, among others, the reaction force 1300 that occurs as the third gear 1020 attempts to rotate—but is prevented from rotating—in the direction 1115 and is halted by the one-way bearing of the fourth gear 1025 can be directed through the pivot axis 330. As discussed above, the pivot axis 330 is the axis about which the lever 335 and the tensioner assembly 120 pivot. For example, the lever 335 pivots about the pivot axis 330 to raise the or lower the feed wheel 300 of the tensioner assembly 120 relative to the base 125 (or relative to a strap 200 supported by the base 125). Because the reaction force 1300 is directed through or proximate to the pivot axis 330, the reaction force 1300 does not introduce any moment or rotational force to the lever 335 or the tensioner assembly 120. For example, the lever 335 and the tensioner assembly 120 are not subject to any substantial rotational force about the pivot axis 330 by virtue of the reaction force 1300 because the reaction force 1300 is directed through the pivot axis 330. Because the lever 335 and the tensioner assembly 120 are not subject to any substantial rotational force via the reaction force 1300, the lever 335 and the tensioner assembly 120 can remain in a downward position in which the feed wheel 300 can be compressed against the strap 200 and can effectively apply and hold tension within the strap 200, which can in turn facilitate a successful welding operation.

As depicted in FIGS. 14-16, among others, the fourth gear 1025 can be selectively separated from the third gear 1020. For example, the fourth gear 1025 is coupled to the lever 335 and, as a consequence, can move with a movement of the lever 335. As the lever 335 pivots about the pivot axis 330, so too does the fourth gear 1025. With the lever 335 in the second position 500, the fourth gear 1025 can be separated from the third gear 1020 such that a space 1400 exists between the fourth gear 1025 and the third gear 1020. With the lever 335 in the first position 399 or the third position 700, for example, the fourth gear 1025 can be engaged with (e.g., meshed with) the third gear 1020. Accordingly, the fourth gear 1025 can act to permit rotation of the third gear 1020 in the direction 1110 and prevent rotation of the third gear 1020 in the direction 1115 when the lever 335 is in the first position 399 or the third position 700. In other words, the fourth gear 1025 can hold tension in the strap 200 when the lever 335 is in positions in which the feed wheel 300 is positioned to apply tension to the strap 200. On the other hand, the fourth gear 1025 is unable to prevent rotation of the third gear 1020 in the direction 1115 when the lever 335 is in the second position 500 because the space 1400 between the fourth gear 1025 and the third gear 1020 prevents the one-way bearing of the fourth gear 1025 from acting on the third gear. Accordingly, the third gear 1020 is permitted to rotate in the direction 1115 with the space 1400 exists between the third gear 1020 and the fourth gear 1025 (e.g., when the lever 335 is in the second position 500).

In other examples, the linkage 360 can itself be a resilient member having some elastic or flexible material characteristics. For example, rather than the linkage 360 being a rigid body, the linkage 360 can be resilient and can include a rigid member positioned within the opening 362 of the linkage 360. In such examples, the linkage 360 can be or including a resilient portion (e.g., a resilient portion extending between the first linkage end 910 and the second linkage end 361), where the resilient portion includes a first dimension when at rest (e.g., without any substantial load applied thereto). For example, the resilient portion of the linkage 360 can include the first dimension with the tension holding gear 1025 disengaged from the third gear 1020 (e.g., when the crank 385 is in the first position 915 and when the tensioner assembly 120 is lifted above the strap 200). The resilient portion of the linkage 360 can include a second dimension that is greater than the first dimension with the tension holding gear 1025 engaged with the third gear 1020 (e.g., when the crank 385 is in the second position 920 or the third position 925 and when the feed wheel 300 of the tensioner assembly 120 is positioned against the strap 200 and applying tension to the strap 200). For example, the resilient portion of the linkage 360 can exert a force on the axle 350 of the lever 335 to which the second linkage end 361 is coupled, where the force exerted on the axle 350 can in turn cause the feed wheel 300 of the tensioner assembly 120 to exert a compressive (e.g., a downward) force against the strap 200 that is positioned between the feed wheel 300 and the base 125 of the strapping device 100.

FIG. 17, among others, depicts a flow chart of a method 1700. The method 1700 can be a method of welding or crimping a strap. For example, the method 1700 can be a method of welding or crimping a strap using the strapping device 100. The method 1700 can include one or more of ACTS 1705-1730. Each of ACTS 1705-1730 can be performed in the order depicted in FIG. 17 or in some other order. Although described below as pertaining to the strapping device 100 disclosed herein, it is understood that the method 1700 can be performed using another strapping device, for example.

The method 1700 can include providing the strap 200 at ACT 1705. For example, at ACT 1705, the lever 335 of the strapping device 100 can be in the second position 500 such that the opening 210 exists between the feed wheel 300 of the tensioner assembly 120 and the base 125. A strap 200 (e.g., opposite end portions of the same strap, two separate straps, or some other number of straps or strap portions) can be inserted into the opening 210 between the feed wheel 300 and the base 125 such that the strap 200 is at least partially oriented along the strap axis 205.

The method 1700 can include rotating a crank at ACT 1710. For example, the method 1700 can include rotating the crank 385 to position the feed wheel 300 against the strap 200. The lever 335 can move from the second position 500 to the third position 700 to position the feed wheel 300 against the strap 200. The crank assembly 370 and the linkage 360 coupled therewith can cause the lever 335 to move from the second position 500 to the third position 700. For example, the crank 385 of the crank assembly 370 can move from the first position 915 to the second position 920, where the feed wheel 300 is positioned against the strap 200 with the crank 385 in the second position 920. The axle 350 of the lever 335 can be positioned a first distance from the sidewall 930 of the second linkage end 361 with the crank 385 in the first position. The axle 350 of the lever 335 can be positioned a second distance from the sidewall 930 of the second linkage end 361 with the crank 385 in the second position. The axis 905 about which the first linkage end 910 rotates can be positioned vertically above the crank axis 380 with the crank in first position 915. The axis 905 about which the first linkage end 910 rotates can be positioned vertically below the crank axis 380 with the crank in second position 920. The feed wheel 300 can be positioned apart from the base 125 of the strapping device 100 with the crank 385 in the first position. The feed wheel 300 can be positioned against the strap 200 with the crank 385 in the second position.

The method 1700 can include rotating the feed wheel 300 at ACT 1715. For example, the method 1700 can include rotating the feed wheel 300 of the tensioner assembly 120 with the feed wheel 300 positioned against the strap 200 in order to apply tension to the strap 200 (e.g., to cause the strap 200 to be under tension along the strap axis 205). The feed wheel 300 can be operatively coupled with the gear train 140 such that actuation of the motor 135 can cause the feed wheel 300 to rotate. For example, the feed wheel 300 can be coupled with the third gear 1020 of the gear train 140, where the third gear 1020 is operatively coupled with the output member 1005 of the motor 135 such that rotation of the output member 1005 causes a corresponding rotation of the third gear 1020 and the feed wheel 300. Rotation of the feed wheel 300 in the direction 1110 with the feed wheel 300 positioned against the strap 200 can cause the strap 200 to be under tension (e.g., under a tensile force) that is at least partially along the strap axis 205 along which at least a portion of the strap 200 is positioned. In order for the feed wheel 300 to effectively create tension in the strap 200, the linkage 360 and the crank 385 can cause the lever 335 to remain in the third position 700 such that the feed wheel 300 remains positioned against the strap 200. The lever 335 can remain in the third position 700 at ACT 1715 such that the fourth gear 1025 that is coupled to the lever 335 remains engaged with the third gear 1020 to prevent back rotation of the third gear 1020. For example, the one-way bearing of the fourth gear 1025 can prevent the feed wheel 300 and the third gear 1020 to which the feed wheel 300 is coupled from back rotating in the direction 1115 and releasing tension in the strap 200.

The method 1700 can include crimping (e.g., welding) the strap 200 at ACT 1720. For example, the method 1700 can include operating the welder 185 to weld, crimp, or otherwise join two or more portions of the strap 200 (or two or more portions of multiple straps 200) together. During the crimping operation, the crank 385 of the crank assembly 370 can rotate from the second position 920 to the third position 925 in which the linkage 360 continues to apply a downward force on the second end 345 of the linkage to retain the lever 335 in the third position 700 where the feed wheel 300 is positioned against and applying some amount of downward force to the strap 200. The lever 335 can remain in the third position 700 at ACT 1720 such that the fourth gear 1025 that is coupled to the lever 335 remains engaged with the third gear 1020 to prevent back rotation of the third gear 1020. For example, the one-way bearing of the fourth gear 1025 can prevent the feed wheel 300 and the third gear 1020 to which the feed wheel 300 is coupled from back rotating in the direction 1115 and releasing tension in the strap 200, particularly during the crimping operation where tension in the strap 200 can affect the quality or success of the crimping operation.

The method 1700 can include rotating a crank at ACT 1725. For example, the method 1700 can include rotating the crank 385 to position the feed wheel 300 against the strap 200 at ACT 1725. The lever 335 can move from the third position 700 to the second position 500 to move the feed wheel 300 away from the strap 200. The crank assembly 370 and the linkage 360 coupled therewith can cause the lever 335 to move from the third position 700 to the second position 500. For example, the crank 385 of the crank assembly 370 can move from the third position 925 to the first position 915, whether directly from the third position 925 or by first moving to the second position 920 before ultimately moving to the first position 915. The feed wheel 300 is positioned against the strap 200 with the crank 385 in the third position 925 or the second position 920, but not with the crank 385 in the first position 915. Because the feed wheel 300 is removed from the strap 200, the feed wheel 300 can cease its application of a downward force against the strap 200 or its application of tension to the strap 200. If the crimping operation was successful, the strap 200 should be crimped and can remain under tension based on the crimp joint, for example. As the crank 385 moves the lever 335 from the third position 700 to the second position 500, the fourth gear 1025 of the gear train 140 can separate from the third gear 1020 to permit movement of the third gear 1020 in the direction 1115.

The method 1700 can include removing the strap 200 at ACT 1730. For example, with the feed wheel 300 moved away from the strap 200 by virtue of the lever 335 being positioned in the second position 500, the strap 200 and the strapping device 100 can be separated from one another.

FIG. 18, among others, depicts a flow chart of a method 1800 of providing a strapping device 100. The strapping device 100 can include the tensioner assembly 120 that is pivotally coupled to the mount 320 of the strapping device 100 via the lever 335. The lever 335 can be coupled with the crank assembly 370 via the linkage 360. The tensioner assembly 120 can include the feed wheel 300 that is driven by the gear train 140 of the drive assembly 130 such that rotation of the third gear 1020 of the gear train 140 can cause the feed wheel 300 to rotate. The crank assembly 370 can include the crank 385 that is rotatably coupled to the crank mount 375 and configured to rotate in response to actuation of the pivot actuator 145. The pivot actuator 145 can rotate the crank 385 about the crank axis 380. The linkage 360 can include the first linkage end 910 coupled with the lobe 390 of the crank 385 in a position located away from the crank axis 380 and the second linkage end 361 coupled with the lever 335. The lever 335 can include the second end 345 having the axle 350 that is received by the resilient member 365 that is positioned in the opening 362 of the second linkage end 361 of the linkage 360. Rotation of the crank 385 about the crank axis 380 can cause at least partially vertical movement of the linkage 360, which can in turn cause vertical movement of the second linkage end 361 of the linkage 360 and ultimately pivotal motion of the lever 335 and the tensioner assembly 120.

As the crank 385 rotates, the linkage 380 can move downwards to lower the lever 335 and the feed wheel 300 of the tensioner assembly 120 toward the strap 200 that is supported by the base 125 of the strapping device 100. The resilient member 365 through which the axle 350 of the lever 335 is received can deform in response to downward movement of the linkage 360 as the feed wheel 300 is positioned against the strap 200. The deformation of the resilient member 365 can cause the feed wheel 300 to apply a desired downward force against the strap 200. When the feed wheel 300 is positioned against the strap 200 and is applying said downward force against the strap 200, the gear train 140 can be actuated by the motor 135 to cause rotation of the feed wheel 300 and cause the strap 200 to be under tension. A one-way bearing of the fourth gear 1025 can operatively engage with the feed wheel 300 to prevent back-rotation of the feed wheel 300 and hold tension in the strap 200 until a welding or crimping operation is complete or until the feed wheel 300 moves away from the strap 200 via pivotal movement of the lever 335.

While operations are depicted in the drawings in a particular order, such operations are not required to be performed in the particular order shown or in sequential order, and all illustrated operations are not required to be performed. Actions described herein can be performed in a different order.

Having now described some illustrative implementations, it is apparent that the foregoing is illustrative and not limiting, having been presented by way of example. In particular, although many of the examples presented herein involve specific combinations of method acts or system elements, those acts and those elements can be combined in other ways to accomplish the same objectives. Acts, elements and features discussed in connection with one implementation are not intended to be excluded from a similar role in other implementations or implementations.

The phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including” “comprising” “having” “containing” “involving” “characterized by” “characterized in that” and variations thereof herein, is meant to encompass the items listed thereafter, equivalents thereof, and additional items, as well as alternate implementations consisting of the items listed thereafter exclusively. In one implementation, the systems and methods described herein consist of one, each combination of more than one, or all of the described elements, acts, or components.

Any references to implementations or elements or acts of the systems and methods herein referred to in the singular can also embrace implementations including a plurality of these elements, and any references in plural to any implementation or element or act herein can also embrace implementations including only a single element. References in the singular or plural form are not intended to limit the presently disclosed systems or methods, their components, acts, or elements to single or plural configurations. References to any act or element being based on any information, act or element can include implementations where the act or element is based at least in part on any information, act, or element.

Any implementation disclosed herein can be combined with any other implementation or embodiment, and references to “an implementation,” “some implementations,” “one implementation” or the like are not necessarily mutually exclusive and are intended to indicate that a particular feature, structure, or characteristic described in connection with the implementation can be included in at least one implementation or embodiment. Such terms as used herein are not necessarily all referring to the same implementation. Any implementation can be combined with any other implementation, inclusively or exclusively, in any manner consistent with the aspects and implementations disclosed herein.

Where technical features in the drawings, detailed description or any claim are followed by reference signs, the reference signs have been included to increase the intelligibility of the drawings, detailed description, and claims. Accordingly, neither the reference signs nor their absence have any limiting effect on the scope of any claim elements.

Systems and methods described herein may be embodied in other specific forms without departing from the characteristics thereof. Further relative parallel, perpendicular, vertical or other positioning or orientation descriptions include variations within +/−10% or +/−10 degrees of pure vertical, parallel or perpendicular positioning. References to “approximately,” “about” “substantially” or other terms of degree include variations of +/−10% from the given measurement, unit, or range unless explicitly indicated otherwise. Coupled elements can be electrically, mechanically, or physically coupled with one another directly or with intervening elements. Scope of the systems and methods described herein is thus indicated by the appended claims, rather than the foregoing description, and changes that come within the meaning and range of equivalency of the claims are embraced therein.

The term “coupled” and variations thereof includes the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent or fixed) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members coupled directly to each other, with the two members coupled with each other using a separate intervening member and any additional intermediate members coupled with one another, or with the two members coupled with each other using an intervening member that is integrally formed as a single unitary body with one of the two members. If “coupled” or variations thereof are modified by an additional term (e.g., directly coupled), the generic definition of “coupled” provided above is modified by the plain language meaning of the additional term (e.g., “directly coupled” means the joining of two members without any separate intervening member), resulting in a narrower definition than the generic definition of “coupled” provided above. Such coupling may be mechanical, electrical, or fluidic.

References to “or” can be construed as inclusive so that any terms described using “or” can indicate any of a single, more than one, and all of the described terms. For example, a reference to “at least one of ‘A’ and ‘B’” can include only ‘A’, only ‘B’, as well as both ‘A’ and ‘B’. Such references used in conjunction with “comprising” or other open terminology can include additional items.

Modifications of described elements and acts such as variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations can occur without materially departing from the teachings and advantages of the subject matter disclosed herein. For example, elements shown as integrally formed can be constructed of multiple parts or elements, the position of elements can be reversed or otherwise varied, and the nature or number of discrete elements or positions can be altered or varied. Other substitutions, modifications, changes and omissions can also be made in the design, operating conditions and arrangement of the disclosed elements and operations without departing from the scope of the present disclosure.

References herein to the positions of elements (e.g., “top,” “bottom,” “above,” “below”) are merely used to describe the orientation of various elements in the FIGURES. It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure.

The hardware and data processing components used to implement the various processes, operations, illustrative logics, logical blocks, modules and circuits described in connection with the embodiments disclosed herein may be implemented or performed with a general purpose single- or multi-chip processor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A general purpose processor may be a microprocessor, or, any conventional processor, controller, microcontroller, or state machine. A processor also may be implemented as a combination of computing devices, such as a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration. In some embodiments, particular processes and methods may be performed by circuitry that is specific to a given function. The memory (e.g., memory, memory unit, storage device) may include one or more devices (e.g., RAM, ROM, Flash memory, hard disk storage) for storing data or computer code for completing or facilitating the various processes, layers and modules described in the present disclosure. The memory may be or include volatile memory or non-volatile memory, and may include database components, object code components, script components, or any other type of information structure for supporting the various activities and information structures described in the present disclosure. According to an exemplary embodiment, the memory is communicably connected to the processor via a processing circuit and includes computer code for executing (e.g., by the processing circuit or the processor) the one or more processes described herein.

The embodiments of the present disclosure may be implemented using computer processors, or by a special purpose computer processor for an appropriate system, incorporated for this or another purpose, or by a hardwired system. Embodiments within the scope of the present disclosure include program products comprising machine-readable media for carrying or having machine-executable instructions or data structures stored thereon. Such machine-readable media can be any available media that can be accessed by a general purpose or special purpose computer or other machine with a processor. By way of example, such machine-readable media can comprise RAM, ROM, EPROM, EEPROM, or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to carry or store desired program code in the form of machine-executable instructions or data structures and which can be accessed by a general purpose or special purpose computer or other machine with a processor. Combinations of the above are also included within the scope of machine-readable media. Machine-executable instructions include, for example, instructions and data which cause a general purpose computer, special purpose computer, or special purpose processing machines to perform a certain function or group of functions.

Although the figures and description may illustrate a specific order of method steps, the order of such steps may differ from what is depicted and described, unless specified differently above. Also, two or more steps may be performed concurrently or with partial concurrence, unless specified differently above. Such variation may depend, for example, on the software and hardware systems chosen and on designer choice. All such variations are within the scope of the disclosure. Likewise, software implementations of the described methods could be accomplished with standard programming techniques with rule-based logic and other logic to accomplish the various connection steps, processing steps, comparison steps, and decision steps.