Patent Application
20190276171
Several industries—such as the metal production, lumber, mining, shipping, and construction industries—often use steel strapping or steel banding to bundle loads, such as lumber, steel rods, and other objects for storage and/or shipping. Steel banding, however, can pose a safety risk to workers. For example, steel banding can have sharp or jagged edges, which can result in a cutting hazard to workers or passers-by. Further, even if the steel banding is smoothed and deburred, steel banding can become dangerous for workers during normal use. For example, to bundle a load, a worker must wrap the load with the steel banding and place the steel banding under tension, such as with a steel banding device. If the steel banding is suddenly released during application (e.g., the steel banding slips from the steel banding device), the sudden release of tension may cause a free end of the steel banding to propel into one or more objects or persons, potentially damaging the objects or harming the persons. Similar dangers exist when removing the steel banding, as the steel banding is typically cut for removal. By cutting the steel banding, tension is suddenly released, which can result in the steel banding to propel outward.
Additionally, steel banding can scratch or tear the objects being bundled or other objects that come into contact with the steel banding. The steel banding can also be susceptible to rust, which may damage or stain the bundled objects or objects coming into contact with the steel banding.
Furthermore, steel banding typically does not stretch. Once steel banding is applied to a load (e.g., a single object, a bundle of several objects, or some other load), the load can settle or shift such that the steel banding is no longer tightly wrapped around the load. This can also result in potential damage and injury.
To alleviate these and other injury and property damage concerns, synthetic strapping (e.g., woven polyester strapping) has been used as an alternate to steel banding, as synthetic strapping is not sharp and typically has similar strength properties as compared to steel banding, but deficiencies in existing tensioning tools have slowed or prevented widespread industry adoption. For example, existing tensioning tools for use with synthetic straps typically provide an insufficient and uneven amount of tension to strapping. Commonly, such tensioning tools are used in conjunction with a buckle, and such tensioning tools typically include a flat base, a single tensioning shaft, and a ratchet and pawl system configured to rotate the tensioning shaft. In practice, a length of strapping is wrapped around a load, a portion of the length of strapping is looped around a first prong of the buckle such that a first end of the length of strapping is extending freely from the buckle, and another portion of the length of strapping is similarly looped around a second prong of the buckle such that a second end of the length of strapping is extending freely from the opposite side of the buckle. The base of the tensioning tool is then positioned between the load (i.e., the object(s) to be bound or bundled) and the length of strapping encircling the load, and the corresponding end (i.e., either the first end or the second end) of the length of strapping is fed through a slot of the tensioning shaft (also called a ratcheting barrel). The shaft is then caused to rotate, such as by a user manually operating the ratchet and pawl system of the tensioning tool. As the shaft of the tensioning tool is rotated and tension is applied to the strap, the prongs of the buckle deform toward the load and apply pressure to the strap to lock the strap in place by frictional forces. Any excess strapping material at the end inserted into the tensioning shaft is cut away, and the base of the tensioning tool is then slid out from between the load and the length of strapping encircling the load.
As can be seen above, existing tensioning tools are configured to tighten the strap from a single end of the length of strapping and from a single side of the buckle. This may provide uneven tension to the buckle, which may fully deform one prong of the buckle without fully deforming the other prong. Thus, existing tensioning tools may not fully secure the strap on both sides of the prong, which may permit the strap to loosen over time or in response to external forces. In turn, loosening of the strap may permit the bundled load to shift, which could ultimately cause damage to the bundled load or neighboring objects and/or injury to nearby persons.
Additionally, as described above, a user must slide out the base of the tensioning tool from between the load and the length of strapping encircling the load to remove the tensioning tool. This may release tension on the strapping and/or the buckle. This is because, during the tensioning process, the length of strapping was wrapped around both the load and the base of the tensioning tool, and once the tensioning tool is removed, the load is permitted additional space within the constraints of the length of strapping (i.e., the space previously filled by the base of the tensioning tool), thus decreasing the tension of the length of strapping. This may permit the bundled load to shift, which could ultimately cause damage to the bundled load or neighboring objects and/or injury to nearby persons.
Further, existing tensioning tools may be particularly susceptible to introducing, upon removal of the tensioning tool from the load, a decrease in tension to the length of strapping when the load has a round or irregular cross-sectional shape. Because existing tensioning tools typically include an extended, flat base, the ends of the flat base may extend tangentially beyond the surface curvature of a round or irregularly-shaped load, creating a void between the edge of the base and the surface of the round object. Thus, when used with loads having a round or irregular cross-sectional shape, existing tensioning tools are required to place tension on a length of strapping when the strapping is encircling the load, the base of the tensioning tool, and the void created between the edges of the tensioning tool and the surface of the round object. Accordingly, upon removal of the tensioning tool, the load is permitted additional space within the constraints of the length of strapping (i.e., the space previously filled by the base of the tensioning tool and the void between the edges of the tensioning tool and the surface of the round object), resulting in an even greater decrease in tension on a round or irregularly-shaped load as compared to a load having a rectangular shaped cross-section. This may, in turn, result in a higher likelihood of the load shifting, which could ultimately cause damage to the bundled load or neighboring objects and/or injury to nearby persons.
These and other problems may be addressed by the technology disclosed herein. The disclosed technology can include a tensioning mechanism including an input shaft configured to receive torque and a differential having an input portion connected to the input shaft. The differential can have a first output portion and a second output portion. The first output portion can be located on a first side of the differential, and the second output portion can be located on a second side of the differential that is different from the first side. The first side is opposite the second side. The first output portion can be in mechanical communication with a first worm gear, and the second output portion can be in mechanical communication with a second worm gear. The tensioning mechanism can include a first output gear in mesh with the first worm gear and a second output gear in mesh with the second worm gear.
The torque received at the input shaft can be a first torque having a first force, and the tensioning mechanism can be configured to output a second torque at the first output gear and/or the second output gear, such that the second torque is greater than the first torque.
The tensioning mechanism can include a first tensioning barrel fixedly attached to the first worm gear and a second tensioning barrel fixedly attached to the second worm gear.
The first output gear can be configured to rotate in a first rotational direction, and the second output gear can be configured to rotate in a second rotational direction that is opposite the first rotational direction.
The tensioning mechanism can include a first drive shaft having a first end connected to the first output portion of the differential and a second end connected to the first worm gear. The tensioning mechanism can include a second drive shaft having a first end connected to the second output portion of the differential and a second end connected to the second worm gear.
The first and second drive shafts can be coaxially aligned.
The first output gear can be configured to rotate about a first axis, the second output gear is configured to rotate about a second axis, and the first and second axes can be parallel.
The input shaft can be configured to rotate about a third axis that is perpendicular to the first axis and the second axis.
The first driveshaft can be configured to rotate about a fourth axis, the second driveshaft can be configured to rotate about a fifth axis, and the fourth and fifth axes can be perpendicular to each of the first, second, and third axes.
The fourth axis can be parallel to the fifth axis.
The tensioning mechanism can include a motor configured to selectively apply torque to the input shaft.
The tensioning mechanism can include a controller configured to transmit instructions to the motor.
The disclosed technology can include a tensioning mechanism including an input shaft configured to receive torque, a first worm gear in mechanical communication with the input shaft via at least one intermediary gear, and a second worm gear in mechanical communication with the input shaft via the at least one intermediary gear. The tensioning mechanism can include a first output gear in mesh with the first worm gear and a second output gear in mesh with the second worm gear.
The disclosed technology can include a tensioning tool comprising a housing, a system of gears disposed within the housing, and an input shaft in mechanical communication with the system of gears. The tensioning tool can include a first tensioning barrel and a second tensioning barrel, and each tensioning barrel can include a slot configured to receive at least a portion of a length of strapping material and can be in mechanical communication with the system of gears such that torque can be transferred from the input shaft and to either tensioning barrel via the system of gears.
The system of gears can include a differential.
The system of gears can include a worm gear.
The system of gears can include a first worm gear and a second worm gear, and either worm gear can be in mechanical communication with the differential. The system of gears can also include a first output gear in mesh with the first worm gear, and a second output gear in mesh with the second worm gear. The first output gear can be fixedly attached to the first tensioning barrel, and the second output gear can be fixedly attached to the second tensioning barrel.
The first output gear can be configured to rotate in a first rotational direction, and the second output gear can be configured to rotate in a second rotational direction that opposite the first rotational direction.
The housing can comprise a plurality of cutouts.
The tensioning tool can include a handle.
The tensioning tool can include a cutting system, which can include a first cutter housing including a first slot configured to at least partially receive a first portion of a length of strapping, and a second cutter housing including a second slot configured to at least partially receive a second portion of a length of strapping. The cutting system can also include a first cutter at least partially disposed within the first cutter housing, and a second cutter at least partially disposed within the second cutter housing. The first cutter can be configured to rotate within the first cutter housing, and the second cutter can be configured to rotate within the second cutter housing.
The cutting system can include a cutting actuator in mechanical communication with a cutting shaft, and the cutting actuator can be configured to at least partially rotate the cutting shaft. The cutting system can include a first arm in mechanical communication with the cutting shaft and the first cutter, and the first arm can be configured to transmit rotation of the cutting shaft to the first cutter. The cutting system can include a second arm in mechanical communication with the cutting shaft and the second cutter, and the second arm can be configured to transmit rotation of the cutting shaft to the second cutter.
The cutting actuator can be a lever or a button.
The cutters can be disposed on a first side of the housing, and the cutting actuator can be disposed on a second side of the housing that is different from the first side. The second side can be opposite the first side.
The tensioning tool can comprise one or more motors configured to selectively rotate the first tensioning barrel, the second tensioning barrel, the first cutter, and/or the second cutter. The tensioning tool can comprise a controller configured to transmit instructions to the motor.
The first and/or second tensioning barrel is configured to apply tension to a length of strapping and/or a buckle in the range of approximately 500 pound-forces to approximately 800 pound-forces.
The disclosed technology can include a method for bundling a load, and the method can include inserting a first portion of a first end of a length of strapping into a first cutter slot of a first cutter housing of a tensioning tool, inserting a second portion of the first end of the length of strapping into a first barrel slot of a first tensioning barrel of the tensioning tool, inserting a first portion of a second end of the length of strapping into a second cutter slot of a second cutter housing of the tensioning tool, and inserting a second portion of the second end of the length of strapping into a second barrel slot of a second tensioning barrel of the tensioning tool. The method can include applying torque to an input shaft of the tensioning tool, thereby transferring the torque to the first and/or second tensioning barrel via a system of gears included in the tensioning tool, thereby rotating the first and/or second tensioning barrel. The method can include activating a cutting actuator of the tensioning barrel, thereby rotating the first cutter within the first cutter housing and rotating the second cutter within the second cutter housing such that the first cutter cuts the first end from the length of strapping and the second cutter cuts the second end from the length of strapping.
The method can also include wrapping the length of strapping around the load, looping a third portion of the first end around a first prong of a buckle and under a base portion of the buckle, and looping a third portion of the second end around a second prong of a buckle and under the base portion of the buckle.
The step of applying torque to the input shaft may include applying torque to the input shaft until a desired amount of tension is applied to the length of strapping and/or the buckle. The desired amount of tension may be in the range of approximately 500 pound-forces to approximately 800 pound-forces.
Reference will now be made to the accompanying figures, which are not necessarily drawn to scale, and wherein:
Throughout this disclosure, various aspects of a tensioning tool are discussed. Such a tensioning tool may be useful for wrapping and/or bundling a load (i.e., one or more objects) with a length of strapping, such as a length of woven synthetic strapping. But the disclosed technology is not so limited. For example, the disclosed technology may be effective for applying tension to any other object or system. As another example, the disclosed technology may be useful in pulling a portion of an object or system away from another portion of the object or system. As yet another example, the disclosed technology may include a tensioning mechanism, which may, as a non-limiting example, be incorporated in a tensioning tool. Alternately or in addition, the tensioning mechanism may be used in any application where bi-directional tension is applied. As will be appreciated, the tensioning mechanism may be a component of machinery. Other applications of the disclosed technology may become apparent to those having skill in the art and are contemplated herein.
The disclosed technology will be described more fully hereinafter with reference to the accompanying drawings. This disclosed technology may, however, be embodied in many different forms and should not be construed as limited to the examples expressly set forth herein. The components described hereinafter as making up various elements of the disclosed technology are intended to be illustrative and not restrictive. Many suitable components that would perform the same or similar functions as components described herein are intended to be embraced within the scope of the disclosed electronic devices and methods. Such other components not described herein may include, but are not limited to, for example, components developed after development of the disclosed technology.
Throughout the specification and the claims, the following terms take at least the meanings explicitly associated herein, unless the context clearly dictates otherwise. The term “or” is intended to mean an inclusive “or.” Further, the terms “a,” “an,” and “the” are intended to mean one or more unless specified otherwise or clear from the context to be directed to a singular form.
Unless otherwise specified, the use of the ordinal adjectives “first,” “second,” “third,” etc., to describe a common object, merely indicate that different instances of like objects are being referred to, and are not intended to imply that the objects so described should be in a given sequence, either temporally, spatially, in ranking, or in any other manner.
As described herein, the disclosed technology relates to a tensioning tool that can be, for example, useful for wrapping and/or bundling a load (i.e., one or more objects) with a length of strapping, such as a length of woven synthetic strapping. The tensioning tool can include dual tensioning shafts, which can each include one or more slots configured to receive a portion of a length of strapping. The dual tensioning barrels may be configured to rotate in opposite directions (i.e., one tensioning barrel rotates clockwise while the other tensioning barrel rotates counter-clockwise). The tensioning tool may include one or more cutter devices, which may be configured to cut away excess strapping after a desired amount of tension has been applied to the strapping. Various aspects and functionalities of the disclosed technology are discussed more fully below.
The tensioning tool 100 may include one or more cutter housings 108 and each cutter housing may include a slot 110 and a cutter 112. The slot 110 may be configured to receive a portion of strapping, and the cutter 112 may be configured to rotate within the cutter housing 108 such that the cutter 112 pinches the strapping between an edge of the cutter 112 and an edge of the wall of the cutter housing 108 proximate one end of the slot 110. Thus, the cutter 110 and cutter housing 108 may be configured to cut away excess material from the strapping subsequent to the tensioning tool 100 applying tension to the strapping. The cutter may have a semicircular cross-section. The tensioning tool 100 may include a cutter actuator 114 configured to cause the cutter 108 to rotate within the cutter housing 108. As shown in
The tensioning tool 100 may include an input shaft 116. The input shaft 116 may be configured to mate with, and receive torque from, a bit or other insert configured to insert into a common drill/driver. The input shaft 116 may, alternately or in addition, be configured to receive torque from a hand crank or some other source of manual torque input. For example, the input shaft 116 may include a nut or bolt (e.g., a hex bolt), that is nonrotatable with respect to the input shaft 116. The bolt which may be configured to mate with a bit that is insertable into a common drill/driver (e.g., a hex nut bit). Thus, a driver or some other external device can rotate the bolt, as well as the input shaft 116.
The tensioning tool 100 may also include one or more handles 118. Each handle 118 may be fixedly mounted to the housing 102. As shown in
Referring to
A cutting shaft 510 may be in mechanical communication with cutting actuator 114, such as the lever depicted in
The various components and subcomponents of the tensioning tool 100 and/or tensioning mechanism 500 may be of metal or plastic. For example, one, some, or all of the components described herein may be made of copper, bronze, steel, aluminum, or any alloy thereof. As another example, one, some, or all of the components described herein may be made of polyethylene, polypropylene, polyvinyl chloride, or any other useful plastic.
Referring to
The method 700 can include wrapping 710 a length of strapping around a load and looping 720 either free end of the length of strapping around a respective prong 602 of a buckle 600 and under a base portion 604 of the buckle 602. The method 700 can include inserting 730 a portion of either end of the length of strapping into a slot 110 of a respective cutter housing 108 of the tensioning tool 100 and inserting 740 a portion of either end of the length of strapping into a slot 106 of a respective tensioning barrel 104 of the tensioning tool 100. The method 700 may or may not include connecting 750 an external torque source (e.g., a drill/driver) to an input shaft 116. The method 700 can include applying 760 torque to the input shaft 116. Applying 760 torque to the input shaft 116 can cause torque to be transferred from the input shaft 116 and to the tensioning barrels 104 via a system of gears (e.g., differential 502, transition gear 506, output gear 508) included in the tensioning tool 100. As will be appreciated, the transfer of torque to the tensioning barrels 104 will cause the tensioning barrels 104 to rotate such that either end of the length of strapping is wound about the outer surface of the respective tensioning barrel, placing tension on the length of strapping and/or the buckle 600. Torque can be applied 760 to the input shaft 116 until the tensioning barrels 114 have placed the length of strapping and/or the buckle under a desired amount of tension. The method 700 include, subsequent to placing, via the tensioning barrels 114, the length of strapping and/or the buckle under a desired amount of tension, activating 770 the cutting actuator 114. Activating 770 the cutting actuator 114 can cause the cutters 112 to cut away excess strapping material proximate the ends of the length of strapping. The method 700 may or may not include removing 780 the tensioning tool 100 from the load and may or may not include removing 790 the cut-away excess strapping material from the tensioning barrels 104.
While the disclosed technology has been described in connection with what is presently considered to be the most practical designs, it is to be understood that the disclosed technology is not to be limited to the disclosed designs, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
This application claims priority to, and the benefit under, 35 U.S.C. § 119(e), of U.S. Provisional Patent Application No. 62/639,832, filed 7 Mar. 2018, the entire contents and substance of which are hereby incorporated by reference as if fully set forth below.
| Number | Date | Country | |
|---|---|---|---|
| 62639832 | Mar 2018 | US |
