Priority

[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63/374,449, filed September 2, 2022, the entire contents of which is incorporated herein by reference.

Field

[0002] The present disclosure relates to strapping devices, and more particularly to strapping devices configured to tension plastic strap around a load and to attach overlapping portions of the strap to one another via friction welding to form a tensioned strap loop around the load.

Background

[0003] Strapping devices are used to tension strap around a load and to attach overlapping portions of the strap to one another to form a tensioned strap loop around the load. One type of strapping device is a battery-powered strapping tool for use with plastic strap, such as polypropylene strap or polyester strap, that uses friction welding to attach the overlapping portions of the strap to one another. To use one of these strapping tools to form a tensioned strap loop around a load, an operator pulls strap leading end first from a strap supply, wraps the strap around the load, and positions the leading end of the strap below another portion of the strap. The operator then introduces these overlapped strap portions between a tensioning wheel and a tensioning plate of the strapping tool. The operator presses a button to initiate a tensioning cycle during which the strapping tool rotates the tensioning wheel to tension the strap around the load. After completion of the tensioning cycle, the strapping tool automatically initiates a sealing cycle during which the strapping tool presses a weld pad onto the overlapped strap portions and rapidly oscillates the weld pad. The combination of the pressure and the rapid oscillation of the weld pad melts the two overlapping portions of the strap and fuses them together. The tensioning wheel and plate are typically positioned near the front of the strapping tool, while the weld pad is positioned rearward of and aligned with the tensioning wheel and plate.

[0004] One problem with certain known strapping tools is that they include separate assemblies — and sometimes even separate motors — for tensioning and sealing the strap, which can make these tools relatively heavy. Since strapping tool operators can use handheld strapping tools hundreds of times each day, there is a need to make the strapping tools as light as possible without sacrificing performance.

[0005] Another problem with certain known strapping tools is that their base plates are relatively long. The base plate separates the tensioning wheel and the weld pad from the load and rests on the load during the tensioning and sealing cycles. Since the weld pad is rearward of and aligned with the tensioning wheel, the base plate is relatively long. This prevents operators from using the strapping tool to strap curved loads with relatively small radii, such as small bundles of metal pipes, because the length of the base plate prevents the strap from retaining adequate tension after the strapping tool is removed from the load. Since this limits the potential applications of these strapping tools, there is a need for strapping tools with shorter base plates.

Summary

[0006] Various embodiments of the present disclosure provide a strapping device with a combined tensioning-and-welding assembly. The tensioning-and-welding assembly includes a tensioning-and-welding wheel that is: (1) rotatable about a tensioning-and-welding- wheel rotational axis to tension strap around a load; and (2) longitudinally movable along the about a tensioning-and-welding-wheel rotational axis to seal two overlapping portions of the strap together.

Brief Description of the Figures

[0007] Figure 1A is a perspective view of one example embodiment of a strapping tool of the present disclosure.

[0008] Figure IB is a block diagram of certain components of the strapping tool of Figure 1A. [0009] Figures 2A-2C are diagrammatic views of the strapping tool of Figure 1 A securing a load to a pallet.

[0010] Figure 3 is a perspective view of the working assembly and the support of the strapping tool of Figure 1A.

[0011] Figure 4 is a perspective view of the working assembly and the support of the strapping tool of Figure 1 A with the rocker removed.

[0012] Figure 5A is a perspective view of the tensioning-and-welding assembly of the working assembly of Figure 3.

[0013] Figure 5B is an exploded perspective view of the tensioning-and-welding assembly of Figure 5 A.

[0014] Figure 5C is a cross-sectional perspective view of the tensioning-and-welding assembly of Figure 5 A taken along line 5C-5C of Figure 5A.

[0015] Figure 6A is a perspective view of the mount of the tensioning-and-welding assembly of Figures 5A-5C.

[0016] Figures 6B and 6C are left- and right-side elevational views, respectively, of the mount of Figure 6 A.

[0017] Figures 7A and 7B are perspective views of the tensioning-and-welding wheel of the tensioning-and-welding assembly of Figures 5A-5C.

[0018] Figure 7C is a right-side elevational view of the tensioning-and-welding wheel of Figures 7 A and 7B.

[0019] Figures 8A and 8B are perspective views of the welding actuator of the tensioning-and-welding assembly of Figures 5A-5C.

[0020] Figure 8C is a front elevational view of the welding actuator of Figure 8A.

[0021] Figure 8D is a left-side elevational view of the welding actuator of Figure

8A.

[0022] Figures 9A-9E are front elevational views of the tensioning-and-welding assembly of Figures 5A-5C and the tensioning plate of the support of Figure 3 as the welding actuator rotates and the tensioning-and-welding wheel moves longitudinally relative to the tensioning plate as the strapping tool carries out part of a sealing cycle.

[0023] Figure 10 is a perspective view of the working assembly and the support of another embodiment of the strapping tool of the present disclosure. Detailed Description

[0024] While the systems, devices, and methods described herein may be embodied in various forms, the drawings show and the specification describes certain exemplary and nonlimiting embodiments. Not all of the components shown in the drawings and described in the specification may be required, and certain implementations may include additional, different, or fewer components. Variations in the arrangement and type of the components; the shapes, sizes, and materials of the components; and the manners of connections of the components may be made without departing from the spirit or scope of the claims. Unless otherwise indicated, any directions referred to in the specification reflect the orientations of the components shown in the corresponding drawings and do not limit the scope of the present disclosure. Further, terms that refer to mounting methods, such as mounted, connected, etc., are not intended to be limited to direct mounting methods but should be interpreted broadly to include indirect and operably mounted, connected, and like mounting methods. This specification is intended to be taken as a whole and interpreted in accordance with the principles of the present disclosure and as understood by one of ordinary skill in the art.

[0025] Figures 1A-9E show one example embodiment of a strapping device of the present disclosure in the form of a strapping tool 50 and certain assemblies and components thereof. As shown in Figures 2A-2C, the strapping tool 50 is configured to carry out a strapping cycle to tension and seal strap S (plastic strap in this example embodiment) around a load L on a pallet P to form a tensioned strap loop that secures the load L to the pallet P. An operator pulls strap S from a strap supply (not shown) and wraps the strap around the load L and through openings in the pallet P until a lower portion LP of the strap S (which includes the leading end of the strap S) is positioned below an upper portion UP of the strap S, as shown in Figure 2A. The operator then introduces the overlapped upper and lower portions UP and LP of the strap S into the strapping tool 50 and actuates one or more buttons to initiate the strapping cycle. As shown in Figure 2B, the strapping tool 50 carries out a tensioning cycle during which the strapping tool 50 tensions strap S around the load L. Once a preset tension is reached in the strap S, the strapping tool 50 carries out a sealing cycle during which the strapping tool 50 welds the upper and lower portions UP and LP of the strap S together via friction welding and cuts the strap S from the strap supply. Figure 2C shows the strap after welding and cutting. [0026] The strapping tool 50 includes a housing 100 (Figure 1 A), a working assembly 200 (Figures 3 and 4), a display assembly 1300 (Figures 1A and IB), an actuating assembly 1400 (Figures 1A and IB), a power supply (not shown), a controller 1600 (Figure IB), and one or more sensors 1700 (Figure IB).

[0027] The housing 100, which is shown in Figure 1A, is formed from multiple components (not individually labeled) that collectively at least partially enclose and/or support some (or all) of the other assemblies and components of the strapping tool 50. In this example embodiment, the housing 100 includes a front housing section 110, a rear housing section 120, and a handle section 150. The front housing section 110 at least partially encloses and/or supports at least some of the components of the working assembly 200 and the actuating assembly 1400. The rear housing section 120 at least partially encloses and/or supports at least some of the components of the display assembly 1300 and defines a receptacle 122 sized, shaped, and otherwise configured to receive and at least partially enclose and/or support the power supply and the controller 1600. The handle housing section 150 extends between and connects the tops bottoms of the front and rear housing sections 110 and 120 and defines a handle usable by the operator. This is merely one example, and in other embodiments the components of the strapping tool may be supported and/or enclosed by any suitable portion of the housing 100. The housing 100 may take any suitable shape and be formed from any suitable quantity of components joined together in any suitable manner. In this example embodiment, the housing 100 is formed from plastic, though it may be made from any other suitable material in other embodiments.

[0028] The working assembly 200, which is best shown in Figures 3 and 4, includes the majority of the components of the strapping tool 50 that are configured to carry out the strapping cycle to tension the strap around the load and attach the overlapping portions of the strap to one another. The working assembly 200 includes a support 300, a tensioning-and- welding assembly 400, a transmission assembly 500, a motor 600, a rocker 700, and a rocker lever 800.

[0029] The support 300, which is best shown in Figure 3 and 4, serves as a direct or indirect common mount for the tensioning-and-welding assembly 400, the transmission assembly 500, the motor 600, the rocker 700, and the rocker lever 800. The support 300 includes a base 310 having generally planar upper and lower surfaces, a support arm 320 extending upward from the upper surface of the base 310 and having first and second mounting ears 322 and 324, and a tensioning plate 330 on the upper surface of the base 310. The tensioning plate 330 has a base 332 and a concave tensioning surface 334. In this example embodiment, the tensioning surface 334 is textured (such as knurled) to facilitate gripping the strap during tensioning and welding as the tensioning-and-welding wheel presses the strap against the tensioning surface 334.

[0030] The tensioning-and-welding assembly 400, which is best shown in Figures 3A-8C, is configured to tension the strap around the load during the tensioning cycle and attach overlapping portions of the strap to one another to form a tensioned strap loop around the load during the sealing cycle via friction welding. The tensioning-and-welding assembly 400 includes a mount 410, a welding actuator 420, multiple spacers 430, a welding-actuator bearing 440, a tensioning-and-welding wheel 450, multiple supports 460, a tensioning-and-welding-wheel- biasing element 470, and a mount bearing 480.

[0031] The mount 410, which is best shown in Figures 6A-6C, directly or indirectly supports other components of the tensioning-and-welding assembly 400 and defines a longitudinally extending tensioning-and-welding-wheel rotational axis A450 (Figures 5A-5C). Certain components of the tensioning-and-welding assembly 400 are centered on and certain components of the tensioning-and-welding assembly 400 are rotatable about the tensioning-and- welding-wheel rotational axis A450. The mount 410 includes a driven shaft 412, a weldingactuator mount 414, a collar 415, a tensioning-and-welding-wheel shaft 416, and a flange 418, all of which are integrally formed with one another in this example embodiment (though the mount may be formed from any suitable quantity of components attached to one another in any suitable manner in other embodiments) and all of which are centered on and rotatable about the tensioning-and-welding-wheel rotational axis A450.

[0032] The driven shaft 412 is sized, shaped, positioned, oriented, and otherwise configured to be drivingly engaged by the transmission assembly 500 (such as via a splined, keyed, or geared connection), as described below. The welding-actuator mount 414 is connected to the driven shaft 412. The welding-actuator mount 414 is cylindrical and is sized and shaped so the welding-actuator bearing 440 (described below) can be mounted thereon via interference fit. In this example embodiment, the diameter of the welding-actuator mount 414 is greater than the diameter of the driven shaft 412. A circumferential groove 414c is defined around the outer surface of in the welding-actuator mount 414 and is sized and shaped to receive a retainer (explained below). The collar 415 is connected to the welding-actuator mount 414, is cylindrical, and has a diameter greater than the diameter of the welding-actuator mount 414.

[0033] The flange 418 is disc-shaped, is connected to the collar 415, and has an outer diameter greater than the outer diameter of the collar 415. The flange 418 defines five longitudinally extending cylindrical spacer-receiving bores 418o therethrough. The spacerreceiving bores 418o are each sized and shaped to receive one of the spacers 430, as described below. As shown in Figure 6C, in this example embodiment, the center of each spacer-receiving bore 418o is positioned at a radius RE from the center of the flange 418, which is positioned on the tensioning-and-welding-wheel rotational axis A450. As also shown in Figure 6C, in this example embodiment, the spacer-receiving bores 4180 are equally circumferentially spaced such that the center of each spacer-receiving bore 4180 is angularly offset from the center of each adjacent spacer-receiving bore 4180 by an angle a.

[0034] The tensioning-and-welding-wheel shaft 416 is connected to the other side of the flange 418 so the flange 418 separates the tensioning-and-welding-wheel shaft 416 from the collar 415. The tensioning-and-welding-wheel shaft 416 is generally cylindrical and slightly tapers in the longitudinal direction (along the tensioning-and-welding-wheel rotational axis A450) moving toward its free end, which facilitates mounting the tensioning-and-welding wheel 450 as described below. Put differently, and as shown in Figure 6B, the tensioning-and-welding-wheel shaft 416 has a first radius R4i6,o where it meets the flange 418 and a second radius R416 , which is smaller than the first radius R4i6,o, at its free end. Several distinct, longitudinally extending, and circumferentially spaced support-receiving channels 416c are defined around the outer surface of the tensioning-and-welding-wheel shaft 416. Each support-receiving channel 416c extends longitudinally (along the tensioning-and-welding-wheel rotational axis A450) from an open channel end at the free end of the tensioning-and-welding wheel mount 416 to at a wall 416w inward of the free end. Each support-receiving channel 416c is sized, shaped, positioned, oriented, and otherwise configured to receive a plurality of the supports 460, as described below.

[0035] The welding actuator 420, which is best shown in Figures 8A-8D, is actuatable by the transmission assembly 500 to move the tensioning-and-welding wheel 450 longitudinally to seal two overlapping strap portions together. The welding actuator 420 includes an annular driven portion 422 and an annular actuating portion 424 connected to (and in this example embodiment, integrally formed with) and coaxial with the driven portion 422. The driven portion 422 includes teeth 422t extending around its outer surface that are sized, shaped, positioned, oriented, and otherwise configured to be drivingly engaged by the transmission assembly 500, as described below. As best shown in Figure 8B, the inner diameter of the actuating portion 424 is smaller than the inner diameter of the driven portion 422 so the actuating portion 424 extends radially inward from the driven portion 422. The actuating portion 424 includes an annular actuating surface 424s. The actuating surface 424s is centered at the radius RE from the center of the actuating portion 424, which corresponds to the tensioning-and- wel ding-wheel rotational axis A450 when the welding actuator 420 is mounted to the mount 410, as described below. As best shown in Figures 8A and 8C, the actuating surface 424s has an undulating profile that defines alternating peaks 424p and valleys 424v (five of each, though any suitable quantity may be employed). The actuating surface 424s is furthest from the driven portion 422 at the peaks 424p and closest to the driven portion 422 at the valleys 424v. As shown in Figure 8D, the peaks 424p are equally spaced so each peak 424p is angularly offset from each adjacent peak 424p by the angle a, and the valleys 424v are equally spaced so each valley 424v is angularly offset from each adjacent valley 424v by the angle a.

[0036] The tensioning-and-welding wheel 450, which is best shown in Figures 7A- 7C, is rotatable to tension strap around a load and longitudinally movable to seal two overlapping portions of the strap together. The tensioning-and-welding wheel 450 includes an annular body 452 having a textured (such as a knurled) outer surface 452s, an annular biasing-element seat 454 extending from one side of and coaxial with the body 452, and a spacer seat 456 extending from the other side of and coaxial with the body 452. As best shown in Figure 7C, the spacer seat 456 includes a generally annular hub 456h and five spokes 456s extending radially from the hub 456h and each having an end (not labeled). The approximate center of each end, labeled EP, is centered at the radius R from the center of the hub 456h, which corresponds to the tensioning- and-welding-wheel rotational axis A450 when the tensioning-and-welding wheel 450 is mounted to the mount 410, as described below. Additionally, the approximate center EP of the end of each spoke 456s is angularly offset from the approximate center EP of the end of each adjacent spoke 456s by the angle a.

[0037] Several distinct, longitudinally extending, and circumferentially spaced support-receiving channels 458c are defined around the inner cylindrical surface of the body 452, the biasing-element seat 454, and the spacer seat 456. Each support-receiving channel 458c extends longitudinally (along the tensioning-and-welding-wheel rotational axis A450) from an open channel end at the spacer seat 456 to a wall 458w inward of the spacer seat 456. Each support-receiving channel 458c is sized, shaped, positioned, oriented, and otherwise configured to receive a plurality of the supports 460, as described below. The tensioning-and-welding wheel 450 has the same quantity of support-receiving channels 458c as the mount 410 has supportreceiving channels 416c. Additionally, the angular spacing of the support-receiving channels 458c relative to the center of the tensioning-and-welding wheel 450 matches the angular spacing of the support-receiving channels 416c relative to the tensioning-and-welding-wheel rotational axis A450.

[0038] Figures 5A-5C best show the assembled tensioning-and-welding assembly 400. The outer race of the welding-actuator bearing 440 is press-fit within the driven portion 422 of the welding actuator 420, and the inner race of the welding-actuator bearing 440 is press-fit onto the welding-actuator mount 414 of the mount 410 so the actuating surface 424s of the actuating portion 424 of the welding actuator 420 faces the flange 418 of the mount 410. This mounting configuration enables the welding actuator 420 to rotate (via the welding-actuator bearing 440) relative to the mount 410 around the tensioning-wheel axis A450. A retainer (not shown), such as a retaining ring, is received in the groove 414c of the welding-actuator mount 414 and, along with the collar 415, prevents the welding-actuator bearing 440 and the welding actuator 420 from moving longitudinally (along the tensioning-and-welding-wheel rotational axis A450) relative to the mount 410.

[0039] The tensioning-and-welding wheel 450 is mounted to the tensioning-and- welding-wheel shaft 416 of the mount 410 via the supports 460 so the spacer seat 456 of the tensioning-and-welding wheel 450 is adjacent the flange 418 of the mount 410. Specifically, three of the supports 460, which are rolling elements (such as rolling balls) in this example embodiment but may be any other suitable components, are captured between each opposing pair of support-receiving channels 416c and 458c of the tensioning-and-welding-wheel shaft 416 and the tensioning-and-welding wheel 450, respectively. The supports 460 collectively fix the tensioning-and-welding wheel 450 in rotation with the mount 410 while enabling the tensioning- and-welding wheel 450 to move longitudinally (along the tensioning-and-welding-wheel rotational axis A450) relative to the mount 410, as described below. [0040] Each spacer 430 is received in a different one of the spacer-receiving bores 418o of the flange 418 and, due to the above-described shapes, sizes, positions, and orientations of various components of the tensioning-and-welding assembly 400, is positioned between one of the ends of one of the spokes 456s of the spacer seat 456 and the actuating surface 424s of the actuating portion 424 of the welding actuator 420. While this embodiment includes five spacers, other embodiments may have any suitable quantity of one or more spacers.

[0041] The inner race of the mount bearing 480 is press-fit onto the free end of the tensioning-and-welding-wheel shaft 416 of the mount 410. The tensioning-and-welding-wheel- biasing element 470, which includes one or more disc springs in this example embodiment but may include any other suitable springs or other types of biasing elements, is positioned between the mount bearing 480 and the biasing-element seat 454 of the tensioning-and-welding wheel 450. The tensioning-and-welding-wheel-biasing element 470 biases the tensioning-and-welding wheel 450 toward the flange 418, which in turn forces the spacer seat 456 to force the spacers 430 into engagement with the actuating surface 424s of the actuating portion 424 of the welding actuator 420.

[0042] Due to the undulating shape of the actuating surface 424s (with the peaks 424p and valleys 424v) and the ability of the tensioning-and-welding wheel 450 to move longitudinally along the tensioning-and-welding-wheel rotational axis A450 via the supports 460, the rotational position of the welding actuator 420 controls the longitudinal position of the tensioning-and-welding wheel 450. When the welding actuator 420 is in a home rotational position, shown in Figure 9A, the valleys 424v of the actuating surface 424s are aligned with the spacers 430 and the tensioning-and-welding wheel 450 is in a tensioning longitudinal position. In this example embodiment, the tensioning-and-welding wheel 450 is as close as it can get to the flange 418 when in the tensioning longitudinal position. As the welding actuator 420 begins to rotate in a welding rotational direction WD around the mount 410 and relative to the spacers 430 and the tensioning-and-welding wheel 450 under control of the transmission assembly 500 (as described below), the portions of the actuating surface 424s engaging the spacers 430 begin transitioning from the valleys 424v toward the peaks 424p, as shown in Figure 9B. This forces the spacers 430 to move toward the tensioning-and-welding wheel 450, which in turn forces the tensioning-and-welding wheel 450 to move longitudinally away from the welding actuator 420 against the biasing force of the tensioning-and-welding-wheel-biasing element 470. [0043] Eventually, and after rotating one-half of the angle a from the home rotational position in this example embodiment, the welding actuator 420 reaches an actuated rotational position at which the peaks 424p of the actuating surface 424s are aligned with the spacers 430 and the tensioning-and-welding wheel 450 is in an actuated longitudinal position, as shown in Figure 9C. In this example embodiment, the tensioning-and-welding wheel 450 is as far as it can get from the flange 418 (at least via rotation of the welding actuator 420) when in the actuated longitudinal position. As the welding actuator 420 continues rotating in the welding rotational direction WD, the portions of the actuating surface 424s engaging the spacers 430 begin transitioning from the peaks 424p toward the valleys 424v, as shown in Figure 9D. As this occurs, the biasing force of the tensioning-and-welding-wheel-biasing element 470 forces the tensioning-and-welding wheel 450 to move longitudinally toward the welding actuator 420 to maintain the spacers 430 engaged with the actuating surface 424s. Eventually, and after rotating one-half of the angle a from the actuated rotational position in this example embodiment, the welding actuator 420 reaches the home rotational position at which the valleys 424v of the actuating surface 424s are again aligned with the spacers 430 and the tensioning-and-welding wheel 450 is in the tensioning longitudinal position, as shown in Figure 9E.

[0044] The motor 600, which is best shown in Figures 3 and 4, includes a motor housing 600h and a rotatable output shaft 600s extending from the motor housing 600h. The motor 600 is configured to rotate the output shaft 600s in opposing tensioning and welding rotational directions TD and WD (Figure 4) to carry out the tensioning and sealing cycles, respectively. The motor 600 includes an electric motor in this example embodiment (but may include any suitable motor in other embodiments).

[0045] The transmission assembly 500, which is best shown in Figures 3 and 4, is driven by the motor 600 and is operably connected to the tensioning-and-welding assembly 400 and configured to cause the tensioning-and-welding assembly 400 to tension the strap around the load during the tensioning cycle and attach overlapping portions of the strap to one another to form a tensioned strap loop around the load during the sealing cycle via friction welding. The transmission assembly 500 includes a first transmission-gear assembly 510 and a second transmission-gear assembly 520.

[0046] The first transmission-gear assembly 510 operably connects the motor 600 to the mount 410 of the tensioning-and-welding assembly 400 so the motor 600 can rotate the mount 410 and the tensioning-and-welding wheel 450 thereon Specifically, the first transmission-gear assembly 510 includes suitable gearing (planetary gearing in certain embodiments) and other components (such as one or more freewheels) that operably connects the output shaft 600s of the motor 600 to the drive shaft 412 of the mount 410 of the tensioning- and-welding assembly 400 so the first transmission-gear assembly 510: (1) transmits rotational movement of the output shaft 600s in the tensioning rotational direction TD to the drive shaft 412 to rotate the mount 410 in the tensioning rotational direction TD; and (2) does not transmit rotational movement of the output shaft 600s in the welding rotational direction WD to the drive shaft 412. In this example embodiment, the components of the first transmission-gear assembly 510 are centered on and rotatable about the tensioning-and-welding-wheel rotational axis A450. This is one example configuration of the first transmission-gear assembly 510, and the first transmission-gear assembly 510 may take any other suitable configuration in other embodiments.

[0047] The second transmission-gear assembly 520 operably connects the motor 600 to the welding actuator 420 of the tensioning-and-welding assembly 400 so the motor 600 can rotate the welding actuator 420 and move the tensioning-and-welding wheel 450 longitudinally. The second transmission-gear assembly 520 includes a drive gear 522, a drive-gear freewheel 522f, a driven shaft 524, a first driven gear 526, a second driven gear 528, a first connector 520b 1, and a second connector 520b2.

[0048] The drive-gear freewheel 522f is mounted to, engages, and circumscribes the output shaft 600s of the motor 600. The drive gear 522, which is a gear pulley in this example embodiment, is mounted to, engages, and circumscribes the drive-gear freewheel 522f. The drive-gear freewheel 522f is configured to: (1) transmit rotational movement of the output shaft 600s in the welding rotational direction WD to the drive gear 522 so the drive gear 522 and the output shaft 600s rotate together in the welding rotational direction WD about the tensioning- and-welding-wheel rotational axis A450; and (2) not transmit rotational movement of the output shaft 600s in the tensioning rotational direction TD to the to the drive gear 522 so the output shaft 600s rotates about the tensioning-and-welding-wheel rotational axis A450 in the tensioning rotational direction TD relative the drive gear 522.

[0049] The driven shaft 524 is rotatably mounted to (such as via suitable bearings) and extends between the first and second mounting ears 322 and 324 of the support arm 320 of the support 300 so the driven shaft 524 can rotate relative to the support 300 about a driven-gear- shaft rotational axis A524. In this example embodiment, the driven-gear-shaft rotational axis A524 is parallel to the tensioning-and-welding-wheel rotational axis A450, though these axes may be transverse to one another in other embodiments. The first driven gear 526, which is a gear pulley in this example embodiment, is fixedly mounted to the driven shaft 524 near one end of the driven shaft 524 and the second driven gear 528, which is a gear pulley in this example embodiment, is fixedly mounted to the driven shaft 524 near the opposite end of the driven shaft 524 so the driven shaft 524 and the first and second driven gears 526 and 528 rotate together about the driven-gear-shaft rotational axis A524.

[0050] The first connector 520b 1, which is a toothed belt in this example embodiment but may be any suitable connector, operably connects the drive gear 522 and the first driven gear 524. The second connector 520b2, which is a toothed belt in this example embodiment but may be any suitable connector, operably connects the second driven gear 528 and the driven portion 422 of the welding actuator 420.

[0051] When the motor 600 rotates the output shaft 600s in the tensioning rotational direction TD, the first transmission-gear assembly 510 transmits this rotational movement to the drive shaft 412 of the mount 410 of the tensioning-and-welding assembly 400, which causes the mount 410 and the tensioning-and-welding wheel 450 thereon to rotate in the tensioning rotational direction TD about tensioning-and-welding-wheel rotational axis A450. The drive-gear freewheel 522f does not transmit the rotational movement of the output shaft 600s to the drive gear 522, which remains stationary.

[0052] Conversely, when the motor 600 rotates the output shaft 600s in the welding rotational direction WD, the drive-gear freewheel 522f transmits this rotational movement to the drive gear 522, which rotates in the welding rotational direction WD about the tensioning-and- welding-wheel rotational axis A450. The first connector 520b 1 transmits the rotational movement of the drive gear 522 to the first driven gear 526, which also begins rotating in the welding rotational direction WD. Because the driven shaft 524 and the first and second driven gears 526 and 528 are fixed in rotation, this rotation of the first driven gear 526 causes the driven shaft 524 and the second driven gear 528 to rotate with the first driven gear 526 about the driven-shaft rotational axis A524. The second connector 520b2 transmits the rotational movement of the second driven gear 528 to the driven portion 422 of the weld actuator 420, causing the weld actuator 420 to rotate in about the tensioning-and-welding-wheel rotational axis A450 in the welding rotational direction WD. The first transmission-gear assembly does not transmit the rotational movement of the output shaft 600s to the drive shaft 412 of the mount 410 of the tensioning-and-welding assembly 400.

[0053] The rocker 700, which is shown in Figure 3, supports the tensioning-and- welding assembly 400, the transmission assembly 500, and the motor 600. The rocker 700 includes a body 710 having a cylindrical bore therethrough and two opposing mounting arms 720 and 730 extending from the body 710. The first transmission-gear assembly 510 of the transmission assembly 500 is mounted within the body 710 of the rocker 700. The rocker 700 therefore supports the first-transmission-gear assembly 510 and the tensioning-and-welding assembly 400 and the motor 600 connected thereto. The rocker 700 (and the first-transmissiongear assembly 510, the tensioning-and-welding assembly 400, the motor 600 supported by the rocker 700) is movably mounted to the driven shaft 524 of the transmission assembly 500 via the mounting arms 720 and 730 and configured to pivot relative to the support 300 — and particularly relative to the base 310 and the tensioning plate 330 — under control of the rocker lever 800 or a motor (depending on the embodiment) and about the driven-gear- shaft rotational axis A524 between a tensioning-and-welding position (Figures 3 and 9A-9E) and a strap-insertion position (not shown). When the rocker 700 is in the tensioning-and-welding position, the outer surface 452s of the tensioning wheel 450 is adjacent to (and in this embodiment contacts) the tensioning surface 334 of the tensioning plate 330 (or the upper surface of the upper portion of the strap if the strap has been inserted into the strapping tool 50). When the rocker 700 is in the strapinsertion position, the tensioning-and-welding wheel 450 is spaced-apart from the tensioning surface 334 of the tensioning plate 330 to enable two overlapping portions of the strap to be inserted between the tensioning-and-welding wheel 450 and the tensioning surface 334. One or more springs or other biasing elements (not shown) bias the rocker 700 to the tensioning-and- welding position. In other embodiments, the motor 600 is operably connected to the transmission assembly 500 in any suitable manner that enables the motor 600 to be fixed relative to — i.e., not pivotable with — the rocker 700.

[0054] The rocker lever 800, which is shown in Figure 1A, is operably connected to the rocker 700 (directly or via suitable linkages, gearing, and/or other components) and configured to move the rocker 700 relative to the support 300 from the tensioning-and-welding position to the strap-insertion position. Specifically, the rocker lever 800 is pivotable from a home position (shown in Figure 1 A) spaced-apart from the handle section 150 of the housing 100 of the strapping tool 50 to an actuated position (not shown) closer to the handle section 150 to move the rocker 700 from the tensioning-and-welding position to the strap-insertion position.

[0055] The display assembly 1300, which is shown in Figures 1A and IB, includes a suitable display screen 1310 with a touch panel 1320. The display screen 1310 is configured to display information regarding the strapping tool 50 (at least in this embodiment), and the touch screen 1320 is configured to receive operator inputs such as a desired strap tension and desired weld cooling time. A display controller (not shown) may control the display screen 1310 and the touch panel 1320 and, in these embodiments, is communicatively connected to the controller 1600 to send signals to the controller 1600 and to receive signals from the controller 1600. Other embodiments of the strapping tool do not include a touch panel. Still other embodiments of the strapping tool do not include a display assembly. Certain embodiments of the strapping tool include a separate pushbutton panel instead of a touch panel beneath or integrated with the display screen.

[0056] The actuating assembly 1400, which is shown in Figures 1A and IB, is configured to receive operator input to start operation of the tensioning and sealing cycles. In this example embodiment, the actuating assembly 1400 includes first and second pushbutton actuators 1410 and 1420 that, depending on the operating mode of the strapping tool 50, initiate the tensioning and/or sealing cycles as described below. Other embodiments of the strapping tool 50 do not have an actuating assembly 1400 and instead incorporate its functionality into the display assembly 1300. For instance, in one of these embodiments two areas of the touch panel define virtual buttons that have the same functionality as mechanical pushbutton actuators.

[0057] The controller 1600, which is shown in Figure IB, includes a processing device (or devices) communicatively connected to a memory device (or devices). For instance, the controller may be a programmable logic controller. The processing device may include any suitable processing device such as, but not limited to, a general-purpose processor, a specialpurpose processor, a digital-signal processor, one or more microprocessors, one or more microprocessors in association with a digital-signal processor core, one or more applicationspecific integrated circuits, one or more field-programmable gate array circuits, one or more integrated circuits, and/or a state machine. The memory device may include any suitable memory device such as, but not limited to, read-only memory, random-access memory, one or more digital registers, cache memory, one or more semiconductor memory devices, magnetic media such as integrated hard disks and/or removable memory, magneto-optical media, and/or optical media. The memory device stores instructions executable by the processing device to control operation of the strapping tool 50. The controller 1600 is communicatively and operably connected to the motor 600, the display assembly 1300, the actuating assembly 1400, and the sensor(s) 1700 and configured to receive signals from and to control those components. The controller 1600 may also be communicatively connectable (such as via Wi-Fi, Bluetooth, near- field communication, or other suitable wireless communications protocol) to an external device, such as a computing device, to send information to and receive information from that external device.

[0058] The controller 1600 is configured to operate the strapping tool in one of three operating modes (as set by the operator): (1) a manual operating mode; (2) a semi-automatic operating mode; and (3) an automatic operating mode. In the manual operating mode, the controller 1600 operates the motor 600 to cause the tensioning-and-welding wheel 450 to rotate responsive to the first pushbutton actuator 1410 being actuated and maintained in its actuated state. The controller 1600 operates the motor 600 to cause the welding actuator 420 to move the tensioning-and-welding wheel 450 longitudinally to carry out the sealing cycle responsive to the second pushbutton actuator 1420 being actuated. In the semi-automatic operating mode, the controller 1600 operates the motor 600 to cause the tensioning-and-welding wheel 450 to rotate responsive to the first pushbutton actuator 1410 being actuated and maintained in its actuated state. Once the controller 1600 determines that the tension in the strap reaches the (preset) desired strap tension, the controller 1600 automatically operates the motor 600 to cause the welding actuator 420 to move the tensioning-and-welding wheel 450 longitudinally to carry out the sealing cycle (without requiring additional input from the operator). In the automatic operating mode, the controller 1600 operates the motor 600 to cause the tensioning-and-welding wheel 450 to rotate responsive to the first pushbutton actuator 1410 being actuated. Once the controller 1600 determines that the tension in the strap reaches the (preset) desired strap tension, the controller 1600 automatically operates the motor 600 to cause the welding actuator 420 to move the tensioning-and-welding wheel 450 longitudinally to carry out the sealing cycle (without requiring additional input from the operator). [0059] The sensors 1700 include any suitable sensors, such as microswitches, optical sensors, ultrasonic sensors, magnetic position sensors, and the like, configured to detect the position of certain components of the strapping tool 50 and to send appropriate signals to the controller 1600. The sensors 1700 may include, for instance: one or more rocker-position sensors configured to detect when the rocker 700 is in its tensioning-and-welding position and/or its strap-insertion position, one or more actuating-assembly sensors configured to detect actuation of the first and second pushbutton actuators 1410 and 1420, and one or more tensioning-and- welding-wheel sensors configured to detect when the tensioning wheel is in or has moved away from its tensioning longitudinal position.

[0060] The power supply is electrically connected to (via suitable wiring and other components) and configured to power several components of the strapping tool 50, including the motor 600, the display assembly 1300, the actuating assembly 1400, the controller 1600, and the sensor(s) 1700. The power supply is a rechargeable battery (such as a lithium-ion or nickel cadmium battery) in this example embodiment, though it may be any other suitable electric power supply in other embodiments. The power supply is sized, shaped, and otherwise configured to be received in the receptacle 122 defined by the rear housing section 120 of the housing 100. The strapping tool 50 includes one or more battery-securing devices (not shown) to releasably lock the power supply in place upon receipt in the receptacle. Actuation of a release device of the strapping tool 50 or the power supply unlocks the power supply from the housing 100 and enables an operator to remove the power supply from the receptacle 122.

[0061] Use of the strapping tool 50 to carry out a strapping cycle including: (1) a tensioning cycle in which the strapping tool 50 tensions strap around a load; and (2) a sealing cycle in which the strapping tool 50 attaches two overlapping portions of the strap to one another via friction welding and cuts the strap from the strap supply is described below. Initially, the rocker 700, the rocker lever 800, and the welding actuator 420 are in their respective home positions, meaning the tensioning wheel is initially in its tensioning longitudinal position. The strapping tool 50 is in the automatic mode for the purposes of this example.

[0062] The operator pulls the strap leading-end first from a strap supply, wraps the strap around the load, and positions the leading end of the strap below another portion of the strap. The operator then pulls the rocker lever 800 from its home position to its actuated position to raise the rocker 700 from its tensioning-and-welding position to its strap-insertion position. While holding the rocker lever 800 in its actuated position, the operator introduces the overlapping portions of the strap between the tensioning-and-welding wheel 450 and the tensioning surface 334 of the tensioning plate 330. The operator then releases the rocker lever 800, which causes one or more biasing elements to force the rocker 700 and the rocker lever 800 back to their respective home positions. This causes the outer surface 452s of the tensioning-and- welding wheel 450 to engage the top surface of the upper strap portion and force the bottom surface of the lower strap portion against the tensioning surface 334 of the tensioning plate 330.

[0063] The operator then actuates the first pushbutton actuator 1410 to initiate the strapping cycle. In response, the controller 1600 starts the tensioning cycle by controlling the motor 600 to begin rotating the output shaft 600s in the tensioning rotational direction TD. As explained in detail above, this causes the tensioning-and-welding wheel 450 to begin rotating in the tensioning rotational direction TD and pull the upper portion of the strap over the lower portion of the strap, thereby tensioning the strap around the load. Throughout the tensioning cycle, the controller 1600 monitors the current drawn by the motor 600. When this current reaches a preset value that is correlated with the preset desired strap tension for this strapping cycle, the controller 1600 stops the motor 600, thereby completing the tensioning cycle.

[0064] The controller 1600 then automatically starts the sealing cycle by controlling the motor 600 to begin rotating the motor output shaft 600s in the welding rotational direction WD. As explained in detail above, this causes the welding actuator 420 to rotate relative to the mount 410 and the tensioning-and-welding wheel 450 in the welding rotational direction WD, which causes the tensioning-and-welding wheel 450 to oscillate in the longitudinal direction (along the tensioning-and-wel ding-wheel rotational axis A450) as the spacers 430 are sequentially brought into and out of contact with the peaks and valleys 424p and 424v of the actuating surface 424s of the welding actuator 420. The combination of the downward pressure the tensioning- and-welding wheel 450 exerts on the strap and the rapid longitudinal oscillation of the tensioning-and-welding wheel 450 melts the two overlapping portions of the strap and fuses them together. After a certain period of time elapses, the controller 1600 stops the motor 600, thereby completing the sealing cycle.

[0065] The strapping tool of the present disclosure solves the above problems. First, using the tensioning-and-welding wheel to tension and weld the strap eliminates the need for a separate welding assembly (and in some embodiments a separate welding motor), which renders the tool lighter and easier to use for prolonged periods of time compared to traditional strapping tools. Second, elimination of the separate welding assembly enables the base of the support to be shorter (in the longitudinal direction of the strap) than the base of traditional strapping tools, which enables the strapping tool of the present disclosure to be used for more applications (such as to strap curved loads with relatively small radii).

[0066] Other embodiments of the strapping tool do not include a rocker lever that the operator pulls to pivot the rocker from the tensioning-and-welding position to the strap-insertion position. Rather, in these embodiments, the motor is operably connected (via suitable gearing, linkages, and/or other components) to the rocker and configured to pivot the rocker from the tensioning-and-welding position to the strap-insertion position. In these embodiments, the strapping tool includes a suitable input device, such as a trigger supported by the handle portion of the housing, actuatable to cause the motor to pivot the rocker from the tensioning-and-welding position to the strap-insertion position

[0067] In the example embodiment described above, only one motor is used to drive the mount of the tensioning-and-welding assembly and the welding actuator during the tensioning and sealing cycles. In other embodiments, the strapping tool includes separate tensioning and sealing motors. In these embodiments, the tensioning motor is operably connected to the first transmission-gear assembly to rotate the mount and the tensioning-and-welding wheel mounted thereto during the tensioning cycle, and the sealing motor is operably connected to the second transmission-gear assembly to rotate the welding actuator (and thereby oscillating the tensioning-and-welding wheel in the longitudinal direction) during the sealing cycle. Figure 10 shows the working assembly and the support of one such strapping tool. In this illustrated embodiment, the motor 600 is a first motor that is operably connected to the tensioning-and- welding wheel via the first transmission-gear assembly. The strapping tool includes a second motor M2 that is operably connected to the welding actuator via the second transmission-gear assembly. For instance, the second motor M2 directly drives the driven shaft. In further embodiments in which the strapping tool includes a motor operably connected to the rocker and configured to pivot the rocker, the strapping tool includes a third motor for that purpose.

[0068] In the example embodiment described above, the flange of the mount of the tensioning-and-welding assembly is fixed in rotation relative to the welding actuator, which is rotatable (driven by the second transmission-gear assembly) relative to the flange. In other embodiments, the welding actuator is fixed in rotation relative to the mount (such as via a keyed or splined connection), and the flange is rotatable relative to the welding actuator and driven in rotation by the second transmission-gear assembly.

[0069] Other embodiments of the strapping tool may include fewer assemblies, components, and/or features than those included in the strapping tool 50 described above and shown in the Figures. In other words, while the strapping tool 50 includes all of the assemblies, components, and features described above, they are independent of one another and may be independently included in other strapping tools.

[0070] In the example embodiment described above, the tensioning-and-welding assembly is employed as part of a portable handheld strapping tool. The tensioning-and-welding assembly may be incorporated into any other type of strapping device, such as a general-purpose strapping machine or the strapping head of a special-purpose strapping machine.

[0071] Other embodiments of the strapping device may use any suitable components and/or transmission to operatively connect a motor to the tensioning-and-welding wheel such that the motor can move the tensioning-and-welding wheel longitudinally between the tensioning longitudinal position and the actuated longitudinal position. For instance, in certain embodiments, the strapping device includes a linear actuator operably connected to the tensioning-and-welding wheel and configured to move the tensioning-and-welding wheel longitudinally between the tensioning longitudinal position and the actuated longitudinal position.