WO2024081475A1

WO2024081475A1 - Strapping device with motor-driven rocker

Info

Publication number: WO2024081475A1
Application number: PCT/US2023/073956
Authority: WO
Inventors: Mirco Neeser
Original assignee: Signode Industrial Group Llc
Priority date: 2022-10-14
Filing date: 2023-09-12
Publication date: 2024-04-18

Abstract

Various embodiments of the present disclosure provide a strapping device with a rocker movable from a tensioning position to a strap-insertion position to increase a distance between a tension wheel and a tension plate of the strapping device. The strapping device also includes a motor and a decoupling assembly. When the decoupling assembly is in a coupled configuration, the decoupling assembly operably connects the motor to the rocker such that operation of the motor moves the rocker from the tensioning position to the strap-insertion position. When the decoupling assembly is in a release configuration, the decoupling assembly does not operably connect the motor to the rocker such that operation of the motor does not move the rocker from the tensioning position to the strap-insertion position.

Description

STRAPPING DEVICE WITH MOTOR-DRIVEN ROCKER

Priority

[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63/379,552, filed October 14, 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 strap around a load and to attach overlapping portions of the strap to one another to form a tensioned strap loop around the load.

Background

[0003] Strapping devices are configured 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. Battery-powered strapping tools are one type of strapping device. 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 one or more (depending on the type of strapping tool) of these overlapped strap portions into the strapping tool and actuates one or more buttons to initiate: (1) a tensioning cycle during which a tensioning assembly tensions the strap around the load; and (2) after completion of the tensioning cycle, a sealing cycle during which a sealing assembly attaches the overlapped strap portions to one another (thereby forming a tensioned strap loop around the load) and during the strap is cut from the strap supply.

[0004] How the strapping tool attaches overlapping portions of the strap to one another during the sealing cycle depends on the type of strapping tool and the type of strap. Certain strapping tools configured for plastic strap (such as polypropylene strap or polyester strap) include friction welders, heated blades, or ultrasonic welders configured to attach the overlapping portions of the strap to one another. Some strapping tools configured for plastic strap or metal strap (such as steel strap) include jaws that mechanically deform (referred to as “crimping” in the strapping industry) or cut notches into (referred to as “notching” in the strapping industry) a seal element positioned around the overlapping portions of the strap to attach them to one another. Other strapping tools configured for metal strap include punches and dies configured to form a set of mechanically interlocking cuts in the overlapping portions of the strap to attach them to one another (referred to in the strapping industry as a “sealless” attachment).

[0005] Since strapping tool operators can use handheld strapping tools hundreds of times each day, there is a continuing need to make the strapping tools as easy-to-use as possible (without sacrificing performance) and to reduce operator fatigue.

Summary

[0006] Various embodiments of the present disclosure provide a strapping device with a rocker movable from a tensioning position to a strap-insertion position to increase a distance between a tension wheel and a tension plate of the strapping device. The strapping device also includes a motor and a decoupling assembly. When the decoupling assembly is in a coupled configuration, the decoupling assembly operably connects the motor to the rocker such that operation of the motor moves the rocker from the tensioning position to the strap-insertion position. When the decoupling assembly is in a release configuration, the decoupling assembly does not operably connect the motor to the rocker such that operation of the motor does not move the rocker from the tensioning position to the strap-insertion position.

Brief Description of the Figures

[0007] Figures 1A and IB are perspective views of one example embodiment of a strapping tool of the present disclosure.

[0008] Figure 1C is a block diagram of certain components of the strapping tool of Figures 1A and IB.

[0009] Figures 2A-2C are diagrammatic views of the strapping tool of Figures 1A and IB securing a load to a pallet. [0010] Figure 2D is a perspective view of a friction-weld strap joint formed by the strapping tool of Figure 1 A to attach two overlapping portions of strap.

[0011] Figures 3A and 3B are perspective views of the working assembly of the strapping tool of Figures 1A and IB.

[0012] Figure 4A is a perspective view of the tensioning-assembly of the working assembly of Figures 3A and 3B.

[0013] Figure 4B is an exploded perspective view of the tensioning-assembly of Figure 4 A.

[0014] Figure 4C is a cross-sectional perspective view of the tensioning-assembly of Figure 4 A taken along line 4C-4C of Figure 4 A.

[0015] Figures 5 A and 5B are perspective views of the switching assembly of the working assembly of Figures 3A and 3B.

[0016] Figure 6A is a perspective view of the first and second decoupling assemblies of the switching assembly of Figures 5 A and 5B.

[0017] Figure 6B is an exploded perspective view of the first and second decoupling assemblies of Figure 6A.

[0018] Figure 6C is a cross-sectional perspective view of part of the switching assembly of Figures 5 A and 5B taken along line 6C-6C of Figure 5 A, which extends through the first and second decoupling assemblies of Figure 6 A.

[0019] Figures 7A and 7B are perspective views of the trigger assembly of the switching assembly of Figures 5 A and 5B.

[0020] Figure 8A is a side view of part of the working assembly of Figures 3 A and 3B with the tensioning assembly and the trigger assembly in their respective home positions and the first decoupling assembly in its release configuration.

[0021] Figure 8B is a side view corresponding to Figure 8A but with the trigger assembly in its actuated position and the first decoupling assembly in its coupled configuration.

[0022] Figure 8C is a cross-sectional view corresponding to Figure 8B taken along line 8C-8C of Figure 4C.

[0023] Figure 8D is a side view corresponding to Figure 8B but with the tensioning assembly in its strap-insertion position. [0024] Figure 8E is a cross-sectional view corresponding to Figure 8D taken along line 8C-8C of Figure 4C.

[0025] Figure 8F is a cross-sectional view corresponding to Figure 8A.

Detailed Description

[0026] 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.

[0027] Figures 1A-8F show one example embodiment of a strapping device of the present disclosure in the form of a strapping tool 50 (sometimes referred to as the “tool” in the Detailed Description for brevity) 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 the 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, a motor drives a tensioning assembly to carry 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, as shown in Figure 2C, the motor drives a sealing assembly to carry out a sealing cycle during which the strapping tool 50 connects the upper and lower portions UP and LP of the strap S to one another via friction welding to form a strap joint SJ, as shown in Figure 2D, and cuts the strap S from the strap supply.

[0028] The strapping tool 50 includes a housing 100 (Figures 1A and IB), a working assembly 200 (Figures 3A and 3B), a display assembly 1300 (Figures 1A-2), an actuating assembly 1400 (Figures 1A-1C), a power supply 1500, a controller 1600 (Figure 1 C), and one or more sensors 1700 (Figure 1 C).

[0029] The housing 100, which is shown in Figures 1A and IB, 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, a motor housing section 130, 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 sized, shaped, and otherwise configured to receive and at least partially enclose and/or support the power supply 1500 and the controller 1600. The motor housing section 130 extends between and connects the bottoms of the front and rear housing sections 110 and 120 and at least partially encloses and/or supports at least some of the components of the working assembly 200, including the motor 1100. The handle housing section 150 extends between and connects the tops of the front and rear housing sections 110 and 120 and defines a handle used 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 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.

[0030] The working assembly 200, which is best shown in Figures 3A and 3B, 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, attach the overlapping portions of the strap to one another, and cut the strap from the strap supply. The working assembly 200 includes: a support 300; a tensioning assembly 400; a switching assembly 500 including a first decoupling assembly 600, a second decoupling assembly 700, and a trigger assembly 800; a sealing assembly 900; a transmission 1000; and a motor 1100.

[0031] The support 300, which is best shown in Figures 3A and 3B, serves as a direct or indirect common mount for the tensioning assembly 400, the switching assembly 500, the sealing assembly 900, the transmission 1000, and the motor 1100. The support 300 includes a base 310, first and second tensioning-and-switching-assembly mounts 320 and 330 extending from the base 310, and a sealing-and-transmission assembly mount 340 extending from the base 310. The base 310 supports a tension plate 312 below the tension wheel 400w of the tensioning assembly 400 (described below) and a weld plate 314 below the weld shoe 912 of the sealing assembly 900 (described below).

[0032] The tensioning assembly 400, which is best shown in Figures 4A-4C, is operable in: (1) a tensioning mode to tension the strap around the load during the tensioning cycle; and (2) a rocker-movement mode to move the tensioning assembly 400 relative to the support 300. The tensioning assembly 400 includes a rocker 400r, tensioning-assembly gearing 400g, and a tension wheel 400w driven by the tensioning-assembly gearing 400g. The tension wheel 400w is supported by the tensioning-assembly gearing 400g, which is in turn supported by the rocker 400r.

[0033] The tensioning-assembly gearing 400g includes: a driven shaft 410; a tensioning-assembly freewheel 412; a first set of planet gears 414a, 414b, and 414c; a rockermovement ring gear 416; a rocker-movement intermediate gear 418, a rollback ring gear 420; a rollback intermediate gear 422; a second set of planet gears 424a, 424b, 424c, and 424d; a second carrier 426; a bushing 428; a third carrier 430; a third set of planet gears 432a, 432b, and 432c; and bearings 405b 1, 405b2, and 405b3. Certain components of the tensioning-assembly gearing 400g are centered on and certain components of the tensioning-assembly gearing 400g are rotatable about a tension-wheel rotational axis A4oow. The driven shaft 410 includes a shaft portion 410a and a first sun gear 410b at one end of the shaft portion 410a. The first set of planet gears 414a-414c are rotatably mounted (such as via respective bearings and mounting pins) to the rocker 400r. The rocker-movement ring gear 416 includes internal teeth 416it and external teeth 416ot. The rollback ring gear 420 includes internal teeth 420it and external teeth 420ot. The second carrier 426 includes a second planet-gear carrier 426a to which the second set of planet gears 424a-424d are rotatably mounted (such as via respective bearings and mounting pins) and a second sun gear 426b rotatable with (and here integrally formed with) the planet-gear carrier 426a about the tension-wheel rotational axis A400W. The third set of planet gears 432a-432c are rotatably mounted to the third carrier 430 (such as via respective bearings and mounting pins).

[0034] The shaft portion 410a of the driven shaft 410 extends through and is engaged by the tensioning-assembly freewheel 412, which is itself supported by and positioned within a bore defined through the rocker 400r. The tensioning-assembly freewheel 412 is configured to permit rotation of the driven shaft 410 relative to the rocker 400r in a tensioning rotational direction T — referred to as the tensioning direction T — and to prevent rotation of the driven shaft 410 in a rollback direction TREV, which is the rotational direction opposite the tensioning direction T. The first sun gear 410b of the driven shaft 410 meshes with and the first set of planet gears 414a-414c. The first set of planet gears 414a-414c mesh with the internal teeth 416it of the rocker-movement ring gear 416. The bearing 405bl rotatably supports the rocker-movement ring gear 416 and separates it from the rocker 400r. The first sun gear 410b of the driven shaft 410 also meshes with and drivingly engages the second set of planet gears 424a- 424d. The second set of planet gears 424a-424d mesh with the internal teeth 420it of the rollback ring gear 420. The bushing 428 rotatably supports the rollback ring gear 420 and separates it from the third carrier 430. The third carrier 430 is fixedly mounted to the rocker 400r. The second sun gear 426b of the second carrier 426 meshes with and drivingly engages the third set of planet gears 532a-532c. The tension wheel 400w is rotatably mounted to the third carrier 430 via bearings 405b2 and 405b3 such that the third set of planet gears 432a-432c mesh with internal teeth (not labeled) of the tension wheel 400w. The tension wheel 400w is held in place longitudinally (in the direction of the tensioning-wheel axis A4oow) via a suitable retainer and suitable fasteners (not shown for clarity).

[0035] The tensioning assembly 400 is movably mounted to the support 300 via the rocker 400r and a tensioning-assembly mounting shaft 390 and configured to pivot relative to the support 300 — and particularly relative to the base 310 of the support 300 — under control of the motor 1100 (as described below) and about a rocker-pivot axis A4oor between a tensioning position (Figures 8A-8C and 8F) and a strap-insertion position (Figures 8D and 8E) When the tensioning assembly 400 is in the tensioning position, the tension wheel 400w is adjacent to the tension plate 312 of the support 300 (or the upper surface of the upper portion of the strap if the strap has been inserted into the strapping tool 50). When the tensioning assembly 400 is in the strap-insertion position, the tension wheel 400w is spaced-apart from the tension plate 312 to enable the overlapping upper and lower portions of the strap to be inserted between the tension wheel 400w and the tension plate 312. The weight of the tensioning assembly 400 and one or more springs or other biasing elements (not shown) bias the tensioning assembly 400 to the tensioning position.

[0036] Specifically, the tensioning-assembly mounting shaft 390 extends through openings defined through the first and second tensioning-and-switching-assembly mounts 320 and 330 of the support 300 and openings defined through first and second mounting ears 400rl and 400r2 of the rocker 400r. The mounting ears 400rl and 400r2 of the rocker 400r are positioned between the mounts 320 and 330 of the support 300. The rocker-movement intermediate gear 418 and the rollback intermediate gear 422 are rotatably mounted to the tensioning-assembly mounting shaft 390 and positioned between the mounting ears 400rl and 400r2 of the rocker 400r such that teeth of the rocker-movement intermediate gear 418 mesh with the external teeth 416ot of the rocker-movement ring gear 416, and teeth of the rollback intermediate gear 422 mesh with the external teeth 422ot of the rollback ring gear 422.

[0037] The switching assembly 500, which is best shown in Figures 5A and 5B, is configured to interact with the tensioning assembly 400 to control whether the tensioning assembly is in the tensioning mode or the rocker-movement mode. The switching assembly 500 includes a switching-assembly mount 505, the first decoupling assembly 600, the second decoupling assembly 700, and the trigger assembly 800. The switching-assembly mount 505 is attached to the tensioning-and-switching-assembly mounts 320 and 330 of the support 300 above the tensioning assembly 400 and serves as a common mount for the first and second decoupling assemblies 600 and 700 and the trigger assembly 800.

[0038] The first decoupling assembly 600, which is best shown in Figures 6A-6C, controls whether the rocker-movement intermediate gear 418 can rotate about the rocker axis A4001. This, in turn, controls whether the tensioning assembly 400 is in the tensioning mode or the rocker-movement mode. Generally, when the first decoupling assembly 600 is in a coupled configuration, the first decoupling assembly 600 prevents the rocker-movement intermediate gear 418 from rotating about the rocker axis A4oor, and operation of the motor 1 100 causes the tensioning assembly 400 to move from the tensioning position to the strap-insertion position. Conversely, when the first decoupling assembly 600 is in a release configuration, the rockermovement intermediate gear 418 is rotatable about the rocker axis A4oor, and operation of the motor 1100 does not cause the tensioning assembly 400 to move from the tensioning position to the strap-insertion position. The first decoupling assembly 600 includes a decoupling-assembly shaft 610, a first engageable element 620, a second engageable element 630, an expandable element 640, a sleeve 650, and a threaded fastener 660.

[0039] The decoupling-assembly shaft 610 includes a body 612 having a first end 612a having an irregular cross-section and second end 612b having radially extending teeth around its circumference. A first support 614 extends from the first end 612a. The first engageable element 620 comprises a tubular bushing having a cylindrical outer surface and an interior surface having a perimeter that matches the perimeter of the first end 612a of the body 612 of the decoupling-assembly shaft 610. The second engageable element 630 includes a tubular body 632 and an annular flange 634 at one end of the body 632. An opening 634o is defined through the flange 634. The expandable element 640 includes a torsion spring having a first end 640a and a second end 640b. The sleeve 650 includes a tubular body 652 having teeth 654 extending around its outer circumference. The body 652 defines an opening 652o.

[0040] As best shown in Figure 6C, the first engageable element 620 is mounted on the first end 612a of the body 612 of the decoupling-assembly shaft 610 for rotation therewith about a decoupling-assembly rotational axis Aeoo,7oo. The second engageable element 630 circumscribes the first support 614 of the body 612 of the decoupling-assembly shaft 610 and is positioned such that the body 632 is adjacent and coaxial with the first engageable element 620. The expandable element 640 circumscribes the first engageable element 620 and the body 632 of the second engageable element 630. The outer diameters of the first engageable element 620 and the body 632 of the second engageable element 630 are substantially the same and are equal to or larger than the resting inner diameter of the expandable element 640. This means that when the first decoupling assembly is in the coupled configuration (described below), the expandable element 640 exerts a compressive force on the first engageable element 620 and the body 632 of the second engageable element 630 that prevents those components (and the decouplingassembly shaft 610) from rotating relative to one another about the decoupling-assembly rotational axis Asoo, 700. The second end 640b of the expandable element 640 is received in the opening 634o defined through the flange 634 of the second engageable element 630. At least part of the decoupling-assembly shaft 610, the first engageable element 620, the second engageable element 630, and the expandable element 640 are housed within and circumscribed by the sleeve 650. The first end 640a of the expandable element is received in the opening 652o defined through the body 652 of the sleeve 650.

[0041] As best shown in Figure 6C, the first decoupling assembly 600 is mounted to the switching-assembly support 505 and operatively connected to the tensioning-assembly gearing 400g. More specifically, the first decoupling assembly 600 is mounted to the switchingassembly support 505 via a bearing 600b and the fastener 660, which fixes the second engageable element 630 in rotation relative to the switching-assembly support 505 such that the second engageable element 630 — and the second end 640b of the expandable element 640 received in the opening 634o of the flange 634 of the second engageable element 630 — cannot rotate relative to the switching-assembly support 505 about the decoupling-assembly rotational axis Aeoo, 700. An intermediary gear 510 mounted to (and freely rotatable relative to) the switching-assembly support 505 operably connects the body 612 of the decoupling-assembly shaft 610 to rocker-movement intermediary gear 418 of the tensioning-assembly gearing 400g. Specifically, the teeth on the second end 612b of the body 612 of the decoupling-assembly shaft 610 mesh with teeth of the intermediary gear 510, which mesh with the teeth of the rockermovement intermediary gear 418.

[0042] The first decoupling assembly 600 has a coupled configuration and a release configuration. Figure 6C shows the first decoupling assembly 600 in the coupled configuration. When the first decoupling assembly 600 is in the coupled configuration, the expandable element 640 exerts a compressive force on the first engageable element 620 and the body 632 of the second engageable element 630 that prevents them from rotating relative to one another about the decoupling-assembly rotational axis Asoo, 700. Since the body 632 of the second engageable element 630 is fixed in rotation relative to the switching-assembly support 505 and the decoupling-assembly shaft 610 is fixed in rotation with the first engageable element 620, the decoupling-assembly shaft 610 — and thus the intermediary gear 510 — is fixed in rotation relative to the switching-assembly support 505. Since the intermediary gear 510 meshes with the rockermovement intermediary gear 418, the first decoupling assembly 600 prevents the rocker- movement intermediary gear 418 from rotating about the rocker axis A4oor when in the coupled configuration.

[0043] The first decoupling assembly 600 is switchable (such as by the trigger assembly 800 as described below) from the coupled configuration to the release configuration to enable the first engageable element 620 and the decoupling-assembly shaft 610 to rotate relative to the second engageable element 630 about the decoupling-assembly rotational axis Aeoo, 700. As explained above, the second engageable element 630 and the second end 640b of the expandable element 640 (that is received in the opening 634o of the flange 634 of the second engageable element 630) are fixed in rotation relative to the switching-assembly support 505. To switch the first decoupling assembly 600 from the coupled configuration to the release configuration, the sleeve 650 is rotated about the decoupling-assembly rotational axis Aeoo, 700 from a coupled position to a release position in a release direction Reso relative to the switching-assembly support 505, the second end 640b of the expandable element 640, and the second engageable element 630. Since the first end 640a of the expandable element 640 is received in the opening 652o defined in the body 652 of the sleeve 650, the first end 640a rotates with the sleeve 650. As this occurs, the inner diameter of the expandable element 640 near its first end 640a begins expanding, and eventually expands enough (thereby reducing the compression force or eliminating it altogether) to enable the first engageable element 620 and the decoupling-assembly shaft 610 to rotate about the decoupling-assembly rotational axis Aeoo, 700 relative to the second engageable element 630 (and the expandable element 640). When the sleeve 650 is released, the first end 640a of the expandable element 640 biases the sleeve 650 to rotate in a coupling direction Ceso opposite the release direction Reso until the sleeve 650 reaches the coupled position (meaning the first decoupling assembly 600 is back in its coupled configuration).

[0044] The second decoupling assembly 700, which is best shown in Figures 6A- 6C, controls whether the rollback ring gear 422 can rotate about the tensioning-wheel axis A400W. Generally, when the second decoupling assembly 700 is in a coupled configuration, the second decoupling assembly 600 prevents the rollback ring gear 422 from rotating about the tensioningwheel axis A oow, which enables the motor to drive the tension wheel 400w to tension the strap and enables the tension wheel 400w to hold tension in the strap after the tensioning cycle is complete. Conversely, when the second decoupling assembly 700 is in a release configuration, the rollback ring gear 422 is rotatable about the tensioning-wheel axis A400W such that the tension wheel 400w can release the held tension The second decoupling assembly 700 includes a decoupling-assembly shaft 710, a first engageable element 720, a second engageable element 730, an expandable element 740, a sleeve 750, a threaded fastener 760, and a gear 780.

[0045] The decoupling-assembly shaft 710 includes a body 712 having a first end 712a having an irregular cross-section and second end 712b having radially extending teeth around its circumference. A first support 714 extends from the first end 712a. The first engageable element 720 comprises a tubular bushing having a cylindrical outer surface and an interior surface having a perimeter that matches the perimeter of the first end 712a of the body 712 of the decoupling-assembly shaft 710. The second engageable element 730 includes a tubular body 732 and an annular flange 734 at one end of the body 732. An opening 734o is defined through the flange 734. The expandable element 740 includes a torsion spring having a first end 740a and a second end 740b. The sleeve 750 includes a tubular body 752 having teeth 754 extending around its outer circumference. The body 752 defines an opening 752o.

[0046] As best shown in Figure 6C, the first engageable element 720 is mounted on the first end 712a of the body 712 of the decoupling-assembly shaft 710 for rotation therewith about the decoupling-assembly rotational axis A6oo,7oo. The second engageable element 730 circumscribes the first support 714 of the body 712 of the decoupling-assembly shaft 710 and is positioned such that the body 732 is adjacent and coaxial with the first engageable element 720. The expandable element 740 circumscribes the first engageable element 720 and the body 732 of the second engageable element 730. The outer diameters of the first engageable element 720 and the body 732 of the second engageable element 730 are substantially the same and are equal to or larger than the resting inner diameter of the expandable element 740. This means that when the second decoupling assembly is in a coupled configuration (described below), the expandable element 740 exerts a compressive force on the first engageable element 720 and the body 732 of the second engageable element 730 that prevents those components (and the decouplingassembly shaft 710) from rotating relative to one another about the decoupling-assembly rotational axis Aeoo, 700. The second end 740b of the expandable element 740 is received in the opening 734o defined through the flange 734 of the second engageable element 730. At least part of the decoupling-assembly shaft 710, the first engageable element 720, the second engageable element 730, and the expandable element 740 are housed within and circumscribed by the sleeve 750. The first end 740a of the expandable element is received in the opening 752o defined through the body 752 of the sleeve 750. The gear 780 is mounted to the second end 712b of the body 712 of the decoupling-assembly shaft 710 such that the gear 780 is fixed in rotation with the decoupling-assembly shaft 710.

[0047] As best shown in Figure 6C, the second decoupling assembly 700 is mounted to the switching-assembly support 505 and operatively connected to the tensioning-assembly gearing 400g. More specifically, the second decoupling assembly 700 is mounted to the switching-assembly support 505 via a bearing 700b and the fastener 760, which fixes the second engageable element 730 in rotation relative to the switching-assembly support 505 such that the second engageable element 730 — and the second end 740b of the expandable element 740 received in the opening 734o of the flange 734 of the second engageable element 730 — cannot rotate relative to the switching-assembly support 505 about the decoupling-assembly rotational axis Aeoo,7oo. The gear 780 operably connects the body 712 of the decoupling-assembly shaft 710 to rollback ring gear 422 of the tensioning-assembly gearing 400g. Specifically, the teeth on the gear 780 mesh with the external teeth 422ot of the rollback ring gear 422.

[0048] The second decoupling assembly 700 has a coupled configuration and a release configuration. Figure 6C shows the second decoupling assembly 700 in the coupled configuration. When the second decoupling assembly 700 is in the coupled configuration, the expandable element 740 exerts a compressive force on the first engageable element 720 and the body 732 of the second engageable element 730 that prevents them from rotating relative to one another about the decoupling-assembly rotational axis Aeoo, 700. Since the body 732 of the second engageable element 730 is fixed in rotation relative to the switching-assembly support 505 and the decoupling-assembly shaft 710 is fixed in rotation with the first engageable element 720, the decoupling-assembly shaft 710 — and thus the gear 780 — is fixed in rotation relative to the switching-assembly support 505. Since the gear 780 meshes with the rollback ring gear 422, the second decoupling assembly 700 prevents the rollback ring gear 422 from rotating about the tensioning-wheel axis A400W when in the coupled configuration.

[0049] The second decoupling assembly 700 is switchable (such as by the trigger assembly 800 as described below) from the coupled configuration to the release configuration to enable the first engageable element 720 and the decoupling-assembly shaft 710 to rotate relative to the second engageable element 730 about the decoupling-assembly rotational axis Aeoo, 700. As explained above, the second engageable element 730 and the second end 740b of the expandable element 740 (that is received in the opening 734o of the flange 734 of the second engageable element 730) are fixed in rotation relative to the switching-assembly support 505. To switch the second decoupling assembly 700 from the coupled configuration to the release configuration, the sleeve 750 is rotated about the decoupling-assembly rotational axis Aeoo, 700 from a coupled position to a release position in a release direction R750 relative to the switching-assembly support 505, the second end 740b of the expandable element 740, and the second engageable element 730. Since the first end 740a of the expandable element 740 is received in the opening 752o defined in the body 752 of the sleeve 750, the first end 740a rotates with the sleeve 750. As this occurs, the inner diameter of the expandable element 740 near its first end 740a begins expanding, and eventually expands enough (thereby reducing the compression force or eliminating it altogether) to enable the first engageable element 720 and the decoupling-assembly shaft 710 to rotate about the decoupling-assembly rotational axis Aeoo, 700 relative to the second engageable element 730 (and the expandable element 740). When the sleeve 750 is released, the first end 740a of the expandable element 740 biases the sleeve 750 to rotate in a coupling direction C750 opposite the release direction R750 until the sleeve 750 reaches the coupled position (meaning the second decoupling assembly is back in its coupled configuration).

[0050] The trigger assembly 800, which is best shown in Figures 7A and 7B, is operably connected to the first and second decoupling assemblies 600 and 700 to switch them between their coupled and release configurations. The trigger assembly 800 includes a triggerassembly body 810, a first decoupling assembly actuator 820, and a second decoupling assembly actuator 830.

[0051] The trigger-assembly body 810 includes a trigger 812, spaced-apart first and second mounting ears 814 and 816 extending from the trigger 812, and an actuating rod 818 extending between the mounting ears 814 and 816. The first and second mounting ears 814 and 816 define aligned openings 814o and 8160, respectively, therethrough. The first decoupling assembly actuator 820 includes an L-shaped actuated arm 822, a gear arm 824 connected to the actuated arm 822, and a gear 826 at a free end of the gear arm 824. Similarly, the second decoupling assembly actuator 830 includes an L-shaped actuated arm 832, a gear arm 834 connected to the actuated arm 832, and a gear 836 at a free end of the gear arm 834.

[0052] The first and second mounting ears 814 and 816 of the trigger-assembly body 810 are pivotably mounted to the switching-assembly mount 505 via pivot pins (not labeled). The first and second decoupling assembly actuators 820 and 830 are pivotably mounted to a actuator mounting pin 890 that extends through the openings 814o and 816o defined through the first and second mounting ears 814 and 816 of the trigger-assembly body 810 and that is secured (such as via retaining rings) to the switching-assembly mount 505. The actuated arms 822 and 832 of the first and second decoupling assembly actuators 820 and 830 are above the actuating rod 818.

[0053] The trigger-assembly body 810 is pivotable relative to the switchingassembly mount 505 about a trigger-assembly-body axis Asio between a home position (Figures 8A and 8F) and an actuated position (Figures 8B-8E). A biasing element (not shown), such as a compression spring, biases the trigger-assembly body 810 to the home position. When the trigger-assembly body 810 is in the home position, the actuator mounting pin 890 is positioned at the top of the openings 814o and 816o defined through the first and second mounting ears 814 and 816 of the trigger-assembly body 810. Conversely, when the trigger-assembly body 810 is in the actuated position, the actuator mounting pin 890 is positioned at the bottom of the openings 814o and 816o.

[0054] The first and second decoupling assembly actuators 820 and 830 are pivotable relative to the switching-assembly mount 505 about a actuator axis As2o, 830 between respective home positions (Figures 8A and 8F) and respective actuated positions (Figures 8B- 8E). A biasing element (not shown), such as a compression spring, biases the first and second decoupling assembly actuators 820 and 830 to their respective home positions. The first and second decoupling assembly actuators 820 and 830 are in their respective home positions when the trigger-assembly body 810 is in its home position. The trigger-assembly body 810 is operably connected to the first and second decoupling assembly actuators 820 and 830 to move the first and second decoupling assembly actuators 820 and 830 from their respective home positions to their respective actuated positions. Specifically, as the trigger-assembly body 810 moves from its home position toward its actuated position, the actuating rod 818 engages the actuated arms 822 and 832 of the first and second decoupling assembly actuators 820 and 830 and forces them to pivot about the actuator axis A«2o 830 until they (and the trigger-assembly body 810) reach their respective actuated positions.

[0055] The first and second decoupling assembly actuators 820 and 830 are positioned, oriented, and otherwise configured to control which configuration the first and second decoupling assemblies 600 and 700, respectively are in. As described in detail below, use of the first and second decoupling assembly actuators 820 and 830 and the first and second decoupling assemblies 600 and 700 enables the tensioning assembly 400 to switch between the tensioning and rocker-movement modes and, therefore, enables the motor 1100 to carry out two different functions when rotating the driven shaft 410 in the tensioning direction T depending on which decoupling assembly is in the coupled configuration and which is in the release configuration.

[0056] Turning to the first decoupling assembly actuator 820, when the first decoupling assembly actuator 820 is in its home position, as shown in Figure 8F, the first decoupling assembly 600 is in its release configuration. The teeth of the gear 826 are meshed with the teeth 654 of the sleeve 650 to hold the sleeve 650 in its release position and prevent the sleeve 650 from rotating back to its coupled position. When the first decoupling assembly actuator 820 moves from its home position to its actuated position, as shown in Figure 8C, the gear 826 moves to enable the sleeve 650 to rotate in the coupling direction Ceso back to its coupled position such that the first decoupling assembly 600 is in its coupled configuration. In this embodiment, the gear 826 unmeshes from the teeth 654 of the sleeve 650 near the end of its movement. When the first decoupling assembly actuator 820 moves from its actuated position back to its home position, the gear 826 again meshes with the teeth 654 of the sleeve 650 and rotates the sleeve 650 in the release direction Reso until the sleeve 650 reaches its release position and the first decoupling assembly 600 is in its release configuration.

[0057] Turning to the second decoupling assembly actuator 830, when the second decoupling assembly actuator 830 is in its home position, as shown in Figure 8A, the second decoupling assembly 700 is in its coupled configuration. The teeth of the gear 836 are unmeshed from the teeth 754 of the sleeve 750, and the sleeve 750 is in its coupled position. When the second decoupling assembly actuator 830 moves from its home position to its actuated position, as shown in Figure 8B, the gear 836 meshes with the teeth 754 of the sleeve 750 and rotates the sleeve 750 in the release direction R750 until the sleeve 750 reaches its release position and the second decoupling assembly 700 is in its release configuration. When the second decoupling assembly actuator 830 moves from its actuated position back to its home position, the gear 836 moves to enable the sleeve 750 to rotate in the coupling direction C750 back to its coupled position such that the second decoupling assembly 700 is in its coupled configuration. In this embodiment, the gear 836 unmeshes from the teeth 754 of the sleeve 750 near the end of its movement.

[0058] The sealing assembly 900, which is best shown in Figure 3A, is configured to 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 sealing assembly 900 includes a weld arm 910, a weld shoe 912, a cutter 914, a linkage 916, and an eccentric shaft (not shown). The weld shoe 912 is slidably mounted to the weld arm 910 such that the weld shoe 912 can slide relative to the weld arm 910. The cutter 914 is mounted to the weld arm 910. The weld arm 910 is pivotably mounted to the sealing-and-transmission assembly mount 340 of the support 300 and pivotable relative to the support 300 and the weld plate 314 about a weld-arm axis A910 between a home position (Figure 3 A) in which the weld shoe 912 is spaced-apart from the weld plate 314 and a welding position (not shown) in which the weld shoe 912 is adjacent the weld plate 314 and positioned to weld the strap. The linkage 916 operably connects the transmission 1000 to the weld arm 910 such that the transmission 1000 can move the weld arm 910 from the release home position to the welding position (and vice-versa in certain embodiments). The eccentric is operably connected to the weld shoe 912 and configured to, when rotated, cause the weld shoe 912 to oscillate. A toothed belt 990 operably connects the transmission 1000 to the eccentric to rotate the eccentric.

[0059] The transmission 1000, which is best shown in Figures 3 A and 3B, is driven by the motor 1100, is operably connected to the tensioning assembly 400 and configured to cause the tension wheel 400w to rotate in the tensioning direction T to tension the strap and to cause the tensioning assembly 400 to pivot to its strap-insertion position, and is operably connected to the sealing assembly 900 and configured to cause the sealing assembly 900 to attach the overlapping portions of the strap to one another. The transmission 1000 includes transmission gearing 1010 including a drive gear 1012 (which is a bevel pinion gear in this example embodiment) and an offset coupling 1020 including a driven gear 1022 (which is a bevel wheel gear in this example embodiment). The transmission gearing 1010 and the offset coupling 1020 are mounted to the sealing-and-transmission assembly mount 340 of the support such that the drive gear 1012 meshes with the driven gear 1022.

[0060] The transmission gearing 1010 includes suitable components (such as gears, bearing, and freewheels) that transmit rotational movement of the output shaft of the motor 1100 in a first drive direction to the drive gear 1012 to rotate the drive gear 1012 (but not to drive any components of the sealing assembly 900 in this example embodiment). The drive gear 1012 drives the driven gear 1022 to rotate in the tensioning direction T, and the other components of the offset coupling transmit the rotational movement of the driven gear 1022 to the driven shaft 410 of the tensioning assembly 400 to rotate the driven shaft 410 in the tensioning direction T. The components of the transmission gearing 1010 transmit rotational movement of the output shaft of the motor 1100 in a second drive direction opposite the first drive direction to: (1) the linkage 916 of the sealing assembly 900 to move the weld arm 910 from its home position to its welding position; and (2) the toothed belt 990 to rotate the eccentric and cause the weld shoe 912 to oscillate (but not to drive the drive gear 912 in this example embodiment).

[0061] This is merely one example transmission assembly, and the strapping tool may include any suitable transmission assembly or assemblies operably connecting one or more motors to the tensioning and sealing assemblies to drive those assemblies.

[0062] The motor 1100, which is best shown in Figures 3 A and 3B, is operably connected to (via the transmission 1000) the tensioning assembly 400 and the sealing assembly 900 and is configured to drive those assemblies as explained herein. The motor 1100 includes the output shaft (not shown) referenced above. The motor 1100 is an electric motor in this example embodiment but may be any suitable motor.

[0063] The display assembly 1300, which is shown in Figures 1A-1C, 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.

[0064] The actuating assembly 1400, which is shown in Figures 1A-1C, 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.

[0065] The controller 1600, which is shown in Figure 1C, 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 1100, 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, nearfield 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.

[0066] The controller 1600 is configured to operate the strapping tool in one of three operating modes to carry out the strapping cycle: (1) a manual operating mode; (2) a semiautomatic operating mode; and (3) an automatic operating mode. In the manual operating mode, the controller 1600 operates the motor 1100 to cause the tension wheel 400w to rotate responsive to the first pushbutton actuator 1410 being actuated and maintained in its actuated state. The controller 1600 operates the motor 1100 to cause the sealing assembly 900 to carry out the sealing cycle responsive to the second pushbutton actuator 1420 being actuated. In the semiautomatic operating mode, the controller 1600 operates the motor 1100 to cause the tension wheel 400w 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 1100 to cause the sealing assembly 900 to carry out the sealing cycle (without requiring additional input from the operator). In the automatic operating mode, the controller 1600 operates the motor 1100 to cause the tension wheel 400w 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 1100 to cause the sealing assembly 900 to carry out the sealing cycle (without requiring additional input from the operator).

[0067] 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 tensioning-assembly- position sensors configured to detect when the tensioning assembly 400 is in its tensioning position and/or its strap-insertion position; one or more trigger-position sensors configured to detect when the trigger-assembly body 810 is in its home position and/or its actuated position; and one or more actuating assembly sensors configured to detect actuation of the first and second pushbutton actuators 1410 and 1420.

[0068] The power supply 1500 is electrically connected to (via suitable wiring and other components) and configured to power several components of the strapping tool 50, including the motor 910, the display assembly 1300, the actuating assembly 1400, the controller 1600, and the sensor(s) 1700. The power supply 1500 includes 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 1500 is sized, shaped, and otherwise configured to be received in the receptacle defined by the rear housing section 120 of the housing 100. The strapping tool 50 includes one or more power-supply-securing devices (not shown) to releasably lock the power supply 1500 in place upon receipt in the receptacle. Actuation of a release device of the strapping tool 50 or the power supply 1500 unlocks the power supply 1500 from the housing 100 and enables an operator to remove the power supply 1500 from the receptacle.

[0069] Use of the strapping tool 50 to form a tensioned strap loop around a load is described below. Initially, the tensioning assembly 400 is in its tensioning position, the trigger body 810 is in its home position (meaning that the first decoupling assembly 600 is in its release configuration and the second decoupling assembly 700 is in its coupled configuration), and the weld arm 910 is in its home position, as shown in Figure 8A. The strapping tool 50 is in the automatic mode for the purposes of this example.

[0070] The operator pulls the strap leading-end first from a strap supply (not shown), wraps the strap around the load, and positions the leading end of the strap S below another portion of the strap to form upper and lower portions of strap. The operator then pulls the trigger 812 and in doing so moves the trigger body 810 from the home position to the actuated position, as shown in Figures 8B and 8C. As this occurs, and as described above, the first decoupling assembly actuator 820 switches the first decoupling assembly 600 from the release configuration to the coupled configuration, and the second decoupling assembly actuator 830 switches the second decoupling assembly 700 from the coupled configuration to the release configuration. Once one of the sensors 1700 detects that the trigger body 810 has reached the actuated position, the controller 1600 controls the motor 1100 to rotate the output shaft in the first drive direction.

[0071] As explained above, the transmission 1000 transmits this rotational movement of the output shaft to the drive shaft 410 of the tensioning assembly 400 and rotates it in the tensioning direction T. This causes the first sun gear 410b to rotate about the tensionwheel rotational axis A4oow in the tensioning direction T. The first sun gear 410b drives the first set of planet gears 414a-414c. Since the first set of planet gears 414a-414c are fixed in rotation about the tensioning-wheel axis A400W, they drive the rocker-movement ring gear 416 to rotate about the tension-wheel rotational axis A400W in the tensioning direction. Since the first decoupling assembly 600 is in its coupled configuration, the rocker-movement intermediate gear 418 is fixed in rotation. This results in the rocker-movement ring gear 416 “climbing” the rockermovement intermediate gear 418, as shown in Figures 8D and 8E, and as a result raising the tensioning assembly 400 toward its strap-insertion position. As this occurs, the first sun gear 410b also drives the second set of planet gears 424a-424d. Since the second decoupling assembly 700 is in its release configuration, it the rollback ring gear 420 is rotatable about the tension-wheel rotational axis Awow, and rotation of the second set of planet gears 424a-424d causes the rollback ring gear 420 to rotate about the tension-wheel rotational axis A400W in the tensioning direction rather than causing the second carrier 426 — and the tension wheel 400w — to rotate (though there may be a small amount of rotation due to drag torque). Once one of the sensors 1700 detects that the tensioning assembly 400 has reached its strap-insertion position, the controller 1600 controls the motor 1100 to stop rotating the output shaft. The tensioningassembly freewheel 412 prevents the driven shaft 410 from reversing, ensuring the tensioning assembly 400 remains in the strap-insertion position so long as the trigger-assembly body 810 remains in the actuated position. Accordingly, the tensioning-assembly gearing 400g operatively connects the motor 1100 and the transmission 1000 to the tensioning assembly 400 to move the tensioning assembly 400 from its tensioning position to its strap-insertion position.

[0072] While holding the trigger-assembly body 810 in its actuated position, the operator introduces the overlapping upper and lower portions of the strap between the tension wheel 400w and the tension plate 312 between and the weld shoe 912 and the weld plate 314. The operator then releases the trigger-assembly body 810, which causes various biasing elements to force the trigger-assembly body 810 back to its home position. As this occurs, and as described above, the first decoupling assembly actuator 820 switches the first decoupling assembly 600 from the coupled configuration to the release configuration, and the second decoupling assembly actuator 830 switches the second decoupling assembly 700 from the release configuration to the coupled configuration. When the first decoupling assembly actuator 820 switches to the release configuration, it enables the rocker-movement intermediate gear 418 to freely rotate, which (via the weight of the tensioning assembly 400 and a biasing element) enables the tensioning assembly 400 to move back to its tensioning position such that the tension wheel 400w engages the top surface of the upper portion of strap and forces the bottom surface of the lower portion of strap against the tension plate 312.

[0073] 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 1100 to rotate the output shaft in the first drive direction. As explained above, the transmission 1000 transmits this rotational movement of the output shaft to the drive shaft 410 of the tensioning assembly 400 and rotates it in the tensioning direction T. This causes the first sun gear 410b to rotate about the tension-wheel rotational axis A400W in the tensioning direction. The first sun gear 41 Ob drives the first set of planet gears 414a-414c. Since the first set of planet gears 414a-414c are fixed in rotation about the tensioning-wheel axis A400W, they drive the rocker-movement ring gear 416 to rotate about the tension-wheel rotational axis A-roow in the tensioning direction. Since the first decoupling assembly 600 is in its release configuration, the rocker-movement intermediate gear 418 is freely rotatable, and the rocker-movement ring gear 416 drives the rocker-movement intermediate gear 418 to rotate, as shown in Figure 8F.

[0074] As this occurs, the first sun gear 410b also drives the second set of planet gears 424a-424d. Since the second decoupling assembly 700 is in its coupled configuration, it prevents the rollback ring gear 420 from rotating about the tension-wheel rotational axis A400W, and rotation of the second set of planet gears 424a-424d causes the second carrier 426 — including the second sun gear 426b — to rotate about the tension-wheel rotational axis A400W in the tensioning direction. The second sun gear 426b drives the third set of planet gears 432a- 432c. Since the third carrier 430 cannot rotate about the tension-wheel rotational axis A400W, rotation of the third set of planet gears 432a-432c causes the tension wheel 400w to rotate about the tension-wheel rotational axis A400W in the tensioning direction. Accordingly, the tensioningassembly gearing 400g operatively connects the motor 1100 and the transmission 1000 to the tension wheel 400w to rotate the tension wheel 400w about the tension-wheel rotational axis A400W in the tensioning direction.

[0075] As the tension wheel 400w rotates in the tensioning direction, it pulls 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 1100. 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 1100, thereby terminating the tensioning cycle. At this point, the strap exerts a torque on the tension wheel 400w in the rollback direction TREV. The tension wheel 400w transmits this torque to the third set of planetary gears 432a-432c, which transmit this torque to the second sun gear 426b of the second carrier 426. The second set of planetary gears 424a-424d transmit this torque to the first sun gear 410b of the driven shaft 410 and to the rollback ring gear 420. The tensioning assembly freewheel 412 prevents the driven shaft 410 from rotating in the rollback direction TREV. The second decoupling assembly 700 is in its coupled configuration and prevents the rollback ring gear 420 from rotating in the rollback direction TREV. Accordingly, the torque the strap exerts on the tension wheel 400w is absorbed by components of the tensioning assembly 400 and the second decoupling assembly 700, enabling the tension wheel 400w to hold tension in the strap without rotating in the rollback direction TREV.

[0076] After completion of the tensioning cycle, the controller 1600 automatically starts the sealing cycle by controlling the motor 1100 to begin rotating the output shaft in the second drive direction. This causes the transmission 1000 to drive the toothed belt 990 to begin rotating the eccentric and oscillating the weld shoe 912 and pivot the weld arm 910 to its welding position. As the weld arm 910 reaches the welding position, the weld shoe 912 forces the overlapping upper and lower layers of strap against the weld plate 314 while the cutter 916 cuts the upper strap layer from the strap supply. The oscillating movement of the weld shoe 912 locally melts the portions of the upper and lower strap layers together. After a preset period of time, the controller 1600 controls the motor 1100 to stop rotating the output shaft, completing the sealing cycle.

[0077] After the sealing cycle is complete, the operator again pulls the trigger 812, and in doing so moves the trigger body 810 from the home position to the actuated position, as shown in Figure. As this occurs, and as described above, the first decoupling assembly actuator 820 switches the first decoupling assembly 600 from the release configuration to the coupled configuration, and the second decoupling assembly actuator 830 switches the second decoupling assembly 700 from the coupled configuration to the release configuration. After the sealing cycle is complete, the strap continues to exert the torque on the tension wheel 400w that acts in the rollback direction TREV. Switching the second decoupling assembly 700 from the coupled configuration to the release configuration enables the tension wheel 400w to rotate in the rollback direction TREV to release that torque in a controlled manner.

[0078] Specifically, upon completion of the strapping process, the second decoupling assembly 700 continues to prevent the rollback ring gear 420 of the tensioningassembly gearing 400g from rotating in the rollback direction TREV, which as explained above prevents the tension wheel 400w from rotating in the rollback direction TREV after tensioning so the tension wheel 400w can hold the tension in the strap. As the operator moves the triggerassembly body 810 to its actuated position, the second decoupling assembly actuator 830 begins rotating the sleeve 750 of the second decoupling assembly 700 to its release position, and the inner diameter of the expandable element 740 of the second decoupling assembly 700 begins expanding. Eventually, the torque the rollback ring gear 420 exerts on the decoupling-assembly shaft 710 of the second decoupling assembly 700 (via the rollback intermediary gear 422 and the gear 780 of the of the second decoupling assembly 700) exceeds the compression force the expandable element 740 exerts on the first engageable element 720. When this occurs, the rollback ring gear 420 begins rotating in the rollback direction TREV about the tension-wheel rotational axis Awow, enabling the second set of planetary gears 424a-424d and the second carrier 426 to rotate in the rollback direction TREV about the tension-wheel rotational axis A ow. This causes the tension wheel 400w to rotate in the rollback direction TREV about the tensionwheel rotational axis A4oo_w to release the torque exerted by the tensioned strap.

[0079] Once one of the sensors 1700 detects that the trigger body 810 has reached the actuated position, the controller 1600 controls the motor 1100 to rotate the output shaft in the first drive direction to raise the tensioning assembly 400 to its strap-insertion position, as explained above. The operator then removes the strapping tool 50 from the tensioned strap loop.

[0080] Although the sealing assembly of the above-described example embodiment of the strapping tool is configured to form a friction-welded strap joint, the sealing assembly may comprise other sealing mechanisms (such as notching jaw assembly, a crimping jaw assembly, a sealless joint assembly, an ultrasonic welding assembly, or a hot-knife assembly) in other embodiments configured to seal any suitable type of strap (such as metal, plastic, or paper strap).

[0081] The above-described example embodiment of the strapping tool includes a single motor configured to drive both the tensioning assembly and the sealing assembly. In other embodiments, the strapping tool includes separate motors configured to drive the respective tensioning and sealing assemblies and may include separate transmissions for each motor.

[0082] 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. For instance, certain embodiments of the strapping tool include the first decoupling assembly but not the second decoupling assembly or a decoupling assembly different than the second decoupling assembly including the expandable element. [0083] While the strapping device described above is a handheld strapping tool, the strapping device may be any other suitable strapping device in other embodiments, such as a standalone automatic or semi-automatic strapping machine.

Claims

1. A strapping device comprising: a support; a tensioning assembly comprising a rocker, tensioning-assembly gearing supported by the rocker, and a tension wheel drivable by the tensioning-assembly gearing, wherein the tensioningassembly gearing comprises a driven shaft and a first gear, wherein the tensioning assembly is pivotable relative to the support between a tensioning position and a strap-insertion position; a decoupling assembly switchable between a coupled configuration and a release configuration; a second gear connecting the first gear to the decoupling assembly, wherein the decoupling assembly prevents rotation of the second gear when in the coupled configuration and enables rotation of the second gear when in the release configuration; and a motor operably connected to the driven shaft to rotate the driven shaft, wherein when the decoupling assembly is in the coupled configuration, rotation of the driven shaft causes the first gear to rotate and climb the second gear to pivot the tensioning assembly to the strap-insertion position.

2. The strapping device of claim 1 , wherein when the decoupling assembly is in the release configuration, rotation of the driven shaft causes the first gear to rotate and drive the second gear to rotate.

3. The strapping device of claim 1, wherein the first gear comprises a ring gear.

4. The strapping device of claim 1, wherein the tensioning-assembly gearing comprises a first set of planet gears driven by the driven shaft and drivingly engaged to the first gear such that rotation of the driven shaft causes the first set of planet gears to drive the first gear to rotate.

5. The strapping device of claim 1, wherein the decoupling assembly comprises a decoupling-assembly shaft connected to the second gear, wherein the decoupling-assembly shaft is rotatable when the decoupling assembly is in the release configuration and prevented from rotating when the decoupling assembly is in the coupled configuration.

6. The strapping device of claim 5, wherein the decoupling assembly further comprises: a first engageable element connected to and rotatable with the decoupling-assembly shaft; and an expandable element circumscribing at least part of the first engageable element, wherein when the decoupling assembly is in the coupled configuration, the expandable element fictionally engages the first engageable element such that the first engageable element and the decoupling-assembly shaft are prevented from rotating, wherein when the decoupling assembly is in the release configuration, the frictional engagement between the expandable element and the first engageable element is at least partially eliminated such that the first engageable element and the decoupling assembly shaft are rotatable.

7. The strapping device of claim 6, wherein the expandable element comprises a first end, a second end, and multiple windings between the first and second ends, wherein rotation of the first end relative to the second end causes a diameter of one or more of the windings to expand to at least partially eliminate the frictional engagement between the expandable element and the first engageable element.

8. The strapping device of claim 7, further comprising a trigger assembly operably connected to the decoupling assembly to switch the decoupling assembly from the coupled configuration to the release configuration by rotating the first end of the expandable element relative to the second end of the expandable element.

9. The strapping device of claim 8, wherein the trigger assembly comprises a decoupling-assembly actuator movable to cause the first end of the expandable element to rotate relative to the second end of the expandable element.

10. The strapping device of claim 9, wherein the decoupling assembly further comprises a sleeve having a body defining an opening and comprising external teeth, wherein the first end of the expandable element is received in the opening.

11. The strapping device of claim 10, wherein the decoupling-assembly actuator comprises a gear, wherein movement of the gear causes the gear to mesh with the external teeth of the sleeve and drive the sleeve to rotate to cause the first end of the expandable element to rotate relative to the second end of the expandable element.

12. The strapping device of claim 6, wherein the first engageable element is part of the decoupling assembly shaft.

13. The strapping device of claim 6, wherein the second gear is mounted to and rotatable with the decoupling-assembly shaft.

14. The strapping device of claim 1, wherein the decoupling assembly is a first decoupling assembly, the coupled configuration is a first coupled configuration, and the release configuration is a first release configuration, wherein the tensioning-assembly gearing further comprises a third gear, the strapping device further comprising: a second decoupling assembly switchable between a second coupled configuration and a second release configuration; and a fourth gear connecting the third gear to the second decoupling assembly, wherein the second decoupling assembly prevents rotation of the fourth gear when in the second coupled configuration and enables rotation of the fourth gear when in the second release configuration.

15. The strapping device of claim 14, wherein the third gear comprises a ring gear.

16. The strapping device of claim 14, further comprising a trigger assembly comprising a first decoupling-assembly actuator configured to switch the first decoupling assembly between the first coupled configuration and the first release configuration and a second decoupling-assembly actuator configured to switch the second decoupling assembly between the second coupled configuration and the second release configuration.

17. The strapping device of claim 16, wherein the trigger assembly is movable from a home position to an actuated position to cause the first decoupling-assembly actuator to switch the first decoupling assembly from the first release configuration to the first coupled configuration and to cause the second decoupling-assembly actuator to switch the second decoupling assembly from the second coupled configuration to the second release configuration.

18. The strapping device of claim 17, wherein the trigger assembly is movable from the actuated position to the home position to cause the first decoupling-assembly actuator to switch the first decoupling assembly from the first coupled configuration to the first release configuration and to cause the second decoupling-assembly actuator to switch the second decoupling assembly from the second release configuration to the second coupled configuration.

19. The strapping device of claim 18, further comprising a controller operably connected to the motor and a first sensor configured to detect that the trigger assembly has reached the actuated position, wherein the controller is configured to activate the motor to rotate the driven shaft responsive to the first sensor detecting that the trigger assembly has reached the actuated position.

20. The strapping device of claim 19, further comprising a second sensor configured to detect that the tensioning assembly has reached the strap-insertion position, wherein the controller is further configured to deactivate the motor to stop rotating the driven shaft responsive to the second sensor detecting that the tensioning assembly has reached the strapinsertion position.