Abstract:
A tension/cutter tool for band-type clamps that include a band for tensioning around an object and a seal for securing the tensioned band around the object, in which the band is bent and severed at the seal to form a J-seal. The tool includes a body, a drive, and a feed wheel mounted to the body and operably connected to the drive. A nose piece includes two rollers and is movably mounted to the body to engage and disengage the two rollers from contact with the feed wheel. The feed wheel and rollers define a band path therebetween. A tail end of the band is fed into the tool, between the feed wheel and the roller and the drive is actuated to tension the band. Upon achieving a desired tension, the seal is engaged with the nose piece and the band is bent to form the J-seal against the seal and the band is cut beyond the J-seal. A controller monitors and controls the tool functions.

Description:
BACKGROUND 
     Hoses are often connected to fittings, such as cam and groove fittings, that require that a clamp or band is secured around the hose to secure the hose to the fitting. One example of such a hose to fitting connection is on the end of a water transfer hose. 
     A typical hose clamp includes a band that is formed into a loop or circle and a seal that holds the loop. The seal encircles the overlapped courses of band. To secure the band onto the hose, a tail end of the band is bent up against the edge of the seal (forming a J-seal) and is cut just beyond the J-seal. 
     One known tool is described and disclosed in Marelin, U.S. Pat. No. 5,566,726 and includes a screw actuated drive which can be fitted to a hand-held drill. One drawback to such a device is that the tool requires the user to hammer the seal closed and to return a gripper portion to a home position to remove the band and to tension a subsequent band. 
     Another tool is a manual tool in which a lead screw is used to facilitate tensioning. In this tool, again, there is no way in which to determine whether proper tension has been reached. In addition, if the lead screw has been fully threaded but tension has not yet been reached, the gripper has to be reset to complete tensioning. 
     Other tools have limited take up and/or can only be used in low tension systems. 
     Accordingly, there is a need for a tensioner/cutter for hose clamps or hose banding tools. Desirably, such a tool can tension the band around the hose with unlimited take-up, form the J-seal and cut the tail end of the band at the seal. More desirably, such a tool provides a consistent tension and provides an easy to use cutting movement. More desirably still, such a tool can be portable or bench mounted and can be powered by battery or supplied AC. Still more desirably, such a tool can include a foot pedal or other device that isolates power unless depressed or actuated. 
     SUMMARY 
     A tension/cutter tool is for use with band-type clamps that include a band for tensioning around an object and a seal for securing the tensioned band around the object. The band is bent and severed at the seal to form a J-seal, to secure the tensioned band around the object. 
     The tool includes a body, a drive and a feed wheel mounted to the body and operably connected to the drive for rotational movement. A nose piece is movably mounted to the body. In a present embodiment, the nose piece is pivotally mounted to the tool. 
     The nose piece includes two rollers and the nose piece pivots to engage and disengage the rollers from contact with the feed wheel. The feed wheel and rollers define a band path therebetween. A cutter assembly is operably connected to the nose piece. The nose piece can be mounted by a spring to bias the nose piece and rollers toward the feed wheel. 
     An end tail of the band is fed into the tool, between the feed wheel and the roller and the drive is actuated to tension the band. Upon achieving a desired tension, the seal is engaged with the nose piece and the band is bent to form the J-seal against the seal and the band is cut beyond the J-seal. 
     A guide can be used to direct the band into the band path, and a shear element can be positioned adjacent the guide. 
     The cutter assembly can include a cradle having a lip and a support surface. When the seal is received in the cradle, the cradle supports the seal, and the lip urges the seal to sever the band at the shear element. 
     The tool can include a cutter/release lever on which the cutter assembly is mounted. 
     Alternately, the tool can include a cutter link pivotally mounted to the tool, such that the cutter assembly is mounted to the cutter link to engage the seal with the cradle as the tool and seal are rolled onto one another. In such a configuration, a roller is mounted to the link opposite the cutter assembly. The roller is configured to engage an arcuate surface to pivot the cutter assembly. 
     A control system is used to control the tool. The control system can be configured to adjust the tension drawn in the band. An actuating trigger or switch actuates the drive. The control system can include a controller for determining an object (e.g., hose) type and for setting a tension appropriate for the determined object type. 
     In such a control system, object types can be catalogued and the object type is selected from the catalog of object types stored within the controller. The controller can also be configured such that multiple depressions or certain time periods of depressing the actuating switch stops and/or reverses operation of the motor. The tool can also include an indicator for indicating a status of the tool. Such an indicator can be a visual and/or an audible indicator. 
     The tool can be portable and as such powered by, for example a battery. The tool can also be configured for use with local (AC) power or other power sources. 
     These and other features and advantages of the present invention will be apparent from the following detailed description, in conjunction with the appended claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a hose clamp tensioner/cutter tool shown without a portable battery pack; 
         FIG. 2  is a front view of the tensioner/cutter tool; 
         FIG. 3  is a side view of the tensioner/cutter tool; 
         FIG. 4  is a perspective view the tensioner/cutter tool shown with a portable battery pack; 
         FIG. 5  is an exploded view of the tensioner/cutter tool; 
         FIGS. 6   a  through  6   f  are enlarged side views of the tension wheel and rollers as the tail end of the band is fed into the tool and as the band is tensioned; 
         FIGS. 7   a  through  7   f  are enlarged and partial views of the seal cradled in the cutter assembly ( FIGS. 7   a - 7   d ) and rotation of the handle as the seal is cradled ( FIG. 7   e ) and the tail end of the band is cut ( FIG. 7   f ); 
         FIGS. 8   a  through  8   e  illustrate an alternate cutter assembly in which cutting is carried out automatically; 
         FIGS. 9   a  and  9   b  illustrate a bench mount for the tensioner/cutter tool; 
         FIG. 10  is a graphical illustration of the current in amps drawn by the motor plotted against time for various types of hose; 
         FIGS. 11   a  and  11   b  illustrates a band prior to forming the seal ( FIG. 11   a ) and a typical J seal formed on the band ( FIG. 11   b ); and 
         FIGS. 12   a  and  12   b  are flow charts of various operational schemes for the tool. 
     
    
    
     DETAILED DESCRIPTION 
     While the present device is susceptible of embodiment in various forms, there is shown in the figures and will hereinafter be described a presently preferred embodiment with the understanding that the present disclosure is to be considered an exemplification of the device and is not intended to be limited to the specific embodiment illustrated. 
     Referring to the figures and in particular to  FIGS. 1-5  there is shown a tensioner/cutter tool  10  for hose clamps C. The tool  10  is used to tension a hose clamp or band B around a hose H (see, for example,  FIG. 11   a ), form a J-seal J of the tensioned band B and cut the end tail T of the band B after the J-seal J has been formed (see, for example,  FIG. 11   b ). 
     One embodiment of the tool  10  includes, generally, a body  12  that encloses a powertrain  14 , a housing  16  which houses the body  12  and a controller  18 , a power supply  20 , such as the exemplary battery pack, a nose piece  22 , a feed or tension wheel  24  and a cutter and release lever  26 . 
     A motor  28  is operably connected to the powertrain  14 , which in turn is operably connected to the feed wheel  24  by a drive shaft  30 . The powertrain  14  converts the rotational movement of the motor  28  to provide a desired power (torque) to the feed wheel  24  to tension the band B. 
     The nose piece  22  is a carriage that is moveably mounted to the body  12 , preferably pivotally mounted, by a pivot pin  32 . The nose piece  22  includes a pair of rollers  34   a  and  34   b  which function as pinch wheels to pinch the band B between the rollers  34   a  and  34   b  and the feed wheel  24 . The nose piece  22  is mounted to the body  12  by a biasing element  36 , such as the illustrated spring to bias the rollers  34   a  and  34   b  toward and into contact with the feed wheel  24 . The rollers  34   a  and  34   b  are mounted to the nose piece  22  by roller pins  38 . Two rollers  34   a  and  34   b  are provided to increase the surface area over which the band B contacts the feed wheel  24 . This can reduce milling of the band B and allow tension to be drawn on softer band B materials. 
     A connecting plate  40  mounts to an end of the drive shaft  30  and to the pivot pin  32  that mounts the nose piece  22  to the body  12 . In this arrangement, the feed wheel  24  and nose piece  22  are secured to the tool  10 , and the nose piece  22  can pivot about the pivot pin  32  to bring the rollers  34   a  and  34   b  into contact with the feed wheel  24 . 
     An alignment or guide plate  42  is mounted to a front lower portion of the nose piece  22 . The alignment plate  42  is configured to provide a guide (as indicated at  43 ) for the band end tail T to be positioned in the tool  10 . A shear plate  44  is positioned adjacent to and below the alignment plate  42 . The shear plate  44  defines a lower portion of the guide  43  and also serves as an anvil against which the band B is held during the cutting operation. The alignment plate  42  and shear plate  44  can be secured to the nose piece  22  by fasteners  46 , such as the illustrated screws. 
     The cutter and release lever  26  is mounted to the nose piece  22 . The lever  26  includes an elongated handle  48  and a cutter portion  50 . The cutter portion  50 , which is at the pivot end of the lever  26  has a cradle  52  that includes a lip  54 , a support surface  56  and a pivot or contact corner  58 . The lever  26  is mounted to the nose piece  22  by a pivot pin  60 . The cutter portion  50  can be an element separate from the lever  26  and secured thereto by fasteners or pins  51  to facilitate replacement of the cutter portion  50 . Alternately, the cutter portion  50  can be formed integral with the lever  26 . The cutter and release lever  26  provides a number of functions. First, as the tool  10  is pivoted or rolled up onto the seal S and the lever  26  is pivoted forward, away from the body  12 , it provides a seat into which the seal S rests as the end tail T of the band B is bent to form the J-seal J. Second, as the lip  54  engages the end of the seal S, it forces the seal S downward to cut the end tail T on the shear plate  44 , at the end of the J-seal J. Third, as the lever  26  is rotated rearward, toward the body  12 , it pivots the nose piece  22 , against the spring  36  bias to move the nose piece  22  and the rollers  34   a  and  34   b  away from the feed wheel  24 , thus creating the gap G between the feed wheel  24  and the rollers  34   a  and  34   b.    
     The control system or controller  18  includes circuitry to sense the tension on the band B, preferably by measuring the current drawn by the motor  28 , and appropriate circuitry or programming, to stop the motor  28  when a desired tension is reached. A tension adjuster  64 , such as a manual or electronic dial, knob, button or the like can be provided to set the desired tension. Indicators  68 , such as LEDs can be used to provide visual indication of the cycle of the tool  10 , the achievement of the desired tension, as well as other operator indicators, for example, battery  20  power. A trigger or actuating switch  66  closes a circuit to commence the tensioning cycle. 
     Alternately, the tension adjustment function can be incorporated into the trigger or actuating switch  66 . For example, the switch  66  can be used to enter a set-up mode in which the tension adjustment can be made by depressing the switch  66  a predetermined number of times to set the tension and then exit the set-up mode. 
     The controller  18  can also be configured to provide various automatic functions. In an embodiment, the controller  18 , in conjunction with the actuating switch  66 , provides both indication (e.g., of the status of the tool  10  and/or mode of operation) and control of tool  10  functions.  FIG. 12   a  is one such operating scheme for the controller  18  and the tool  10 . 
     At step  210  the controller  18  recognizes that a battery  20  has been inserted into the tool  10 . At step  212  the tool  10  performs a self-test. Indication can be provided by, for example, a lighting scheme (e.g., flashing) of a lamp such as an LED  68  in the tool  10 . When the controller  18  determines that the tool  10  has successfully passed the self-test, it enters ready mode. 
     In ready mode, at step  214  the motor  28  is off (e.g., in sleep mode), but ready to actuate. Upon actuation by, for example, depressing the actuating or trigger button  66 , the tool  10  enters an operating or tensioning mode at step  216 . The LED  68  can be used to indicate the state of the tool  10  and the mode, as desired. The motor  28  then commences to tension the band B until the desired tension is reached at which time the motor  28  stops, as at step  218 . The tension cycle is then complete, and the LED  68  can illuminate (flash, steady or any pattern) or remain off, to indicate completion of the cycle. 
     The controller  18  can be configured such that a second depression of the switch  66  during the tension cycle stops and/or reverses operation of the motor  28 . Alternately, the controller  18  can be configured such that depressing and holding the switch  66  reverses the motor  28 , as at step  220 , to relieve tension in the band B. An audible indictor can also be used instead of, or in conjunction with, the visual indicator. Those skilled in the art will appreciate that because the controller  18  can be configured or programmed, there are a wide variety of tool  10  functions, including control and monitoring functions, that can be achieved and that such other functions are within the scope and spirit of the present disclosure. 
     In use, a clamp C having a band B and a seal S is positioned around a hose H and fitting. The cutter and release lever  26  is urged toward the tool body  12  to pivot the nose piece  22  which moves the rollers  34   a  and  34   b  away from the feed wheel  24 , opening the gap G. The end tail T of the band B is positioned between the feed wheel  24  and the rollers  34   a  and  34   b  and the lever  26  is released. 
     The trigger or actuator button  66  is depressed which actuates the motor  28 , turning the feed wheel  24 . The spring  36  biases nose piece  22  and thus the roller  34   a  and  34   b  toward the feed wheel  24  to capture the end tail T between the feed wheel  24  and the rollers  34   a  and  34   b . In addition, as the seal S begins to move into the nosepiece  22 , this also increases the clamping force on the band B, by further urging the nosepiece  22  (and rollers  34   a  and  34   b ) against the band B and into the feed wheel  24 . 
     As the feed wheel  24  rotates, it draws tension in the band B, tightening the band B around the hose H. When a predetermined tension is reached, the motor  28  stops, but the drivetrain  14  maintains tension in the band B. The feed wheel  24  then reverses slightly, but not so much as to lose tension in the band B. Alternately, tension can be drawn in the band B, the feed wheel  24  can be reversed slightly, and then the band B retensioned to a final tension. 
     Over-tensioning the band B (but not so much as to exceed the material yield strength) is done to remove pockets that may have occurred due to friction between the overlapping band B courses. Slightly backing-off from the over-tension point then allows for forming the J-seal J at a desired seal strength, without over-tensioning the band B during the J-seal J forming step. 
     Alternatively still, the tension can be slowly increased to reach the desired tension without over-tensioning and backing-off. It will thus be appreciated by those skilled in the art that the final tension can be achieved in a variety of manners of operation. 
     The tool  10  is then rolled up toward and onto the seal S. As the seal S contacts the pivot or contact corner  58 , the force on the corner  58  tends to move the lever  26  forward toward the cutting position, which moves the support surface  56  against the seal S (essentially, as seen in  FIG. 7   d , the seal lies S flat on the support surface  56 ). Once the seal S is fully seated in the cradle  52 , the lever  26  is further urged forward which forces the seal S down to form the J-seal J and to cut the end tail T of the band B. The hose H is thus separated from the end tail T, and can be used. Moving the lever  26  rearward, toward the body  12 , opens the nose piece  22  and allows for easy removal of the end tail T that remains between the feed wheel  24  and the rollers  34   a  and  34   b.    
     In an alternate embodiment, as seen in  FIGS. 8   a  through  8   e , the cutter  150  has an automatic actuation configuration. In this arrangement, the cutter  150  is automatically actuated (as opposed to actuated by the cutter and release lever). The cutter  150  includes a cutter link  152  that is mounted to the nose piece  122  by a link pin  124 . The link pin  124  rides in a slotted opening  126  in the link  152 . A roller or bearing  128  is positioned at a rear of the link  152  that cooperates with an arcuate surface  154  on the body  112 . 
     A cradle  156  that includes a lip  158 , a support surface  160  and a pivot or contact corner  162  is formed at an end of the link  152  opposite the roller  128 . As seen in  FIGS. 8   a - 8   e , the tool  110  is rolled up toward and onto the seal S (see,  FIGS. 8   a - 8   b ). As the seal S contacts the pivot or contact corner  162 , the force on the corner  162  tends to pivot the link  152  about the link pin  124 . The roller  128  rides up along the arcuate surface  154  (see,  FIG. 8   c ), which moves the support surface  160  against the seal S. Once the seal S is fully seated in the cradle  156 , further rolling the tool  110  up on the seal S moves the link roller  128  up along the surface  154 , which forces the seal S down to form the J-seal J and to cut the end tail T of the band B (see,  FIG. 8   e ). 
     As best seen in  FIGS. 9   a  and  9   b , the tool  10  can be bench mounted. In such an arrangement, the tool  10  is secured in a mount  180  that includes a base plate  182  that can be mounted to a bench top, a movable cart or the like. The mount  180  preferably includes a fully opening quick release clamp  184 , such as the illustrated cam-lock clamp, that can be readily opened or closed to secure the tool  10  in place. 
     The tool can include a foot pedal  170  as illustrated in  FIG. 4 . The foot pedal  170  can be used in lieu of the switch ( 66  as seen in  FIG. 4 ), or as an alternative switch. The foot pedal  170  is operably connected to the controller  18  via, for example, socket  62 , such that the foot pedal  170  must be depressed in order for the tool  10  to operate and releasing the foot pedal  170  will automatically stop and/or reverse operation of the tool  10 . 
     It is also anticipated that the controller  18  can be used to provide preset tension values for a variety of hose H types and sizes, band B types and sizes and the like. The controller  18 , in conjunction with appropriate sensors (e.g., within the controller  18 ) can also be configured to detect the type of hose H, e.g., hose-detection technology, which will allow the tool  10 ,  110  to determine the type of hose H on which it is used and to apply an appropriate tension to achieve a desired J-seal J strength. In one embodiment, this can be achieved using a relationship between force and current (as drawn by the motor  28 ) over a predetermined period of time. 
     It is anticipated that the hose detection methodology can be accomplished in a number of ways. In one methodology, various hoses will be tested by tensioning bands B to an appropriate tension over a period of time. The time and motor  28  current will be recorded and a slope of the curve, which is assumed to be a near straight-line, will be calculated. The slope for each type of hose H will be determined in this manner and the slope for each hose H type will be catalogued. The controller  18  will be programmed with the catalog of hose H types and slopes. In this manner, as the tool  10 ,  110  commences tensioning, the controller  18  will recognize the type of hose H from the catalog of time-motor current slopes and will adjust the tool  10 ,  110  to achieve the proper final tension accordingly. 
       FIG. 10  is a graphical representation of the tension rate curves (current v. time) for two different hoses, a lay flat hose and a rubber hose, from which the proper tension rate and final band B tension can be determined. 
     It will be appreciated by those skilled in the art that the relative directional terms such as upper, lower, rearward, forward and the like are for explanatory purposes only and are not intended to limit the scope of the disclosure. 
     All patents referred to herein, are hereby incorporated herein by reference, whether or not specifically done so within the text of this disclosure. 
     In the present disclosure, the words “a” or “an” are to be taken to include both the singular and the plural. Conversely, any reference to plural items shall, where appropriate, include the singular. 
     From the foregoing it will be observed that numerous modifications and variations can be effectuated without departing from the true spirit and scope of the novel concepts of the present disclosure. It is to be understood that no limitation with respect to the specific embodiments illustrated is intended or should be inferred. The disclosure is intended to cover all such modifications as fall within the scope of the claims.