Abstract:
A portable electrically powered clamp application tool has a bench mounting kit with a foot pedal control for bench work. The tool has two grippers which enable a powered clamp cutting operation, wherein the only manual step is bending the tightened clamp prior to triggering the cutter arm. A gripper element is non-rotational and has teeth. It locates the material being gripped in a repeatable manner in spite of oil or other lubricants on the clamp. After the cutting operation an automatic release assembly releases the clamp. A manual lever(s) can also release a tail of a clamp.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
   The present application is a continuation in part claiming priority to non-provisional application Ser. No. 09/982,420 filed Oct. 17, 2001 now U.S. Pat. No. 6,601,616. 

   FIELD OF INVENTION 
   The present invention relates to a band application and cutting machine that pulls one end of a band loop around a workpiece via a powered jaw and then cuts the band via a powered cutter. 
   BACKGROUND OF THE INVENTION 
   The industrial applications for winding a metal band or hose clamp around a workpiece such as a hose to secure the hose to a pipe or fitting are well known in the art. One mechanical system is disclosed in U.S. Pat. No. 5,918,866 (1999) to Klimach. A metal band is wound around a workpiece, and then the two ends of the band are fed into two receiving ports on a manually operated strap clamping tool. The clamp is tightened under the effect of a double pulley. 
   The closest known prior art is made by Band-It-Idex, Inc., a Unit of IDEX Corp., Denver, Colo., model Ultra-Lok®, see  FIGS. 1 and 2  herein. Models include an AC or a battery powered unit. The unit only handles a one size ¾″ specialty clamp made by Band-It™. The clamps can be preformed with the special buckle integral, or free-end with the special buckle separate from the band. Either hose or pole applications can be handled. 
   Referring to  FIGS. 1 ,  2  an AC unit  1  has a housing  2  which includes a commercial drill motor with integral gear box. The gear box powers a pulling assembly  3 . The pulling assembly  3  has a pulling element  4 . The gear box powers a screw  6  which pulls the pulling element  4  rearward during the clamp tightening cycle. 
   In operation a tail of the band to be applied is inserted into the band entry port  7  and gripped by the gripper  5  inside the pulling element  4 . Next the gear box is powered to pull the pulling element  4  rearward via the screw  6 . Next the cutoff arm  8  is manually pulled forward to form a locking dimple on the tail and then to cut the tail. 
     FIG. 2  shows a battery powered unit  20  which functions identically to unit  1 . 
   Problems with the Band-It™ units include the limitation of use with Band-It&#39;s expensive custom clamps, only available in a ¾″ width. 
   Another problem with the Band-It™ units is the requirement to manually pull the cutoff arm  8  while the operator still needs to control the unit as well as the workpiece. This operation leads to two hands controlling three objects. 
   Another problem with the Band-It™ units is the inability to bench mount the units for production runs. 
   These problems are solved by the present invention which provides a bench mount, and can be made portable by detaching the tool from the bench mount, AC or DC system. Either system can handle generic buckles, or pre-formed clamp (band and buckle) or smooth I.D. clamp (eliminates leak path) or center punch clamp or open end clamps. The tool will handle the full range of clamp widths from ¼″ to ¾″. All of the present invention systems have a powered cutoff assembly. 
   SUMMARY OF THE INVENTION 
   The main aspect of the present invention is to provide a power tool which can apply a clamp and cut the clamp end in a powered operation. The application process involves a tightening step. 
   Another aspect of the present invention is to provide the power tool with the flexibility to handle a wide range of band widths, wherein the bands are of a generic off-the-shelf design. 
   Another aspect of the present invention is to provide a portable DC power tool that has a bench mount capability for production runs. 
   Another aspect of the present invention is to provide the power tool with the flexibility to handle both pre-wound and free end clamps. 
   Another aspect of the present invention is to provide the power tool with a pair of band grippers, one member to pull the band for a tightening operation, and the other member to automatically hold the tightened band in preparation for the cutting operation. 
   Another aspect of the present invention is to provide a portable clamp application tool which applies prewound steel clamps and by adding an attachment will apply free end clamps as well. 
   Another aspect of the present invention is to provide an apparatus to manually release each gripper via a lever. 
   Another aspect of the present invention is to provide an automatic front and rear gripper release assembly. 
   The tool consists of 12V DC electric motor and clutch-gearbox coupled to a reduction gear get, which actuates a threaded nut incorporated into the reduction gear, which rotates around a threaded rod. The rod is attached to a gripping mechanism which pulls the tail of the clamp through a uniquely designed holding pressure mechanism which automatically provides the precise holding pressure required when the clamp is rolled 90° and the excess tail cutoff. Furthermore the act of resetting the pulling gripper automatically cuts the excess from the clamp and requires no hand actuation of a cutoff mechanism. 
   This tool can be operated portably with a small battery power supply. This allows the operator to go into the field and apply hose clamps without having compressed air or AC electricity available. The tool is of light enough weight to allow bringing the tool to the job as opposed to the present system which demands that the job be brought to the tool. This tool can also be operated as a bench tool with foot operated control, either by drawing its power requirements from a battery or a power supply, which operates from 110V AC. This versatility allows the tool to be operated portably by hand, or mounted to the rear of a service truck, or as a bench-mounted tool in the shop. This is the first application tool, which is portable, battery powered and features adjustable tension control, which will apply the full range of clamps from ¼″ to ¾″ as well as apply free end clamps. 
   Incorporated into the device is a pair of spring loaded serrated gripping elements which are essentially free in one direction and which when the product, which is being fed under them in one direction is reversed, one element firmly and repeatably moves a controlled distance before gripping the fed product positively. The distance, which the product moves before being positively gripped, is controlled by the angle of the inclined plane against which the gripping element moves. 
   This device is very useful for preformed clamp application tools in as much as much as it replaces the complex valving, gaging and plumbing which is presently being used in application tools to accomplish the necessary holding pressure when applying preformed host clamps. 
   Other aspects of this invention will appear from the following description and appended claims, reference being made to the accompanying drawings forming a part of this specification wherein like reference characters designate corresponding parts in the several views. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  (prior art) is a side perspective view of an AC powered Ultra-Lok® Band Clamping System. 
       FIG. 2  (prior art) is a side perspective view of a battery powered Ultra-Lok® Band Clamping System. 
       FIG. 3  is a side perspective view of the alternate embodiment clamp applicator system. 
       FIG. 4  is a rear perspective view of the foot controller shown in  FIG. 3 . 
       FIG. 5  is a side perspective view of the clamp applicator of  FIG. 3  in the portable DC mode. 
       FIG. 6  is a rear plan view of the forward housing ( 600 ) of the disassembled gear box housing. 
       FIG. 7  is a front plan view of the rear housing ( 502 ) of the gear box. 
       FIG. 8  is a top plan view of the clamp applicator shown in  FIG. 3 . 
       FIG. 9  is a longitudinal sectional view of the clamp applicator taken along line  9 — 9  of  FIG. 8 . 
       FIG. 10  is a rear perspective view of the clamp applicator showing the tension setting knob. 
       FIG. 11  (prior art) is a top perspective view of a preformed clamp on a workpiece. 
       FIG. 12  is a front perspective view of the clamp of  FIG. 11  being fed into the entry port of the clamp applicator of  FIG. 3 . 
       FIG. 13  is a right side partial cutaway view of the clamp being inserted into the entry port of the clamp applicator of  FIG. 3 . 
       FIG. 14  is the same view as  FIG. 13  with the clamp fully inserted into the two grippers and ready for the application procedure. 
       FIG. 15  is the same view as  FIGS. 13 ,  14  with the pulling gripper fully extended rearward. 
       FIG. 16  is the same view as  FIGS. 13 ,  14 ,  15  with the pulling gripper reversed back to its forward position, the holding gripper has maintained the tension on the taught band, the operator has manually pushed the clamp downward, and the cutting jaw has rotated clockwise to complete the powered cutting procedure. 
       FIG. 17  is the same view as  FIGS. 13 ,  14 ,  15 ,  16  showing the cutting procedure completed. 
       FIG. 18  is a top perspective view of the first step of a free end clamp procedure, where the free end clamp has been manually wound around a post, anchored at one end to a buckle, with the free end of the band about to be fed into the entry port of the free end adapter on the clamp applicator. 
       FIG. 19  is a top partial cutaway view of the next step after the  FIG. 18  step, where the free end of the band is partially fed into the clamp applicator. 
       FIG. 20  is the same view as  FIG. 19  showing the free end of the band fully inserted past the two grippers. 
       FIG. 21  is the same view as  FIGS. 19 ,  20  showing the pulling gripper fully extended rearward. 
       FIG. 22  is the same view as  FIGS. 19 ,  20 ,  21  showing the pulling gripper reversed and returned back to its start position, and the clamp applicator (rather than the post) has been manually rotated clockwise to bend the free end into the locked position in the buckle in preparation for the cutting procedure which is almost completed. 
       FIG. 23  is the same view as  FIGS. 19 ,  20 ,  21 ,  22  with the cutting procedure complete. 
       FIG. 24  is a top plan view of the shear plate on top of the tool. 
       FIG. 25  is a side plan view of the gripper in partial cutaway. 
       FIG. 26  is a back plan view of the gripper. 
       FIG. 27  is a bottom plan view of the gripper. 
       FIG. 28  is a side plan view of the preferred cutter jaw having one near side and one far side attached spurs to open the gripper  902 . 
       FIG. 29  is a top plan view of the cutter jaw. 
       FIG. 30  is a bottom plan view of the cutter jaw with spur able to open the adjacent gripper. 
       FIG. 31  is a side partial cutaway view of the cutter jaw spur disengaged from the gripper. 
       FIG. 32  is the same view as  FIG. 31  with the cutter jaw spur engaged with the gripper allowing the band to be withdrawn from the gripper. 
       FIG. 33  is an exploded view of the improved automatic front gripper release assembly. 
       FIG. 34  is a side cutaway view of the improved automatic front and rear gripper release assembly also showing the manual release levers, the preferred embodiment. 
       FIG. 35  is a top exploded view of the improved gripper housing and cutter. 
       FIG. 36  is a side cutaway view of the rear gripper manual release lever. 
       FIG. 37  is a side plan view of the improved automatic release lever mounted on the cutter. 
   

   Before explaining the disclosed embodiment of the present invention in detail, it is to be understood that the invention is not limited in its application to the details of the particular arrangement shown, since the invention is capable of other embodiments. Also, the terminology used herein is for the purpose of description and not of limitation. 
   DESCRIPTION OF THE PREFERRED EMBODIMENT 
   Referring next to  FIG. 3  a universal clamp application system  3000  is shown. For portable use a battery pack  3001 , is plugged into the application module  3002  at handle  3003 . The application module is detached from the bench mount  3004  and fully operational. 
   The bench mount  3004  is attached to a working surface  3005 . For bench mounted operation power to the application module can either come from the battery pack  3001  or the AC/DC power supply  3006  which is plugged into wall power. The AC/DC power supply  3006  feeds DC power via cord  3007  to the foot control module  3008 . 
   For AC use the foot pedal  3012  activates DC power to card  3010  which is plugged into socket  3011 . The adapter  3009  receives the cord  3007 . 
   For bench mount DC operation the adapter  3009  is replaced with a battery pack  3001 . 
   For applying a generic clamp assembly, the tail of the band is inserted into band entry port  70 . Internal assemblies in the application module  3002  grip the tail, pull the tail to the correct tension. The operator then bends the clamp 90°, and finally the application module is reversed and in a powered mode cuts the tail from the clamp. 
   Referring next to  FIG. 4  the foot pedal module  3008  has the pedal  3012  with a pivot at P so that the dotted position R controls the reverse direction of the application module  3002  which is used in the cutoff operation. The tightening operation is controlled by the left position shown in solid lines. Depressing the pedal  3012  in direction ON powers the application module  3002 . 
   Referring next to  FIG. 5  the application module  3002  is ready to operate in portable DC mode. The battery pack  3001  is plugged into the handle  3003 . The trigger  504  controls power to the unit. The switch  505  controls forward, neutral and reverse modes of operation. In the tightening mode the tail of the band is pulled in direction T inside slot  503 . In the cutoff mode the switch  505  is set to reverse. When the trigger  504  is activated and the automatic cutoff operation is consummated as noted below. 
   The gear box  502  powers the screw  500  in a known manner. To allow for variable pulling tension on various width bands, a tension adjustment knob  501  is set for each band width. A known variable clutch assembly varies the transmitted power from the motor to the gear box  502  and ultimately to the non-rotating screw  500 . 
   Referring next to  FIG. 6  the housing  502  has been removed to disclose the base  600 , primary gear  602  and secondary gear  601 . 
   Referring next to  FIG. 7  the thrust bearing  700  can be seen seated at the rear end of the gear box cover  502 , screw hole  563  being shown empty. A primary gear shaft support bearing  701  is seen. A second thrust bearing (not shown) rests against the opposite side of the secondary gear  6   d.    
   A bolt  692  passes through holes  691  and then  690 , and similar bolts secure members  502  and  600  together as shown. 
   Referring next to  FIG. 8  the slot  503  is clearly shown on top of the clamp applicator  3002 . The rest of the top of the top front of the tool consists of a shear plate  805  which has a clearance channel  806 . This clearance channel  806  may be about the depth of a typical band to allow the band and workpiece to allow the band and workpiece to be drawn up against the shear plate  805  as shown in  FIG. 14 . The reaction plate  803  and bolts  804  structurally support the moving gripper. 
   The main housing  844  may be made of aluminum or other preferably lightweight material. A channel  801  accommodates the non-rotatable screw  500 . Bearings  800  are supporting the nut gear shift assembly. 
   Referring next to  FIG. 9  the air vents  939  in the housing  844  allow the motor and primary gear box assembly  909  to cool. The primary gear shaft  908  turns the primary gear  602 . The tail  999  of clamp is shown manually inserted into the entry port  70  and past both the stationary gripper  902  and the movable gripper  901 . When the trigger  504  is activated, the movable gripper  901  moves rearward in direction tighten “T” by means of the non-rotating screw  500 . For the cutting operation the switch  505  is set to reverse, and the movable gripper  901  is moved back where it started, and the movable gripper  901  releases its grip on the tail  999  in the reverse direction. But in the reverse direction the stationary gripper  902  engages the tail  999  to prevent an unwinding of the tightened clamp.  FIG. 9  shows the cutter  903  in the neutral position, held there by the return spring  904 . The movable gripper  901  consists of a housing  905  which contains a band exit port  929 . When the movable gripper  901  returns to the forward position, the loose tail  999  slides out the band exit port  929 . 
     FIGS. 10–17  show the entire operational sequence for the application of a preformed clamp  1100  around a workpiece  1101 . Preformed clamp consists of a tail  999  which is part of a continuous band  998 , wherein a buckle anchors both ends of the continuous band  998  when the application is complete. 
   First the operator adjusts the torque adjustment knob  501  to the width of the band  998 . If the torque on the movable gripper  901  is too strong, then the band  998  would yield and finally snap. 
   Next the tail  999  of  FIG. 11  is inserted into the port  70  of the clamp applicator  3002  as shown in  FIGS. 12 ,  13 ,  14  until the buckle  997  rests against the clearance channel  806  of shearplate  805 . The tail  999  must pass through both grippers  901 ,  902  as shown in  FIG. 14 . 
     FIG. 15  shows the movable gripper  901  powered in direction T, which has tightened the clamp  1100 . In  FIG. 16 , the clamp  1100  has been manually rotated counterclockwise in direction BT, thereby locking the band  998  into the buckle  997 . 
   Next in  FIG. 16  the operator has reversed the direction of movement of movable gripper  901  so as to return the movable gripper  901  to its starting position. The tail  999  has exited the band exit port  929 . 
   The cutter  903  has been pivoted around pivot  1605  by means of the inclined plane forward edge  1602  of the movable gripper housing  905 , which has pushed the roller  1601  of the cutter  903  downward. The roller  1601  has an axle  1600 . 
     FIG. 17  shows the completion of the cutting cycle where the cutter  903  has engaged the buckle moving it and the captured tail  999  upward thereby shearing the tail  999  against the shear portion of the stationary gripper  902  housing  805 , and the workpiece  1101  falls free from the clamp applicator  3002 . 
   Referring next to  FIGS. 18–23  the application sequence for a free end clamp  1850  applied around a pole P is shown. The clamp applicator  3002  is the same but for the addition of the free and clamp adapter  1800 , preferably with four bolts  1801 . An extension entry port  1802  extends the entry port for tail  9090  about one inch out from entry port  70 . 
   The prior art free end clamp  1850  consists of a band  1860  where a first end is anchored via a hand bent tab  1852  to the buckle  1851 . The tail  9090  slides through the buckle  1851  and then is manually fed into the extension entry port  1802 . At the completion of the cutting operation which uses the shear element  1844  to brace the clamp, the lock tabs  1853  are hammered down onto the tail  9090 . 
   In  FIGS. 19 ,  20  the tail  9090  is being manually inserted past both the grippers  901 ,  902 . 
     FIG. 21  shows the movable gripper  901  powered in direction T to tighten the free end clamp  1850  which has been pulled snug against the extension opening  1802 . 
   Next the operator rotates the clamp applicator  3002  clockwise in order to bend the tail  9090  into a locked mode on the buckle  1851  and prepare for the cutting operation. 
     FIG. 22  shows the same cutting operation with cutter  903  as described in  FIG. 16 . In this case there is left a one inch lock tail  9999  at the end of tail  9090 . 
     FIG. 23  shows the completed cutting operation. The lock tail  9999  has been hammered down onto the buckle  1851 . The lock tabs  1853  need to be hammered down to complete the application. 
   Referring next to  FIGS. 24–27  the stationary gripper  902  is shown where  FIG. 24  shows the top which is the shear plate  805  with gap (clearance channel) G. Bolts  2400  hold the gripper  902  together. 
     FIG. 25  shows the base  2505  holding the gripper body  2500 . The gripper body  2500  has a pocket  2501  in which rides the jaw  2502 . The bottom  2506  of the jaw  2502  consists of an arcuate surface having small teeth to grip the bands. The jaw  2502  slides up or down inclined plane  2525  to allow the bottom  2506  to grip and release the bands. The movable gripper release pin  2504  engages the jaw  2502  gripper and releases the excess tail from the movable gripper assembly when the tool is reversed and fully at the end of its travel. A spring  2503  holds the jaw  2502  against the top of the base  2505 , and jaw  2502  is displaced rearward and upward to allow the band to slip under it. The band rides in gap G in the top of base  2505 . 
     FIG. 27  shows the limits or width of the track  2700  in which rides the band which is gripped by the bottom  2506  of the jaw  2502 . Cutter arm housing  2505  supports the cutter arm  903 , and provides the reaction surface for the gripper  902 . Shearing edge  2801  shears the clamp in the cutting operation. 
   Referring next to  FIGS. 28 ,  29 ,  30 , the spurs  2800  on the cutter  903  push the jaw  2502  loose from the band just after the cutting edge  2801  cuts the band. This allows the tail of the band  9090  to be removed and discarded. 
   Referring next to  FIGS. 23 ,  31 ,  32  the jaw  2502  slides along an angled surface  3100  of the pocket  2501 . The angle L is preferably 20°. The angle L is chosen to allow the band B to move forward a tiny bit (0.010–0.030 inch) when the cutting operation begins and the movable gripper  901  moves forward. This tiny slack releases the considerable tension which exists between the clamp/workpiece and the shearplate  805 . This tiny slack allows the manual bending of the clamp in preparation for the cutting operation, and eliminates complex known holding mechanisms. 
     FIGS. 31 ,  32  show how the spur  2800  moves the jaw  2502  back to allow release of the excess band B after the cutting operation. 
   Referring next to  FIGS. 33–37 , the new and improved manual gripper release levers  5 ,  7  are pivotally mounted at  5009 ,  700  respectively. They each have a hook  501 ,  701  respectively which lift the grippers  901 ,  902  respectively when the user raises the levers  5 , 7  as shown in dots in  FIG. 34 . The grippers  901 ,  902  rise up to compress their respective mounting springs  9010 ,  9020 . This manual release is desirable in case the operator inserted a clamp incorrectly into the port  70 . The improved clamp applicator is denoted  30029 , the preferred embodiment. 
   The improved automatic gripper release works as follows. The screw  500  moves the gripper housing  905  forward after the clamp has been tightened. The function of mobile gripper release pin is to automatically contact and release the mobile gripper  901  at the end of its forward travel. 
   The cutter (also called the mobile shear actuator)  903  is pivotable around pivot  4002  such that its tail  9033  moves downward D as pushed by the tapered front edge  3469  of the gripper housing  905 . The automatic gripper release lever  3  is also pivotable around pivot  4002 . The roller  1601  has an axle  9039 . As the screw  500  moves the gripper housing  905  forward, the automatic release lever actuators  4  also move forward. The automatic release lever actuators  4  have a forward pin  4000  that contacts recess  4001  of the automatic gripper release lever(s)  3 , thereby rotating the automatic gripper release lever(s)  3  clockwise as shown by arrow C in  FIG. 37 . The top and rear facing tip  3769  of the automatic gripper release lever(s)  3  each push the stationary gripper  901  backward against spring  9010  as the gripper housing  905  reaches the end of its forward travel. Mounting screws  4111  secure the automatic release lever actuators  4  to the gripper housing  905 . 
   The function of  3  and  4  is to release the stationary gripper  902  automatically, when the mobile gripper  901  is very near the end of its travel which must occur after the mobile shear actuator  903  has removed the tail of the smallest width clamp, i.e. ¼″. 
   PARTIAL PARTS List 
   
       
       
         
           1. Mobile gripper HSG-1 required. 
           2.  903  Cutter (also called the Mobile shear actuator)- 1  required. 
           3. Gripper release lever, automatic- 2  required. 
           4. Release lever actuator, automatic- 2  required. 
           5. Manual gripper release lever- 1  required. 
           6. Mobile gripper release pin, automatic- 1  required. 
           7. Manual gripper release lever- 1  required. 
         
       
     
  
   Although the present invention has been described with reference to preferred embodiments, numerous modifications and variations can be made and still the result will come within the scope of the invention. No limitation with respect to the specific embodiments disclosed herein is intended or should be inferred.