Wire tying tool with drive mechanism

A wire tying tool having a set of movable talons for channeling a loop of hard wire around a rebar joint or other object(s) to be tied with a wire knot at high speed; a heavy duty wire drive with a pullback feature to retract the loop under tension to tighten the loop around the joint; a clutch-controlled retractable reel to hold the tension on the hard wire on the reel; a spinner/cutter that extrudes a knot by turning, kinking, and cutting the wire (holding the cut ends under tension) and then spinning in complete revolutions to twist the wire into a knot while drawing the spinner away from the work surface. In a preferred embodiment a single reversible motor powers each of a wire drive, a talon drive and a spinner drive; logic and control elements control a sequence of operations of the various drives.

FIELD OF THE INVENTION 
The present invention relates to a wire tying tool, and more particularly 
to a portable, power assisted tool for binding rebar to be used in 
reinforced concrete, or for binding other object(s) with twisted wire. 
BACKGROUND OF THE INVENTION 
Concrete is a commonly used building material. Forms are fashioned and 
concrete is poured into the forms to harden, and then the forms are 
removed. To reinforce the concrete, a grid of metal "rebar" rods may be 
placed within the forms so that when the concrete hardens, it is 
strengthened by the rebar. The grid can be formed by a set of horizontal 
rebar rods which intersects with a set of vertical rebar rods. To hold the 
rebar grid in place, it is common to tie off the cross joints of the 
intersecting horizontal and vertical bars with a wire. This is a 
time-consuming process when done by hand, using standard 16 gauge annealed 
wire (about 67,000 psi). 
A conventional hand tie, using pliers or similar tool, involves looping a 
strand of wire over a cross joint and pulling it tight so that the loop 
tightly encloses the joint with the ends of the wire twisted off to 
prevent unraveling. Two complete twists of 360 degrees each will hold the 
tie in place. Sometimes the wire is doubled to prevent the wire from 
breaking at the tie/twist point. 
Because the tied joint has to hold while concrete is subsequently poured 
over it into the form, and may also (when the rebar is preassembled 
off-site) have to hold securely while the rebar grid is lifted, moved, 
stepped on, and handled, the wire tie must be tight and strong. Because of 
the difficulties associated with hand tying, it would be desirable to 
develop a light weight, portable, and reliable mechanical wire-tying tool. 
A desirable mechanical wire-tying tool should be able to: 
(a) loop a strand of wire over the joint to be tied--for this purpose a 
movable set of talons may be used with the talons placed over the joint 
and closed, the wire fed through the talons, and the wire then released 
from the talons so as to form a loop over the joint; 
(b) cut and twist the ends of the wire looped over the joint--for this 
purpose a spinner/cutter may be used to cut the ends of the wire loop, to 
hold the loop under tension, and to twist the ends so as to form a "knot" 
without breaking the wire before the knot is formed, and drawing out the 
cut off ends of the wire loop as the knot is formed to leave the tie in 
place; 
(c) pull back the slack on the ends of the loop after it is placed over the 
joint and then keep the loop under tension as the ends are twisted and the 
knot is being formed so as to form a tight knot--for this purpose, some 
sort of pullback mechanism and tension device should be used; and 
(d) feed a hard wire through the device without misfeeding through the 
talons or otherwise--for this purpose, a heavy duty wire drive mechanism 
should be used, and other portions of the device should be designed so as 
to cooperate in order to handle a hard wire delivered at high speed. 
A desirable mechanical wire tying machine should be able to accomplish all 
of the foregoing functions rapidly and reliably with a hard wire, and 
should be capable of being operated by a single person. Prior art 
mechanical wire tying tools have not been completely satisfactory in 
meeting all of the desired features. 
U.S. Pat. No. 3,391,715 of Thompson and U.S. Pat. No. 5,217,049 of Forsyth 
show wire tying devices having talons that are movable; cutters that 
include clamps with shear-plates (a shear disk); and feeding systems with 
a standard, paired wheel friction drive. Pullback is accomplished by 
reversing the drive wheels. 
Other variations on a device having a talon, and including shear disk 
cutters (or a moveable disk cutter or a single blade "loper"), 
conventional feeding systems such as standard paired wheel friction 
devices, or drive wheel reversal for pullback are shown in U.S. Pat. No. 
4,362,192 of Furlong et al.; U.S. Pat. No. 4,117,872 of Gott et al.(double 
wire system with talons that are channeled and not fully enclosed); U.S. 
Pat. No. 4,354,535 of Powell et al. (open groove); U.S. Pat. No. 4,685,493 
of Yuguchi; U.S. Pat. No. 4,953,598 of McCavey (single hook, open groove); 
and U.S. Pat. No. 4,834,148 of Muguruma et al. (open groove with 
semi-enclosing member). 
U.S. Pat. No. 4,542,773 of Lafon describes a wire tying machine with two 
lower jaws. Hand powered wire tie machines are shown in U.S. Pat. No. 
5,178,195 of Glaus et al. and U.S. Pat. No. 3,593,759 of Wooge. 
A principal disadvantage of current mechanical wire tying devices is their 
inability reliably to replace hand tying. The wire often misfeeds through 
the talons. The ends of the looped wire are frequently not twisted under 
tension sufficient to create a tight knot, and/or the knot breaks as it is 
being spun. The feed systems may not support a rapid advancement of a 
relatively hard wire, nor do the pullback or spools take up the wire. 
It can be seen that there is a need for a reliable mechanically assisted 
wire tying tool. Preferably, the tool would include enclosed or partially 
enclosed talons for channeling a loop of relatively hard wire around a 
rebar joint at high speed, a pullback feature to retract the loop under 
tension to tighten the loop around the joint, a spinner/cutter that 
extrudes a knot by turning, kinking, and cutting the wire (holding the cut 
ends under tension) and then spinning in complete revolutions to twist the 
wire into a knot while drawing the spinner away from the work surface (so 
as not to break the knot as it is being formed), and a reset control to 
immediately reset the tool for the next tie. 
The complete cycle should be completed in the space of about 2 to 3 
seconds. The tool should be hand held and driven by electricity or 
compressed air. It should weigh around 15 to 20 pounds, be about 18 to 24 
inches long, and about 4 to 6 inches in diameter. The tool should be able 
to improve upon the standard 16 gauge annealed wire rated at approximately 
67,000 psi and which is commonly used in hand tied knots, by handling, 
instead, a much harder wire, such as a 16 gauge "green" (nonannealed) hard 
wire rated above 67,000 psi and up to approximately 127,000 psi, or 
greater. 
It is a specific object of the wire tying apparatus and method of this 
invention to provide those benefits of reliability and performance which 
will permit a power tool to replace hand tying. 
SUMMARY OF THE INVENTION 
The present invention provides an apparatus and method for tying a wire 
knot around an object. A preferred use for the invention is tying a wire 
knot around rebar, but many other uses for the invention also exist, e.g., 
tying a wire knot around a fence post, a sack of potatoes or a bag of ice, 
or any other object, or combination of objects, around which a wire knot 
is needed or desired. The apparatus of the invention comprises a power 
assisted wire-knot tying tool. In the preferred embodiment, the tool is 
hand held and driven by electrical power, although battery power or 
compressed air could also be used. The tool weighs under 20 pounds (not 
including spool and wire), and is about 18 inches long, and about 4 to 6 
inches in diameter. The preferred tool is designed to take a hard wire 
such as a 16 gauge "green" nonannealed hard wire (up to approximately 
127,000 psi or more). 
The wire tying tool of the invention includes a set of movable enclosed 
talons for channeling a loop of relatively hard wire around a rebar joint 
at high speed; a clutched, spring actuated retractable reel to hold the 
tension on the hard wire on the reel; a spinner/cutter that extrudes a 
knot by kinking and cutting the wire (holding the cut ends under tension) 
and then spinning in complete revolutions to twist the wire into a knot 
while drawing the spinner away from the work surface (so as not to break 
the knot as it is being formed); and a reset control to immediately reset 
the tool for the next tie. 
In a preferred embodiment, the wire tying tool also includes a single 
reversible power source, e.g., an electric motor, which transmits power to 
three drive mechanisms including (i) a talon drive to close the talons 
around the joint to be tied, and then to reopen the talons; (ii) a spinner 
drive to advance and subsequently to retract a spinner shaft, turning and 
retracting the spinner after wire has been fed through the closed talons 
and a wire loop has been tightened around the joint, thereby spinning and 
extruding the knot; and (iii) a heavy duty wire drive to feed the wire 
into the talons and through openings on a spinner head attached to the 
spinner shaft, and then to retract the wire loop under tension to tighten 
the loop around the joint. It is to be understood that the invention is 
not restricted to an electric motor. Any suitable power source, or 
combination of power sources, may be used, e.g., a pnuematic motor(s), a 
hydrolic driver(s), an internal combusition engine (e.g., gasoline 
engine), and the like, coupled to a suitable energy source, e.g., 110/220 
VAC power line, a battery, a source of compressed air, or the like. 
In the preferred embodiment, the drive mechanisms incorporate a system of 
overload clutches, differentials, gears and mechanical logic such that the 
various drive mechanisms open the talons, close the talons, feed the wire 
through the talons and the spinner head, pull the loop, spin the knot, cut 
the wire, and reset the talons to the open position with but a single pull 
on the trigger which powers the motor. 
An operator simply places the open talons over the rebar joint (or other 
object or objects around which the wire knot is to be tied) and presses 
the trigger. Activation of the trigger first transmits power to the talon 
drive and spinner drive. This closes the talons around the joint, forming 
a completely enclosed loop while advancing the spinner head to its fully 
forward position for receiving a length of wire. When the talons have 
fully closed and the spinner is locked forward, a mechanism will direct 
the power to the wire drive, and the wire drive will force a given length 
of wire through a first passage in a spinner/cutter assembly about the 
spinner head, around the talon loop, and back through a second passage in 
the spinner/cutter assembly with the end of the wire lodging through a 
non-return device (the excess wire through the clamp becomes waste and 
will be pushed out and expelled in the next cycle). 
A mechanism is set to detect when the wire has reached the non-return 
device at the end of the loop, and the motor is reversed. The talon drive 
begins to pull back and the talons begin to open as the wire drive pulls 
back on the wire with full force, pulling the loop out of the talons and 
tightening the loop as it is released from the talons and pulled around 
the joint. The wire drive pulls the wire back under a preset tension 
(anywhere from 5 pounds or less of tension, to 150 pounds or more of 
tension) and tightens the loop around the rebar. The slack wire is reeled 
back automatically onto the spool. 
When the wire drive has pulled the wire loop tight and the talon drive has 
opened the talons, power is redirected to the spinner drive and the 
spinner/cutter is activated. The spinner begins turning, kinks and cuts 
the wire, and turns a number of revolutions to twist the wire into a tie. 
As the spinner begins turning, shaped indentations in the spinner barrel 
form kinks in the wire lodged within the spinner head, and as the spinner 
continues to turn, a cutter cuts the wire lodged within the spinner barrel 
leaving the kinks at the cut ends. The kinks formed at the cut ends of the 
wire then pull through the passageways within the spinner so as to 
maintain the wire under tension after it is cut. The spinner retracts from 
the work surface as it spins, and does so at a rate equivalent to the 
length of the tie it is producing as it turns, thereby extruding the knot 
away from the work surface. The tool is then at a ready position, and the 
operator can move to the next tie point. 
The combination of features provided by the invention permits the 
mechanical wire tying tool to replace hand tying in a reliable, fast and 
efficient manner.

Corresponding reference characters indicate corresponding components 
throughout the several views of the drawings. 
DETAILED DESCRIPTION OF THE INVENTION 
The following description is of the best mode presently contemplated for 
carrying out the invention. This description is not to be taken in a 
limiting sense, but is made merely for the purpose of describing the 
general principles of the invention. The scope of the invention should be 
determined with reference to the claims. 
In the discussion which follows, the invention will be described from two 
different perspectives. 
First, and with reference to FIGS. 1 through 12, the wire tying tool will 
be shown in a first embodiment with an emphasis on the most basic way in 
which the tool works--this will serve to explain how the spinner/cutter 
assembly spins and extrudes a knot, and how the wire drive and talons 
cooperate with the spinner/cutter. This discussion will serve as an 
introduction to the subsequent discussion of a second embodiment of the 
wire tying tool in which a preferred drive mechanism will be described. 
Second, and with reference to FIGS. 13 through 32, the tool will be shown 
in a second embodiment and the drive mechanism will be explained in much 
greater detail--this will serve to explain how a single motor can power 
the three drives (talon drive, spinner drive, and wire drive) with 
associated clutches, differentials, gearings and mechanical logic so that 
each of the subassemblies of the wire tying tool performs its function in 
the proper sequence. 
The first embodiment will be described under the heading "First Embodiment 
(Basic Operations)." The second embodiment will be explained under the 
heading "Second Embodiment (Drive Mechanism)." Although there is much in 
common between the two embodiments, each should be understood on its own. 
To emphasize the differences as well as the similarities, different sets 
of reference numbers have been used for the two embodiments. 
FIRST EMBODIMENT 
Basic Operations 
With reference to the perspective view of FIG. 1, it may be understood that 
a first embodiment of the wire tying tool 20 of this invention includes a 
wire drive and pullback assembly 22; a spinner/cutter assembly 24 (carried 
within the bearing block 30, and not visible in FIG. 1); a retractable 
reel or spool assembly 26; and a talon assembly 28. 
Associated mounting, handling, power supply and control systems are also 
included and are indicated in FIG. 1 as bearing block 30, gearbox housing 
32, spinner motor 34, feed drive motor 36, PC board 38, and handle support 
40. With reference to FIGS. 1 and 2, it may be understood that the wire 
drive assembly 22 and talon assembly 28 are mounted on the bearing block 
30, and that the spinner/cutter assembly 24 is carried within the bearing 
block. 
The discussion which follows will describe each of the subassemblies in 
turn, and then describe how the subassemblies connect and cooperate with 
one another to achieve the objects of this invention. 
The Wire Drive and Pullback Assembly 
With reference to FIG. 3, and the more detailed views of FIGS. 3A to 3H, a 
first embodiment of the wire drive and pullback assembly 22 may be seen as 
a wheel drive. The assembly 22 includes a frame bracket 42 which is 
connected to the bearing block 30 (not shown in FIG. 3), and a pivot block 
44 which is attached to the frame bracket. 
A feed roller 46 is carried on feed roller shaft 48 carried on the pivot 
block 44 and frame bracket 42. Cooperating feed pinch rollers 50, 52 are 
carried on feed pinch roller shafts 54, 56 carried on the pivot block and 
frame bracket. A worm gear 58 transmits power from the feed drive motor 36 
(not shown in FIG. 3) to feed roller shaft 48, and friction gears 60 cause 
the feed pinch roller shafts to move in concert with the feed roller 
shaft. It can be understood that the wire will feed between the feed 
roller 46 and the feed pinch rollers 50, 52. In a preferred embodiment, 
the contact surfaces of those rollers are grooved and are given a rough 
texture to better grip the wire. Such texture may be imparted by sand 
blasting the surfaces. A stripper 62 is used for initial loading of the 
wire, lifting the wire from the grooves in the drive rollers and directing 
the wire into feed tube 64 (reference FIGS. 1 and 2). 
With reference to FIG. 4, and the more detailed views of FIGS. 4A to 4F, a 
second embodiment of the wire drive and pullback assembly 22A may be seen 
as a belt drive. The assembly 22A includes a frame which is connected to 
the bearing block 30 (not shown in FIG. 4) and which includes of a pair of 
side panels 70, 72, a top panel 74 and a bottom panel 76. The frame is 
completed by a pair of end panels 78, 80 and a pair of straps 82, 84. 
A set of feeder pulleys 86 is carried between side panels 70, 72 and a 
feeder belt 88 is engaged on the pulleys. A cooperating set of feeder 
pinch rollers 90 is carried between the side panels and a pinch belt 92 is 
engaged on the rollers. Power from the feed drive motor 36 (not shown in 
FIG. 3) is transmitted to the feeder pulleys 86, and a tractor driven 
drive wheel drives the feeder belt 88 and pinch belt 92. It can be 
understood that the wire will feed between the belts. The feeder belts are 
given a friction surface; such a surface could be imparted by using a poly 
isoprene or other suitable material or coating. 
The Spinner/Cutter Assembly 
With reference to FIG. 5, the spinner/cutter assembly 24 may be understood 
to include a cylindrical spinner head 100 axially affixed to a screw 102 
which is in turn axially affixed to a spline 104. A screw collar 106 
affixed to the bearing block 30 (not shown in FIG. 5) engages the screw 
102, and a spline drive gear 108 transmits power from the spinner motor 34 
(not shown in FIG. 5) to the spinner assembly. Bushings 109 and 103 guide 
the assembly within bearing block 30. 
A first, or "entry" passage 112 and a second, or "exit" passage 110 are 
formed in the spinner head 100. While first passage 112 is referred to as 
the entry passage, and second passage 110 is referred to as the exit 
passage, it should be understood that these designations are for 
convenience of reference only and that the passages are essentially 
identical, and are bores passing diagonally through the spinner head 100, 
and are adapted for receiving the wire fed from the drive assembly 22. A 
pair of cutters 114, 116 are held in the barrel of the bearing block 30 
adjacent the spinner head. Passages 118 and 120 formed within cutters 114, 
116 are aligned with passages 110 and 112 so that wire may be fed through 
cutter 116 to the spinner head 100, and from the spinner head through 
cutter 114. 
Additional details of the spinner/cutter assembly may be understood with 
reference to FIG. 11 and FIG. 12. 
With reference to FIG. 11, it may be seen that passage 118 of cutter 114 is 
fitted with a set of grippers 180 to form a non-return clamp 182. The 
grippers are mounted with spring plates to urge them against a wire 200, 
and the grippers have a series of ridges forming teeth opposed to the 
direction by which the wire enters passage 120. While a similar non-return 
clamp might be provided in cutter 116 as well, it should be remembered 
that cutter 114 is the cutter adjacent the exit passage 110 of spinner 
head 100, and a non-return clamp in cutter 114 will serve to hold the wire 
that is fed through the assembly. 
Cutters 116 and 114 are mounted within bearing block 30 (see FIG. 2) and 
flush against the spinner head 100. Cutters 116 and 114 may be seen to 
have a flat mounting side 240 (FIG. 11B) for mounting against the bearing 
block, and a curved surface 242 (FIG. 11A) that abuts the spinner head. 
With reference to FIG. 12, it may be seen that there is a shaped 
indentation 110A within passage 110 of the spinner head. As shown in FIG. 
12, shaped indentation 110A may be formed by widening the opening of 
passage 110 in an elliptical shape on the surface of spinner head 100. A 
corresponding shaped indentation 112A (not visible in FIG. 12) is formed 
in the same manner by widening the opening of tube 112 on the opposite 
surface of the spinner head. 
The Talon Assembly 
With reference to FIG. 6, the talon assembly 28 may be seen to include a 
first talon 140 set in talon mounting brackets 142 and 143 (reference 
FIGS. 1 and 8A) through pivot point 144, with the mounting brackets 
connected to the bearing block 30. A talon closer arm 146 pivots in 
mounting brackets 142, 143 and cooperates with talon closer 160 to 
effectively immobilize the first talon when engaged. A completely enclosed 
channel 164 within talon 140 can accept wire fed into it. (Note, 
throughout the description that follows, the term "jaw" may be used as a 
synonym for the term "talon"). 
With reference now to FIG. 8, and more detailed views of FIGS. 8A to 8F, 
the talon 140 can be better understood to include a talon arm 170 and a 
talon cover 172. A channel 164 is formed in talon cover 172. When talon 
cover 172 meets talon arm 170, the two members cooperate completely to 
enclose channel 164. 
A second talon 150 (referring again to FIG. 6) is set in talon mounting 
brackets 152 and 153 (not shown) through pivot point 154. A talon closer 
arm 156 pivots in mounting brackets 152, 153 and cooperates with talon 
closer 162 to effectively immobilize the second talon when engaged. A 
completely enclosed channel 166 within talon 150 can accept wire fed into 
it. Although not separately shown, a talon arm 174 and talon cover 176 
form the enclosed channel 166 within second talon 150 in a manner 
corresponding to that of the first talon and as previously described with 
reference to FIG. 8. 
The first and second talons 140, 150 meet when closed so that the enclosed 
channels 164, 166 align. A bullet nose 165 on talon arm 170 of the first 
talon 140 (reference FIG. 8C) mates with an indentation on talon arm 174 
of the second talon 150 and helps to align the channels. 
As shown in FIGS. 6 and 7, a talon motor 220 mounted on bearing block 30 
powers a screw drive 222 for opening and closing the talons 140, 150. In 
the embodiment of FIG. 6, a worm drive translates the rotary motion from 
screw threads 224 to the flanges 226 and 228 which open and close the 
talon closer arms 146 and 156. In the embodiment of FIG. 7, a pair of tie 
rods 230, 232 connect screw 222 to talon closer arms 146 and 156 for 
opening and closing the talon closer arms. 
In both embodiments, the talon closer arms 146 and 156 drive the talons 140 
and 150 to a closed position. In the closed position, talon closers 160 
and 162 hold the talon arm and talon cover of the talon arms tightly 
together to keep the channels enclosed (in the case of the first talon 
140, as held closed by talon closer arm 146, talon closer 160 holds talon 
arm 170 and talon cover 172 tightly together so that channel 164 is 
enclosed; so also in the case of the second talon 150, as held closed by 
talon closer arm 156, talon closer 162 holds talon arm 174 and talon cover 
176 tightly together so that channel 166 is enclosed). 
Likewise, in both embodiments, as the talon closer arms 146 and 156 open, a 
gap will form between the talon closer arm and the respective talons 140 
and 150, and the talon closers 160 and 162 will begin to release their 
hold on the respective talon arms (170 and 174 of the first and second 
talons) and talon covers (172 and 176 of the first and second talons), so 
as to open the space which previously enclosed channels 164 and 166. This 
creates a sufficient "break away" seam in the channels 164 and 166 so that 
a wire fed through the enclosed channels with the talons closed can break 
out of the (now partially opened) channels as the talons open. 
The opening of the talons may be better understood with reference to FIG. 
7, which shows talon 140 in an open position in comparison with talon 150 
in a closed position (in actual operation, the two talons will open and 
close simultaneously, and the unworkable configuration of FIG. 7 with one 
talon open and the other talon closed is provided solely to illustrate 
both an open and a closed position of the talons). 
The Retractable Spool 
Referring now to FIGS. 9 and 9A, the retractable reel or spool assembly 26 
may be understood to include a spring loaded spool 190 contained within 
spool housing 180. A spring 192 is wound from a first point 194 on the 
spool to a second point 196 to create a spring load. The spring load keeps 
the hard wire used in this invention from expanding on the spool, and also 
takes up any slack when the wire drive pulls back on the wire looped 
around the rebar joint to be tied. A one-way clutch 182 stops forward 
overrun of the spool and keeps tension on the wire. 
The Wire Tying Tool 
Having described each of the subassemblies, their cooperative working in 
wire tying tool 20 will now be described. Referring generally to FIG. 2, 
it may be understood that the talons have been closed around a rebar joint 
to be tied. With the talons closed, the wire drive and pullback assembly 
22 draws a length of wire 200 from a spool of wire held in the retractable 
reel or spool assembly 26. The wire drawn by the wire drive and pullback 
assembly 22 is driven through tube 64, through cutter 116 of the 
spinner/cutter assembly 24 and through the entry passage 112 of the 
spinner head 100. Passing through the spinner head 100, the wire is driven 
through enclosed channels 164 and 166 of the talons 140 and 150, and back 
into the spinner head 100, passing through exit passage 110 of the spinner 
head and passing out through passage 118 of cutter 114 and through the 
non-return clamp 182 carried in cutter 114. 
When the wire is through and the end is lodged in the non-return clamp, a 
mechanism opens the talons, allowing the previously enclosed channel to 
open (as discussed previously in connection with FIGS. 6, 7 and 8) and 
activates the pullback function of wire drive assembly 22. The wire drive 
assembly 22 pulls back against the wire with a preset tension (50 to 100 
pounds) with one end of the wire firmly lodged in the non-return clamp. 
This pulls the wire loop from the channel within the talons and draws the 
loop tightly around the rebar joint. 
Now with reference to the sequential series of views of FIGS. 10A, 10B, 10C 
and 10D, the operation of the spinner/cutter can be better understood. 
In the ready position of FIG. 10A, the spinner head 100 is aligned with the 
cutters 116 and 114 so that the entry and exit passages 112 and 110 of the 
spinner head align with passages 120 and 118 of the cutters. 
As can be seen in FIG. 10B, a length of wire 200 is fed through tube 120 of 
cutter 116, tube 112 of the spinner head 100 (and, after forming a loop 
through the talon arms, not shown in FIG. 10), tube 110 of the spinner 
head, and tube 118 of cutter 114. Wire 200 is lodged within the non-return 
clamp 182 (not shown in FIG. 10) of cutter 114. 
With reference to FIG. 10C, it can be understood that, after the loop is 
pulled back and tightened by the wire drive assembly (as previously 
discussed), and as the spinner begins to turn in a counterclockwise 
direction, one end of wire 200 is pushed into shaped indentation 110A in 
passage 110 and the other end of wire 200 is pushed into shaped 
indentation 112A of passage 112. This initial movement of the spinner head 
100 forms a kink in each of the ends of wire 200. 
Next, and with reference to FIG. 10D, it may be understood that the two 
ends of wire 200 are cut by cutters 114 and 116 as the spinner continues 
to rotate. A twist knot 202 forms at the end of the wire loop adjacent to 
the spinner head 100. It may be understood that the knot 202 will continue 
to twist into place with further rotation of the spinner head, dragging 
the kinked ends of wire 200 through passages 110 and 112 of the spinner as 
it rotates. The kinked ends provide resistance within passages 110 and 
112, keeping the wire loop under tension as the twist knot is formed. 
The spinner head 100 extrudes the knot 202 away from the work surface of 
the rebar joint as the knot is being formed and as the kinked ends of the 
wire 200 are being drawn out of the spinner. This is accomplished by the 
cooperation of the screw 102 and collar 106 (reference FIGS. 2 and 5) 
which act to pull the spinner head 100 away from the work surface with 
each moment of rotation of the spinner head. A very precise movement can 
be achieved. Satisfactory results have been obtained using a screw pitch 
of 1/4 inch, where four revolutions of the spinner extrudes a one-inch 
knot. By extruding the knot as it is being formed, the knot is much less 
likely to break off and ruin the twist/tie. 
The associated triggers, motors, control devices, and the like are readily 
known in the industry and can be easily added to the above-described 
invention to complete the working thereof. 
The foregoing description explains how the wire tying tool 20 of this 
invention forms a tight knot around a rebar joint, using a hard wire held 
under constant tension on a clutched-spool 26, a wire drive that sends a 
length of wire through a spinner/cutter assembly 24, looping around a 
completely enclosed track within talon assembly 28, and back through the 
spinner/cutter and through a non-return clamp where it is firmly lodged. 
More importantly, the foregoing description explains how the wire loop is 
tightened under tension supplied by the pullback of the drive assembly, 
how the length of wire is kinked and cut so as to maintain the tension in 
the loop as the knot is being formed, and how the knot is extruded from 
the spinner head as the spinner head withdraws from the work surface. 
The method of this invention has been generally described in connection 
with the foregoing working of the tool, and includes: closing a pair of 
talons around a joint to be tied; driving a length of hard wire through a 
spinner/cutter, through a completely enclosed channel in the talons, and 
back through the spinner/cutter to a clamp; opening the talon channel so 
as to release the loop; pulling back on the loop to tighten it around the 
joint; and kinking, cutting, and twisting the wire so as to extrude a knot 
away from the joint while holding the loop under tension as the knot is 
being formed. 
Accordingly, it can be understood that this invention provides the benefits 
of a tight and uniform wire tie, using a hard wire and replacing hand 
ties. 
SECOND EMBODIMENT 
Drive Mechanism 
The first embodiment described above contemplates three motors, with a 
separate spinner motor (34), wire drive motor (36), and talon motor (220). 
The first embodiment also contemplated conventional electronic logic and 
control devices, as are well known in the field. 
With reference now to the perspective view of FIG. 13, a second embodiment 
of the tool, having a single motor and a system of gears, latches, 
differentials and clutches will now be described. In this embodiment, the 
single motor will drive each of the spinner, the wire, and the talons in 
sequence. Thus, the single motor embodiment of FIG. 13 can be thought of 
as having a three-part drive mechanism, that is, a spinner drive, a talon 
drive, and a wire drive. 
The discussion of the embodiment of FIG. 13 will include an overview, a 
glossary, and then a more detailed discussion which is organized around 
the three drives, followed by a discussion of the sequencing of the drives 
and the operation of the tool. Those three drives of the embodiment of 
FIG. 13 are generally described as follows (more detailed reference 
numerals in the related figures will be introduced subsequently): 
Spinner Drive--The spinner drive actuates a spinner head by way of a 
spinner shaft. During the cycle of the tool, the spinner head first 
advances to a fully forward position and then forms knots by extruding the 
wire with rotary motion while retracting in a controlled manner. 
Talon drive--The talon drive actuates the talons (or jaws) during the cycle 
of the tool, closing them at the beginning of the cycle to establish the 
wire path before the wire drive feeds the wire, and opening the talons 
(jaws) when the wire drive begins wire pullback. 
Wire drive--The wire drive powers a capstan which pulls wire from the 
supply spool, pushes it through the talons, then reverses for 
"pullback"just before the knot is spun and extruded by the spinner drive. 
These three drive functions are coordinated using mechanical logic to 
achieve the proper sequencing and drive flow during the cycle of the tool. 
A single reversible motor is used to power the tool and a small electronic 
control module is utilized to start, stop and reverse the motor at 
appropriate points during the cycle. In the overview, the action will be 
described as "forward" and "reverse," and the action will later be 
amplified in terms of the clockwise or counterclockwise rotation of the 
motor as transmitted to the various other driven shafts of the tool. 
The overview will orient the reader to the three drives, their location 
within the tool, their general purposes and relationship to one another 
and to the single motor which powers all three. The glossary will then 
list most of the working elements of the three drive mechanisms. Because 
of the number of similarly functioning latches, detents, shafts, pins, 
springs, rollers and so on spread over three drive mechanisms, we have 
used distinguishing nomenclature which can be fairly lengthy. For example, 
we will describe a "wire lock release lever," and a "wire lock release 
inhibit lever," cooperating with such things as a "wire lock release 
inhibit lever cam pin" (350 in FIG. 26) and a "wire lock release tab" 
(352). We believe these terms to be helpful to an understanding of the 
invention. To help prevent confusion, we have provided a glossary of 
terms. 
Overview. With reference to the perspective view of FIG. 13, it may be 
understood that this embodiment is not greatly different in external 
appearance from the embodiment of FIG. 1. A wire spool 600 may be seen at 
the right rear of the tool and a capstan 364 may be seen at the top of the 
tool, near the front. The wire drive will power the capstan to draw wire 
from the spool into the tool. Two talons, an upper talon 400 and a lower 
talon 401 are seen in a vertical orientation at the front of the tool. The 
talon drive will pull back on the talons to open them (and push forward to 
close them). It should be noted that, in this particular configuration, 
the talons will open and close in the vertical plane (up and down) and it 
should be apparent that the talons could have been oriented in any other 
position desired. The vertical orientation chosen here allows the talons 
to be conveniently placed over a joint to be tied. Two handles, a trigger 
handle 602 at the rear of the tool, and a support handle 604 near the 
front of the tool, are provided for operator control. The trigger handle 
contains a trigger 606 and a reverse button 608. The support handle 604 
provides a convenient hand-hold for the operator to stabilize and support 
the tool. A long-handled version of the tool (see FIG. 30) extends the 
range of the tool, permitting the operator, for example, to stand more 
comfortably while setting ties near the operator's feet. The motor 300 
(not visible in FIG. 13) is mounted in the rear of the tool and is powered 
through electric cord 610. Of course the tool could be powered by battery, 
hydraulic or other appropriate power source. For safety and other reasons, 
the tool is surrounded by an exterior housing 612 which keeps many of the 
moving parts of the drive mechanism out of the path of the operator's 
hands and otherwise shelters them from exposure. Other similarities, and 
differences, between the embodiment of FIG. 13 and the previously 
discussed embodiment of FIG. 1 will become more apparent as this 
description proceeds. 
The embodiment of FIG. 13 includes three drives, a wire drive, talon drive, 
and spinner drive (not visible in FIG. 13, but to be shown later, with 
reference to other figures). In this embodiment, each of the three drives 
are driven by a single motor. Taking the perspective view of FIG. 13, it 
may be seen that the tool of this embodiment has a right side where the 
spool 600 is carried; a left side; a front (or "fore") part where the 
talons 400 and 401 are carried; a back (or "aft") part from whence the 
cord 610 exits; a top surface where the capstan 364 is carried; and a 
bottom surface. Given this frame of reference, the shafts of the various 
drives will be described as running "vertically" or "horizontally." A 
"vertical" shaft is one whose axis runs generally up and down, from the 
top to the bottom of the tool. A "horizontal" shaft is one whose axis runs 
generally parallel to a longitudinal axis of the tool, that is, from front 
to back. 
One difficulty in presenting an overview of the tool of FIG. 13 is that 
there is no one view of the tool in which all of the three drive 
mechanisms and their associated drive shafts may be clearly seen and 
understood at once--various of the horizontal shafts overlay and obstruct 
a view of other shafts from any angle. But the understanding of the tool 
and of its drive mechanisms becomes straightforward once the orientation 
of the drives is seen with reference to the shafts that tend to define 
them, recognizing that this requires the cooperative viewing of several 
figures. In overview, each of the main shafts and drives will now be 
identified and located. 
The wire drive ultimately powers the capstan 364 (FIG. 13) which, when 
running in the forward direction, will draw wire from the spool 600, feed 
the wire into the openings on the spinner head 332 (not visible in FIG. 
13, but shown, e.g., in FIG. 20) and through the talons 400 and 401; and, 
when running in reverse, will pull back on the wire, pulling a loop about 
the joint to be tied. With reference to FIGS. 24 and 25, it may be 
understood that the wire drive itself includes a vertical shaft 362 and a 
horizontal shaft 340. In the discussion which follows, vertical shaft 362 
will be referred to as the "capstan drive shaft" and horizontal shaft 340 
will be referred to as the "differential output shaft" and other details 
will be shown and discussed. For present purposes, it is sufficient simply 
to note the horizontal and vertical axes of the wire drive, and to orient 
the wire drive within the tool. Referring to FIGS. 13, 14 and 24, it can 
be understood that the horizontal shaft 340 of the wire drive runs 
longitudinally within the housing 612, at the left side of the tool and 
near the top of the tool, and that the vertical shaft 362 of the wire 
drive is perpendicular to the horizontal shaft, extending up within the 
housing to the capstan 364, to which it will transmit power. 
The spinner drive ultimately powers the spinner head 332 (FIG. 20) which, 
when running in the forward direction, will rotate and advance forward 
into a proper position at the front of the tool to receive the wire that 
will be fed by the wire drive into its openings; and, when running in 
reverse, will then rotate and retract, cutting the wire and spinning and 
extruding the knot. With reference to FIG. 20, it may be understood that 
the spinner drive includes a horizontal shaft 326. In the discussion which 
follows, this horizontal shaft 326 will be referred to as the "spinner 
shaft" and other details will be shown and discussed. For present 
purposes, and referring to FIGS. 13, 14 and 20, it is sufficient to 
observe that the horizontal shaft 326 of the spinner drive runs 
longitudinally within the housing 612, near the center bottom of the tool. 
The talon drive ultimately pushes a lever 392 (FIG. 15) at the bottom of 
the tool which, when the drive is running in the forward direction, will 
push the talons 400 and 401 (FIG. 13) closed, enclosing the joint to be 
tied, with the talons ready to receive the wire that will be fed by the 
wire drive into the channel within the talons; and, when running in 
reverse, will pull the talons open, releasing the wire loop around the 
joint to be tied. With reference to FIG. 15, it may be understood that the 
talon drive includes a horizontal shaft 386 and another horizontal member 
390 connected to the shaft. In the discussion which follows, the 
horizontal shaft 386 of the talon drive will be referred to as the "talon 
lead screw shaft," the other horizontal member 390 will be referred to as 
the "talon pushrod," and other details will be shown and discussed. For 
now, and referring to FIGS. 13 and 15, it should be observed only that the 
horizontal shaft 386 of the talon drive runs longitudinally within the 
housing 612 near the bottom of the tool and on the right side. 
The orientation of the three horizontal shafts of the three respective 
drives may now be seen, in overview, with reference to FIG. 26A, which is 
a front sectional view of the tool. The horizontal shaft 340 of the wire 
drive may be seen at the left top; the horizontal shaft 326 of the spinner 
drive may be seen at the center bottom; and the talon pushrod 390 of the 
talon drive may be seen at the right side (the horizontal shaft 386 of the 
talon drive is adjacent the talon pushrod but cannot be seen in FIG. 26A). 
Finally, and with reference to FIG. 14, one more horizontal shaft may be 
noticed, and that is the main shaft 316 driven by the motor 300. The main 
drive shaft 316 will be referred to as the the "differential input shaft" 
316 for reasons which will become clear later. 
Now it may be better understood how and why the sequencing of the drives is 
important to the proper working of the tool. Still with reference to FIG. 
14, the talons 400, 401 should be closing while the spinner head 332 is 
advancing to the forward position: the talon drive and the spinner drive 
should move forward in tandem. The talons 400, 401 should be fully closed 
and the spinner head 332 fully forward before the wire drive feeds any 
wire: the capstan 364 of the wire drive should push the wire through only 
when the talon drive and the spinner drive are not moving their respective 
assemblies. The drives should go into reverse when the proper length of 
wire is fed and engaged. Working in reverse, the capstan 364 of the wire 
drive now pulls back on the wire, the talon drive opens the talon 400 and 
401, and the spinner head 332 rotates and retracts. 
This sequencing presents a problem for logic control, and the more detailed 
discussion which follows this overview is best understood in terms of 
explaining that control. Two final observations concerning the sequencing 
are pertinent in this overview. 
In the first place, a key towards understanding the sequencing is the 
recognition that the motor 300, when triggered, powers two shafts 
simultaneously, and at all times. The two constantly powered shafts are 
(a) the differential input shaft 316 (reference FIG. 14) which is the 
source of power for the spinner drive and the wire drive, and (b) the 
talon lead screw shaft 386 (reference FIG. 15) which is the source of 
power for the talon drive. Each of these are clutched (main overload 
clutch 314 with reference to FIG. 14; and talon overload clutch 384 with 
reference to FIG. 15) so that power may be relieved and the shafts are not 
always driven, but the point is that both the differential input shaft 316 
and the talon lead screw shaft 386 are always powered, and so both may run 
together, or separately. 
Of these two constantly powered shafts, one, the talon lead screw shaft 
386, directly transmits power to the talon drive and thus accounts for one 
of three drive systems (the talon lead screw shaft 386 is the horizontal 
shaft of the talon drive previously discussed in this overview). 
The other of the two constantly powered shafts, the differential input 
shaft 316 (reference FIG. 14), accounts for the other two drive systems. 
The differential input shaft 316 feeds into a differential 318 which 
splits the power to the wire drive or to the spinner drive. The 
differential transmits power either to the wire drive, by way of the 
differential output shaft 340 (which is the horizontal shaft of the wire 
drive previously discussed in this overview) and capstan drive shaft 362 
(which is the vertical shaft of the wire drive previously discussed in 
this overview); or to the spinner drive, by way of intermediate gears to 
spinner shaft 326 (which is the horizontal shaft of the spinner drive 
previously discussed in this overview). The wire drive is clutched (wire 
drive overload clutch 360 on the vertical shaft 362 of the wire drive, 
reference FIG. 25) and the spinner drive may be "detented" or locked so 
that the power is directed to one or the other of the spinner drive or the 
wire drive. 
This arrangement of shafts, clutches and detents or locks permits the three 
drives to be combined as necessary. The tool is sequenced, at various 
points in the cycle, so that the talon drive and either the spinner drive 
or the wire drive are being driven--for example, and with reference to 
FIG. 14, the talon drive together with the spinner drive, so that the 
talons 400 and 401 close and the spinner head 332 advances while the wire 
drive is locked); so that either the spinner drive or wire drive, but not 
the talon drive, is being driven (for example, the wire drive alone, so 
that the capstan 364 feeds wire through the tool while both the talon 
drive and spinner drive are locked); and so on (various other combinations 
will be discussed further in the detailed description). 
This leads to the second point to be made in this overview about the logic 
control system. The particular embodiment discussed herein is essentially 
a mechanical logic system rather than an electronic logic system. The 
mechanical logic was chosen for, among other reasons, its expected 
durability in an anticipated operating environment which may be dirty, 
muddy, cold or hot and otherwise potentially hostile. We believe that the 
mechanical logic design has allowed this wire tying tool to be fabricated 
as a heavy duty, reliable tool with industrial application. Accordingly, 
we believe that the mechanical logic example which is given herein is the 
better way of embodying our invention. It should be remembered, of course, 
that once our invention is understood, it is a simple design choice to 
incorporate its features in electronic logic instead of mechanical logic. 
The translation from mechanical to electronic logic is well known in the 
industry and it should be understood that this invention is suitable for 
either mechanical or electronic logic, and that this invention covers both 
applications. 
Having completed this overview, a glossary of terms will now be presented. 
Glossary. Most of the components which are relevant to the operation and 
sequencing of the drive mechanisms of the tool are numbered and briefly 
defined in the list below (these components will be explained in more 
detail below, and will be more particularly pointed out with reference to 
the various drawings, this glossary is for the reader's aid only): 
______________________________________ 
Ref/FIG Element Description 
______________________________________ 
300 Drive Motor The universal AC/DC reversible 
FIG. 14 motor (approx. 1/4 to 1/3 HP) 
used to power the tool and having 
a motor shaft. 
301 Motor Shaft The shaft of motor 300 
302 Motor Pinion 
The small diameter gear 
integral to the motor shaft of 
motor 300. 
304 Planetary The two gears driven by the Motor 
Gears Pinion 302. 
306 Planetary The carrier for the Planetary 
Cage Gears 304. 
308 Ring Gear The internal gear which the 
Planetary Gears 304 drive 
against. 
310 Intermediate 
The gear which is directly 
Pinion driven by the Planetary Cage 
306. 
312 Main Drive The gear driven by the Intermediate 
Gear Pinion 310, which is the 
source of power for the Spinner 
Drive and the Wire Drive. 
314 Main Overload 
The torque limiting clutch directly 
Clutch driven by the Main Drive 
Gear 312. 
316 Differential 
The shaft directly driven by 
Input Shaft the Main Overload Clutch 314 
which supplies power to the 
Differential. 
318 Differential 
The "power splitting" device 
which powers either the Spinner 
drive or the Wire drive. 
320 Differential 
The outer structure of the 
Cage Differential 318. 
322 Spinner Drive 
The gear mounted to the Differ- 
FIG. 24 Pinion ential Cage 320 which powers 
the Spinner Drive by driving 
the Spinner Drive Gear 324. 
324 Spinner Drive 
The gear driven by the Spinner 
FIG. 20 Gear Drive Pinion 322 which provides 
rotation to the Spinner Shaft 
326. 
326 Spinner shaft 
The shaft which provides rotation 
and linear movement to the 
Spinner Head 332. 
328 Spinner Drive 
The spline which permits linear 
Spline movement to the Spinner Shaft 
326 while transmitting torque. 
330 Spinner Drive 
The thread which causes linear 
Thread movement of the Spinner Shaft 
326 during rotation. 
332 Spinner Head 
The head which extrudes the 
knots after wire has been fed 
through and pulled back. 
334 Cutter Blocks 
The two blocks against which 
the wire ends are sheared when 
knots are extruded. 
336 Wire Sensor The spring loaded rotating tab 
FIG. 21 Toggle which cams and triggers the 
Wire Sensor 338 when the wire 
feeds through the Spinner Head 
332 and which also locks the 
wire upon pullback. 
337 Wire Sensor The tab on the Wire Sensor Toggle 
Toggle Tab 336 in the wire path which 
actuates the toggle 336 and 
locks the wire. 
338 Wire Sensor The proximity switch which is 
triggered by the Wire Sensor 
Toggle 336. 
340 Differential 
The shaft that transfers power 
FIG. 14 Output Shaft 
from the Differential 318 to 
the Wire Drive. 
342 Wire Lock The notched wheel that enables 
FIG. 26 Wheel the wire drive to be locked 
when not being utilized. 
344 Wire Lock The swinging lever/tab that engages 
Pawl the Wire Lock Wheel 342. 
346 Wire Lock Re- 
The cammed lever that actuates 
lease Lever the Wire Lock Pawl 344 via a 
compression spring. 
348 Wire Lock Re- 
The cammed lever that inhibits 
lease Inhibit 
the Wire Lock Pawl 344 from 
Lever disengaging the Wire Lock Wheel 
342. 
350 Wire Lock Re- 
The pin that actuates the Wire 
lease Inhibit 
Lock Release Inhibit Lever 348 
Lever Cam Pin 
(carried on the opposite arm of 
348). 
352 Wire Lock Re- 
The tab rotating with the Spinner 
lease Tab Shaft 326 that actuates 
Wire Lock Release lever 346. 
354 Wire Lock Re- 
The cam located on the Talon 
lease Inhibit 
Push Rod 390 which actuates the 
Lever Cam Wire Lock Release Inhibit Lever 
Cam Pin 350. 
356 Wire Drive The miter gear mounted on the 
FIG. 24 Driver Miter 
end of the Differential Output 
Gear Shaft 340 which supplies power 
to the Wire Drive by driving 
the Miter Gear 358. 
358 Wire Drive The miter gear that is driven 
FIG. 25 Driven Miter 
by the Wire Drive Driver Miter 
Gear Gear 356 and which is directly 
coupled to the Wire Drive 
Overload Clutch 360. 
360 Wire Drive The torque limiting clutch that 
Overload supplies power to the Capstan 
Clutch Drive Shaft 362. 
362 Capstan Drive 
The shaft that transmits power 
Shaft to the Capstan 364. 
364 Capstan The drive module that feeds and 
FIG. 13 pulls back the wire during the 
cycle of the tool. 
366 Capstan Drive 
The gear keyed to the Capstan 
FIG. 17 Pinion Drive Shaft 362 which drives 
the Capstan Sun Gear 368. 
368 Capstan Sun The large gear inside the Capstan 
Gear 364 which directly drives 
the Capstan Drum 370. 
370 Capstan Drum 
The smooth steel drum around 
which the wire wraps during its 
passage through the Capstan 
364. 
372 Capstan The grooved, spring loaded 
FIG. 19 Rollers rollers which surround the Capstan 
Drum 370. 
373 Capstan The springs that push inward 
Roller towards the center of the 
Preload capstan to load the Capstan 
Springs Rollers 372 against the Capstan 
Drum 370. 
374 Capstan The gears which are directly 
Roller Gears 
keyed to the Capstan Rollers 
372 and which are driven by the 
Capstan Sun Gear 368. 
376 Infeed Guide 
The conical guide into which 
FIG. 17 Funnel the wire initially feeds as it 
travels into the capstan 364. 
378 Infeed Guide 
The guide block that guides the 
wire from the Infeed Guide Funnel 
376 to the first Capstan 
Roller 372. 
380 Outfeed Guide 
The guide block that guides the 
wire from the last Capstan 
Roller 372 to the Feed Tube 
382. 
382 Feed Tube The tube that guides the wire 
from the Outfeed Guide 380 to 
the Spinner Head 332. 
384 Talon The torque limiting clutch directly 
FIG. 15 Overload driven from the Intermediate 
Clutch Pinion 310 which directly 
powers the Talon Lead Screw 
Shaft 386. 
386 Talon Lead The threaded shaft which drives 
Screw Shaft the Talon Lead Screw Nut 388 
fore and aft. 
388 Talon Lead The threaded nut, driven by the 
Screw Nut Talon Lead Screw Shaft 386, 
which is directly connected to 
the Talon Pushrod 390. 
390 Talon Pushrod 
The rod driven by the Talon 
Lead Screw Nut 388 which moves 
fore and aft as the Talons 400, 
401 are closed and opened. 
392 Lower Talon The lever on the bottom of the 
Lever tool that is actuated by the 
Talon Pushrod 390 and which 
drives the Talon Cross Shaft 
398 and the lower Talon 
Connecting Rod 396. 
394 Upper Talon The lever on the top of the 
FIG. 22 Lever tool that is actuated by the 
Talon Cross Shaft 398 and 
drives the upper Talon 
Connecting Rod 397. 
396 Talon The adjustable rod which connects 
Connecting the Lower Talon Lever 394 
Rod (lower to the Lower Talon 401. 
talon) 
397 Talon The adjustable rod which connects 
Connecting the Upper Talon Lever 392 
Rod (upper to the Upper Talon 400. 
talon) 
398 Talon Cross The torsion shaft which ties 
Shaft the Upper and Lower Talon 
Levers 394 and 392 together. 
400, 401 
Upper Talon The moving jaws which open to 
FIG. 13 and Lower allow the tool to be placed 
Talon around a bundle of rebar (or 
other items to be tied) and 
close to establish the wire 
path so that wire can be fed 
through the tool. 
402 Moving (optional, alternative concept 
(not Inserts to the traps doors 404) The 
shown) floating plates which contain 
the encapsulating portions of 
the talon wire path, which are 
cammed into place when the 
Talons close. 
404 Trap Doors (alternative concept to the 
FIG. 31 Moving Inserts 402) The 
spring-loaded doors which 
contain the encapsulating 
portions of the wire path, and 
which open and close with a 
pivoting action rather than a 
floating action as the Talons 
open and close. 
406 Spinner The part that mounts on the aft 
FIG. 28 Detent Hub end of the Spinner Shaft 326 
that enables the Spinner Shaft 
to be locked in the forward 
position, which includes the 
Helper Spring Roller 407 for 
compressing the Helper Spring 
424 and which has a pin 409 to 
engage the Detent Latch 412. 
406A Detent Lobe The cam feature on the Spinner 
Detent Hub 406 which engages 
the detect roller 410 to lift 
the detect arm 408. 
407 Helper Spring 
The roller carried on the Spinner 
Roller Detent Hub 406 for 
compressing the Helper Spring 
424. 
408 Detent Arm The swinging spring loaded arm 
on which the Detent Roller 410 
is mounted, which locks the 
Spinner Detent Hub 406 in place 
when the Spinner Shaft 326 is 
in the forward position. 
408A Detent Spring 
The extension spring that pulls 
the Detent Arm 408 downward 
opposing the lifting action of 
the Detent Lobe 4067A on the 
Detent Rollar 410. 
409 Pin The pin carried on the Spinner 
Detent Hub 406 for engaging the 
Detent Latch 412. 
410 Detent Roller 
The roller mounted on the 
Detent Arm 408. 
412 Detent Latch 
The pivoted latch mounted on 
the Detent Arm 408 which 
engages the pin 409 on the 
Detent Hub 406. 
414 Latch Inhibit 
The pivoted lever that inhibits 
Lever the Detent Arm 408 from latching. 
416 Latch Release 
The pivoted finger which trips 
Finger the Detent Latch 412 so the Detent 
Hub 406 can rotate away 
from the Detent Roller 410 
(unlocking the detent hub 406). 
418 Latch Inhibit 
The pin actuating the Latch Inhibit 
FIG. 29 Lever Cam Pin 
Lever 414 (away from its 
inhibit position) that is 
cammed by the Cam Plate 422 
when the Talons 400, 401 are 
closed (pushrod 390 is in its 
forward position). 
420 Latch Release 
The pin actuating the Latch 
Finger Cam Release Finger 416 that is cammed 
Pin by the Cam Plate 422 when the 
Talons 400, 401 are open 
(pushrod 390 is in its aft 
position). 
422 Cam Plate The plate having two cam features, 
423 and 425 and which is 
mounted on the Talon Pushrod 
390. 
423, 425 
Cam Features 
The two cam features of cam 
plate 422. 
424 Helper Spring 
The compression spring that is 
FIG. 28 compressed just before the 
Spinner Detent Hub 406 locks 
into position and which 
provides helping torque to the 
spinner head 332 when it cuts 
the wire. 
426 Rear Limit The proximity switch that 
FIG. 14 Sensor senses when the Spinner Shaft 
326 has retracted, and which 
then signals the motor 300 to 
stop. 
______________________________________ 
Having now completed the overview of the second embodiment, and having set 
forth a glossary of terms, the detailed discussion which follows will 
describe the motor, the motor gears and differential, and each of the 
three drive mechanisms, in turn. 
The Motor, Motor Gears and Differential 
With reference to FIG. 14, it may be understood that the motor 300 is a 
reversible motor which powers the tool. Good results have been obtained 
using a universal AC/DC reversible motor of approximately one-quarter to 
one-third horse power. A small electronic control module (not separately 
numbered) is used to start, stop and reverse the motor at appropriate 
points during the cycle. 
It is to be emphasized that alternate power sources, other than a universal 
AC/DC reversible motor, may be used to practice the invention, such as 
hydraulic motors/pistons, pneumatic motors, and/or gasoline powered 
motors. 
Motor pinion 302 is a small diameter gear integral to motor shaft 301. The 
motor pinion 302 drives two planetary gears 304 held within planetary cage 
306. Coaxial ring gear 308 is the internal gear which the planetary gears 
304 drive against, and intermediate pinion 310 is driven by the planetary 
cage 306. Intermediate pinion 310 drives main drive gear 312. As will be 
explained later in connection with the differential input shaft 316 and 
differential 318, the main drive gear 312 is the source of power for the 
spinner drive and the wire drive by way of main overload clutch 314. 
Main overload clutch 314 is a torque limiting clutch directly driven by the 
main gear 312. The main overload clutch 314 directly drives differential 
input shaft 316. Differential input shaft 316 supplies power to the 
differential 318 which is mounted in differential cage 320. Differential 
318 is a power splitting device which powers either the spinner drive or 
the wire drive. 
Spinner Drive 
With reference now to FIG. 20 (and also with reference to FIG. 14 for the 
relation of the spinner drive to the differential 318 and differential 
cage 320), it may be understood that the spinner drive takes off from the 
differential 318 by way of spinner drive pinion 322 which is mounted to 
the differential cage 320. Spinner drive pinion 322 drives spinner gear 
324 which imparts rotation to spinner shaft 326. Spinner drive spline 328, 
in cooperation with spinner drive thread 330, permits linear movement of 
the spinner shaft 326 during rotation of the shaft while also transmitting 
torque. 
Spinner head 332 is the head which extrudes the knots after wire has been 
fed through the head and pulled back. It operates in the same fashion as 
spinner head 100 previously described in connection with the first 
embodiment. The spinner head 332 shears the wire against two cutter blocks 
334 when the spinner head starts to spin and the knot is extruded. 
In connection with the spinner, there are a number of other elements to be 
seen. These include mechanical logic elements which will be mentioned now, 
but described in greater detail later. With reference to FIG. 21, wire 
sensor toggle 336 is a spring loaded rotating tab which cams and triggers 
wire sensor 338 when the wire feeds through the spinner head 333. Wire 
sensor 338 is a proximity switch. When triggered, the wire sensor 338 will 
stop and reverse the motor 300. It may be seen that a tab 337 on wire 
sensor toggle 336 is in the wire path. As the wire is fed through the 
path, the wire will hit tab 337, actuating toggle 336 to contact the wire 
sensor 338, stopping and reversing the motor 300. When the wire is pulled 
back, the spring-loaded toggle 336 will urge tab 337 against the wire, 
locking the wire in place. Tab 337 is drawn to a point for this purpose. 
Wire Drive 
Referring again to FIG. 14, it will be remembered that differential 318 is 
the power splitting device which powers either the spinner drive or the 
wire drive. With reference now to FIG. 24, it can be seen that the wire 
drive takes off from the differential 318 by way of wire drive driver 
miter gear 356 which is mounted on the end of differential output shaft 
340. Referring to FIG. 25, a wire drive driven miter gear 358, driven by 
driver miter gear 356, is directly coupled to wire drive overload clutch 
360. 
In contrast to the first embodiment of the wire tying tool, previously 
discussed in connection with FIGS. 1 through 12, and which used either a 
wheel drive or a belt drive to feed the wire from the spool to the talons, 
a preferred mechanism for feeding the wire in the second embodiment of the 
tool, now being discussed in connection with FIGS. 13 through 32, is a 
capstan 364 (see FIG. 13) that is driven by the wire drive and which feeds 
and pulls back the wire. 
With reference again to FIG. 25, wire drive overload clutch 360 is a torque 
limiting clutch that supplies power from motor 300 to the capstan 364 by 
way of capstan drive shaft 362. 
The capstan 364 itself can be better understood with reference to FIGS. 16, 
17, 18 and 19. The capstan includes a capstan drum 370, which is a smooth 
steel drum around which the wire will wrap during its passage through the 
capstan, and the capstan also includes a set of capstan rollers 502, 504, 
506, 508, 510, 512, 514, 516, 518, 520 (the rollers are sometimes, and 
when it is not necessary to distinguish among them, collectively referred 
to with reference numeral 372). A capstan sun gear 368 drives the drum 
370, and is itself driven by capstan drive pinion 366. Pinion 366 is keyed 
to the capstan drive shaft 362 (previously discussed in connection with 
FIG. 25). The rollers 372 are grooved and spring loaded by capstan roller 
springs 373 against the capstan drum 370. Roller gears 374 are directly 
keyed to the rollers 372 and are driven by sun gear 368. 
A conical infeed guide funnel 376 receives and guides the wire from the 
spool 600 into the capstan 364 (see FIG. 13). Referring again to FIG. 17, 
it can be understood that infeed guide block 378 guides the wire from 
infeed guide tunnel 376 to the first of the rollers 502, and outfeed guide 
380 guides the wire, after it has wrapped around the drum 370 and passed 
back to roller 502, to feed tube 382. Feed tube 382 is an exit tube which 
feeds wire exiting the capstan 364 into spinner head 332. It is off-line 
from the infeed guide tunnel 376 to facilitate passage of the wire around 
the drum 370. With reference to FIGS. 18A through 18J, it may be seen that 
one way to move the wire across the drum (from the infeed guide tunnel 376 
to the exit feed tube 382) while the wire wraps around the drum is by 
using a number of capstan rollers 372. The rollers are grooved, the 
grooves progressively offset from roller to roller. 
Taking as an example the first capstan roller, now identified as roller 502 
with reference to FIG. 18A, it may be seen that this roller is grooved 
with two grooves, 501 and 503. Groove 501 is subtantially in-line with the 
wire path coming in from the infeed guide tunnel 376 and through the 
infeed guide 378 (this orientation may be understood with reference to 
FIG. 17. Groove 503 of roller 502 is substantially in-line with the wire 
path exiting the drum 370 through outfeed guide 380. The wire is 
progressively passed around the drum 379 by a number of rollers, each of 
which has a single groove progressively moving the wire from (for ease of 
discussion and viewing FIGS. 18A through 18J) left (where groove 501 of 
the first roller 502 receives the incoming wire) to right (where groove 
503 of the first roller 502 is set to send the wire out of the capstan. 
Thus, a second roller 504 has a single groove 505 slightly offset to the 
right of the first roller's groove 501 (FIG. 18B); a third roller 506 has 
a single groove 507 slightly offset to the right of second roller's groove 
505 (FIG. 18C); a fourth roller 508 has a single groove 509 slightly 
offset to the right of third roller's groove 507 (FIG. 18D); and so on 
with fifth, sixth, seventh, eighth, ninth and tenth rollers 510, 512, 514, 
516, 518, 520 and their respective grooves, 511, 513, 515, 517, 519, 521, 
each groove slightly offset to the right from the prior groove (ref FIGS. 
18E through 18J). Here, ten capstan rollers are used, but the number may 
readily be adjusted up or down, based on the desired application. 
In connection with the wire drive, there are a number of other elements to 
be seen. These include mechanical logic elements which will be mentioned 
now, with reference to FIG. 26A, but described in greater detail later. 
Wire lock wheel 342 is engaged by wire lock pawl 344. Wire lock release 
lever 346 is a cammed lever that actuates the wire lock pawl 344. Wire 
lock release inhibit lever 348 engages the wire lock pawl, preventing it 
from disengaging the wire lock wheel 342. Wire lock release inhibit lever 
cam pin 350 actuates lever 348 when tripped by wire lock release inhibit 
lever cam 354. 
Talon Drive 
Referring again to FIG. 14, it will be remembered that intermediate pinion 
310 which is driven by the planetary cage 306 drives main gear 312 which 
is the source of power for the spinner drive (previously discussed in 
connection with, e.g., FIG. 20) and the wire drive (previously discussed 
in connection with, e.g., FIG. 24). In addition, the intermediate pinion 
310 also provides power to the talon drive. 
Referring now to FIG. 15, it may be understood that talon overload clutch 
384 is a torque limiting clutch directly driven from intermediate pinion 
310. Overload clutch 384 powers the talon lead screw shaft 386, rotating 
it through the threaded talon lead screw nut 388, which is a threaded nut 
driven by the lead screw shaft 386. Talon pushrod 390 is connected to the 
talon lead screw shaft 386. Talon pushrod 390 is actuated fore and aft 
(closing and opening the talons) as the screw shaft 386 is rotated 
counterclockwise and clockwise. 
Lower talon lever 392 is the lever on the bottom of the tool that is 
actuated by the talon pushrod 390. Talon cross shaft 398 is a torsion 
shaft, connected to (and driven by) the lower talon lever 392 and also 
connected to upper talon lever 394 (see FIG. 22). Referring again to FIG. 
15, the lower talon lever 392 is connected to the lower talon 401 (not 
shown in FIG. 15) by lower talon connecting rod 396, and the upper talon 
lever 394 (see FIG. 22) is connected to the upper talon 400 by upper talon 
connecting rod 397. 
It can be understood that the talon pushrod 390 cooperates with the cross 
shaft 398 to push both the lower talon lever 392 and upper talon lever 
394. The connecting rods 396, 397 from the talon levers to the talons 400 
and 401, push the talons closed and open as the pushrod pushes forward and 
withdraws backwards. 
Talons 400 and 401 are the moving jaws which open to allow the tool to be 
placed around a bundle of rebar or other items to be tied, and then close 
to establish the wire path so that the wire can be fed through to form a 
loop. Talons 400 and 401 operate generally as previously described in 
connection with the first embodiment already discussed in connection with 
FIGS. 1-12. In addition to the operation earlier described, the talons may 
have a set of moving inserts 402 (not shown in the figures) within the 
interior of the talons. The moving inserts are floating plates which 
contain the encapsulating portions of the wire path, and which are cammed 
into place when the talons close (forming the wire channel), and which 
release as the talons open (thereby allowing the wire loop to be pulled 
out of the talons). 
Alternatively, trap doors 404 (see FIGS. 31 and 32) in the talons 400, 401 
open and close with a pivoting action as the talons are opened and closed, 
likewise forming the wire channel and then releasing the loop at the 
appropriate time. The trap doors 404 are opposed spring-loaded trap doors, 
the trap doors being urged by springs to open as the talons pivot to an 
open position. The trap doors 404 are opposed in the sense that one opens 
to the left side, and the other opens to the right side of the talons; and 
the heels of each trap door are butted against one another so that when 
the talons are closed the trap doors mutually inhibit one another from 
opening, but as the talons begin to open (moving the heels of the doors 
apart), the spring pressure on the trap doors urges them to open. The 
cross sectional view of FIG. 32 shows the pivoting action of door 404 in 
upper talon 400, better showing how, when the ends of the opposed doors 
404 are butted against one another when the talons are closed, the doors 
are inhibited from opening. 
In connection with the wire drive, there are a number of other elements to 
be seen. These include mechanical logic elements which will be mentioned 
now, but described in greater detail later. Because of the necessity that 
the talon drive be sequenced in relation to the spinner drive and the wire 
drive (so that, for example, the wire drive does not feed wire unless the 
talons are closed), and because the spinner drive interacts with the wire 
drive, many of the components introduced here include elements associated 
with the spinner drive. 
Referring to FIG. 28, spinner detent hub 406 mounts on the aft end of 
spinner shaft 326 and serves to lock the spinner shaft in the 
shaft-forward position. Spinner detent hub includes a helper spring roller 
407 for compressing a helper spring 424 and also has a pin 409 to engage a 
detent latch 412. 
Detent roller 410 is mounted on detent arm 408, which is a swinging spring 
loaded arm that locks spinner detent hub 406 in place when the spinner 
shaft 326 is in the forward position. 
Detent latch 412 is a pivoted latch mounted on the detent arm 408. Latch 
412 engages the pin 409 on detent hub 406. 
Latch inhibit lever 414 is a pivoted lever that inhibits the detent arm 
from latching. Latch release finger 416 is a pivoted finger which trips 
the detent latch 412 so that the detent hub 406 can rotate away from the 
detent roller 410. 
The foregoing latches and releases are related to the position of the 
talons 400, 401 by latch inhibit lever cam pin 418 (see FIG. 29), latch 
release finger cam pin 420, and cam plate 422. Latch inhibit pin 418 is 
cammed by the cam plate 422 when the talons are closed (pushrod 390 is 
forward). Latch release finger cam pin 420 is cammed by the cam plate when 
the talons are open (pushrod 390 is aft). The cam plate 422 has two cam 
features, 423, 425, and is mounted on talon pushrod 390. 
Referring now to FIG. 28, helper spring 424 is a compression spring that is 
compressed just before the spinner detent hub 406 locks into position and 
it provides the helping torque to the spinner when it cuts the wire. The 
detent roller 410 on the spinner detent hub 406 compresses the helper 
spring 424. 
With reference to FIG. 14, rear limit sensor 426 is a proximity switch that 
senses when the spinner shaft 326 has retracted, and then signals the 
motor 300 to stop. 
Sequence Of Operations 
The operation of the wire tying tool of the present invention is divided 
into the three main operations previously described: spinner drive, talon 
drive and wire drive. 
The spinner drive actuates the spinner head 332 through the spinner shaft 
326. The spinner head forms knots by "extruding" the wire with rotary 
motion while retracting in a controlled manner. 
The talon drive actuates the talons 400, 401 during the cycle of the tool, 
closing them at the beginning of the cycle to establish the wire path and 
opening them after the wire has been driven through the path at the 
beginning of wire pullback. 
The wire drive powers the capstan 364 which pulls wire from the supply 
spool, pushes it through the talons 400, 401, then reverses for "pullback" 
just before the knot is extruded. 
These three functions are coordinated using mechanical logic to achieve the 
proper sequencing and power flow during the cycle of the tool. A single 
motor is used to power the tool and a small electronic control module is 
utilized to start, stop and reverse the motor at appropriate points during 
the cycle. 
The sequence of operations of the wire tying tool will now be described, 
together with certain variations which may occur. All of the components 
have already been explained in connection with the figures. Those 
discussions will not be repeated here, but the reader may refer back to 
the glossary for aid in locating any of the components and the associated 
figure. 
1. Starting configuration. At the beginning of the cycle, the talons 400, 
401 are open, spinner shaft 326 is retracted, and the wire drive is locked 
(wire lock wheel 342 is engaged by wire lock pawl 344, and the wire lock 
pawl is latched in place by wire lock release inhibit lever 348--this 
holds the wire lock wheel 342 stationary which, in turn, prevents movement 
of the capstan drive shaft 362 and of the differential output shaft 340, 
thereby locking the wire drive). See FIG. 26A. 
From this starting position, the tool is brought into operation as follows. 
In the discussion which follows "clockwise" and "counterclockwise" will 
describe rotational directions as viewed along (or generally parallel to) 
the longitudinal axis of the tool, as viewed from the rear of the tool; 
"RPM" will mean revolutions per minute; and a "cycle" will mean one 
complete sequence of the tool for tying one knot. 
2. Trigger pull (powering the intermediate pinion). From the starting 
configuration, the operator will position the open talons 400, 401 around 
the rebar joint to be tied. When the talons are properly positioned, the 
operator pulls the main trigger 606. 
The trigger pull starts drive motor 300 running in the counterclockwise 
direction. The motor pinion 302 drives the two planetary gears 304 which 
drive against the ring gear 308 thereby rotating the planetary cage 306 
which directly drives the intermediate pinion 310 counter clockwise. This 
powers the main drive gear 312 clockwise which is the source of power for 
both the spinner drive and the wire drive. 
The planetary gearing of the planetary gears 304 achieves the initial 
reduction needed to get from the high motor RPM down to a speed range more 
practical for the three drive systems. 
At this point in the cycle, the intermediate pinion 310 is powered, and 
ready to drive both the talon drive and the spinner drive as detailed 
below. 
3. Power to the Talon Drive and to the Spinner Drive (closing the talons 
and advancing the spinner shaft). In the sequence of operation, the third 
step simultaneously powers the talon drive and the spinner drive, while 
the wire drive is locked. The purpose of the third step is to put the wire 
tying tool in position for the wire drive to form the knot. Thus, it is 
imperative that the talons be completely closed and the spinner head 
locked into place so that the wire channel is properly formed and ready to 
receive the wire. At the end of this third step, therefore, the talons 
will have closed and the spinner shaft will have advanced to its fully 
forward position. When both of these conditions have been met, the wire 
drive will be unlocked, and the third phase in the sequence will come to 
its end. 
3(a). Power To The Talon Drive (closing the talons). The counter clockwise 
motion of the intermediate pinion 310 (see step 2 above) directly drives 
the talon overload clutch 384 which in turn directly drives the talon lead 
screw 386 which rotates counter clockwise. The counter clockwise rotation 
of the talon lead screw 386 drives the lead screw nut 388 forward which in 
turn drives the talon pushrod 390 forward. 
The forward motion of the talon pushrod 390 rotates the lower talon lever 
392 by means of a pin engagement. the lower talon lever 392 in turn 
rotates talon cross shaft 398 which then rotates the upper talon lever 
394. 
Connected to the upper and lower talon levers 392, 394 are two talon 
connecting rods 396 which are connected to the talons 400 and 401. The 
rotation of the talon levers 392 and 394 push on the connecting rods 396 
which close the talons. 
It should be remembered that the intermediate pinion 310 is powering both 
the talon drive and the spinner drive simultaneously. Thus, the spinner is 
moving forward even as the talons are closing. The movement of the spinner 
will be discussed below, but for now it should be noted that the talons 
400, 401, if not obstructed (the situation where the talons are obstructed 
is discussed in step 3(b) below), will reach a fully closed position 
substantially quicker than the spinner shaft 326 will reach its fully 
forward position. 
3(b). Power to the Spinner Drive (moving the spinner shaft forward and 
locking it). The counter clockwise motion of the intermediate pinion 310 
(see step 2 above) rotates the main drive gear 312 clockwise. The main 
drive gear 312 directly rotates the main overload clutch 314 which rotates 
the differential input shaft 316 clockwise. This will supply power to the 
differential 316. 
At this point in the cycle, the wire drive is still locked (see step 1), 
therefore, the differential output shaft 340 is locked. This causes the 
torque from the differential input shaft 316 to be transmitted to the 
differential cage 320. 
Rotating clockwise, the differential cage 320 directly drives the spinner 
drive pinion 322 which in turn rotates the spinner drive gear 324 counter 
clockwise. 
The spinner drive gear 324 engages the spinner drive spline 328, rotating 
it counter clockwise, which in turn rotates the spinner drive thread 330 
counter clockwise. 
The counter clockwise rotation of the spinner drive thread 330 and spinner 
drive spline 328 causes the spinner shaft 326 and spinner head 332 to move 
forward while the spinner drive spline 328 slides through the spinner 
drive gear 324. 
As the spinner shaft 326 nears its full forward position, the detent lobe 
406A on the spinner detent hub 406 engages the detent roller 410 lifting 
the detent arm 408 and stretching the detent spring 408A. 
When the spinner shaft 326 reaches its full forward position, the detent 
roller 410 drops behind the detent lobe 406A on the spinner detent hub 
406, locking the shaft into the forward position. At this point, the 
detent arm 408 is latched down by virtue of the pin 409 on the spinner 
detent hub 406 which engages the detent latch 412. In addition, as the 
detent hub is locked into position, the Helper Spring Roller 407 
compresses the Helper Spring 424. 
As previously noted, the talons 400 and 401 are being closed at the same 
time as the spinner shaft 326 is being moved forward. If not obstructed, 
the talons will reach a fully closed position before the shaft 326 reaches 
its fully forward position (see step 3(a) above). But if the talons are 
obstructed (or were placed around too large a bundle), or have for any 
other reason not fully closed before the spinner shaft 326 has reached its 
full forward position, it is desirable not to latch the spinner detent hub 
406 into place. This is because the operator will want to reverse the tool 
and reset the talons and the spinner shaft to the starting configuration 
(talons open, spinner retracted)--leaving the spinner shaft unlatched in 
the event that the talons have not closed will allow the operator more 
easily to reverse the tool (as will be explained later) and reset it to 
the starting configuration. 
To prevent the spinner shaft 326 from latching and locking in its fully 
forward position when the talons have not closed, the inhibit lever 414 is 
spring loaded counter clockwise and engages the detent arm 408, preventing 
it from dropping far enough to latch. 
However, if the talons 400 and 401 have previously closed (or subsequently 
do close), the cam feature 423 of cam plate 422 on the talon pushrod 390 
will have moved forward far enough to push the latch inhibit lever cam pin 
418 which, in turn, rotates the latch inhibit lever 414 clockwise, 
enabling the detent arm 408 to drop fully and be to latched and locked by 
the detent latch 412 engaging the pin 409 on the detent hub 406. 
3(c). Unlocking the Wire Drive (and locking the spinner head). In this 
third phase of operation, the talons 400 and 401 are closing (see step 
3(a) above), and the spinner shaft 326 is moving to the fully forward 
position (see step 3(b) above). While both the talon drive and the spinner 
drive are moving simultaneously, the talons will close first, and then the 
spinner shaft will reach its forward and locked position. At this point, 
it is time to release the wire drive (which was locked in the initial 
configuration, see step 1 above). 
When the talons 400 and 401 close normally (before the spinner shaft 326 is 
fully forward), the talon pushrod 390 will have advanced to its fully 
forward position. Accordingly, the wire lock release inhibit lever cam 
354, mounted on the talon pushrod 390, will cam the wire lock release 
inhibit lever cam pin 350. The movement of release pin 350 rotates the 
wire lock release inhibit lever 348 clear so it no longer prevents the 
wire lock pawl 344 from lifting away from the wire lock wheel 342. See 
FIG. 26B. This fulfills one of two conditions for unlocking the wire drive 
(that is, the talons are closed) and enables the wire drive to be unlocked 
when the second of the two conditions is met (that is, when the spinner 
shaft 326 later reaches its fully forward position). 
The discussion now continues on the assumption that the talons have closed. 
As the spinner shaft 326 reaches its fully forward position and the detent 
hub 406 latches into place, the spinner drive thread 330 will have moved 
into its fully forward position. Accordingly, the wire lock release tab 
352, which is integral to the spinner drive thread 330, will have cammed 
the wire lock release lever 346. As a result, wire lock release lever 346 
pushes on a spring, which actuates the wire lock pawl 344, disengaging it 
from the wire lock wheel 342. See FIG. 26C At this point, each of the two 
conditions have been met (that is, the talons are closed and the spinner 
shaft is at its fully forward position) and the wire drive is unlocked. 
The wire tying tool of this invention is designed also to take account of 
the possibility that the talons 400 and 401 might not be fully closed 
(because they have met an obstruction or the joint to be tied is too 
large) when the spinner shaft 326 reaches its fully forward position and 
the wire lock release tab 352 cams the wire lock release lever 346. In 
this event the second of the two conditions for releasing the wire drive 
(that is the spinner drive is forward) will have occurred, but the first 
condition will have failed (that is, the talons are not completely 
closed). If this is the case, the wire lock pawl 344 is inhibited from 
moving by the wire lock release inhibit lever 348, and this will prevent a 
premature unlocking of the wire drive. This is done by spring loading the 
wire lock release inhibit lever 348 in the inhibit position, where it 
latches the wire lock pawl 344 to prevent its lifting from the wire lock 
wheel 342. In this case, power can neither be transmitted to the spinner 
drive nor to the wire drive, and will be released through the main 
overload clutch 314. Because the wire drive remains locked, the wire will 
not feed, and the operator of the tool will be able to disengage and 
reset. 
The discussion will resume under the assumption that the talons have 
closed, the spinner shaft is forward, and the wire drive is, accordingly, 
unlocked. 
3(d). Intermediate configuration (talons closed, spinner shaft forward, 
wire drive unlocked). At this point, with the talon drive having closed 
the talons, and with the spinner drive having driven and locked the 
spinner shaft into its fully forward position, the wire tying tool is in 
an intermediate configuration. The talons are now closed, the spinner 
shaft is now forward and locked, and the wire drive is now unlocked. 
4. Power to the Wire Drive (forming and pulling the loop). In the sequence 
of operation, the fourth step powers the wire drive in two directions to 
form the loop and then to pull back on it. In the first direction, the 
wire is driven through the capstan, through the first opening in the 
spinner head, around the talons and out through the second opening in the 
spinner head. 
4(a) Wire Drive Feed Phase (forming the loop). Since the spinner shaft 326 
is fully forward and the spinner detent hub 406 is latched in place (see 
step 3 above), the differential cage 320 can no longer rotate. The power, 
previously directed to the talon drive and the spinner drive (see step 3 
above) must now be directed to the differential output shaft 340 for power 
ing the wire drive. While this is happening, power is still being supplied 
to the talon lead screw 386 of the talon drive, but the drive is 
immobilized and the power is relieved through talon overload clutch 384. 
With the wire drive now unlocked, power is transferred through the 
differential output shaft 340, past the wire lock wheel 342 to the wire 
drive driver miter gear 356, which drives the wire drive driven miter gear 
358. The driven miter gear 358 directly drives the wire drive overload 
clutch 360. 
From the wire drive overload clutch 360, power is transmitted to the 
capstan drive shaft 362 which directly drives the capstan drive pinion 
366. The capstan drive pinion 366 drives the capstan sun gear 368 which 
directly drives the capstan drum 370 and drives the capstan roller gears 
374 which directly drive the capstan rollers 372. 
Wire is pulled from the spool 600, and enters the capstan 364 through the 
infeed guide funnel 376 whence it passes through the infeed guide 378. The 
wire is then fed into the left groove of the first capstan roller 502 
where it is pinched against the capstan drum 370 to provide driving force. 
The wire is guided to the groove in the second capstan roller 504 with a 
slight offset to the right, again pinched against the capstan drum 370 to 
add to the driving force. The wire continues all the way around the 
capstan drum 370 past ten rollers 372, each having a slight offset to the 
right until it reaches the right groove on the original roller 502 (this 
being the only roller having two grooves) whence it passes into the 
outfeed guide 380 where it exits the capstan 364 into the feed tube 382. 
From feed tube 382, the wire then passes through the opening in the top 
side of spinner head 332, around the channel in the talons 400 and 401, 
and back through the opening in the bottom side of spinner head 332, 
exactly as previously discussed in connection with the first embodiment 
and, e.g., FIG. 11. Reference is made to that earlier discussion for the 
details. The wire feeds a short distance out of the bottom of the spinner 
head, until it contacts wire sensor toggle 336. Toggle 336 rotates upon 
being contacted with the wire, and the toggle 336 will meet, and trigger, 
wire sensor 338. 
4(b) Wire Drive Pullback Phase (pulling the loop). 
When the wire is looped through the spinner head 332 and the talons 400 and 
401, and the wire end has hit the sensor toggle 336, it is time to pull 
back on the loop. The wire sensor 338 is a proximity switch, triggered by 
the sensor toggle 336. A signal from wire sensor 338 to the reversible 
motor 300 stops and reverses motor 300. 
Because the spinner head is locked (see step 3 above), the reversed motor 
will power the talon drive and the wire drive, but not the spinner drive. 
Immediately upon reversal, the talons 400 and 401 start to open, and the 
capstan 364 starts pulling the wire back. 
As the wire pulls back and the talons begin to open, the trap doors 404 
open, allowing the wire to escape from the talons 400 and 401 as the loop 
is being tightened around the bundle of rebar. As the wire tightens around 
the rebar, the wire sensor toggle tab 337 cams to lock the wire end. 
This mechanism works to prepare the tool for the knot forming step under 
any of several circumstances. 
If, for example, a small bundle of rebar is being tied, the talons will 
open fully before the wire is pulled back completely by the capstan 364. 
If, instead, a large bundle of rebar is being tied, the capstan 364 will 
tighten up the wire before the talons 400 and 401 are fully open. In this 
case, wire drive overload clutch 360 will hold the wire tight and will 
relieve torque using a detenting action until the talons reach their fully 
opened position, and the knot forming step begins. 
If, finally, the talons are prevented from fully opening for any reason, 
the capstan 364 will pull the wire tight, and the wire drive overload 
clutch 360 will hold the wire tight and will relieve torque by detenting 
until the talons are allowed to open fully. 
4(c) Unlocking the Spinner Head (and relocking the wire drive). In this 
fourth phase of operation, the talons are opening and the wire drive is 
pulling back. When the talons 400 and 401 are fully open and the wire is 
pulled tight, it is time to unlock the spinner head 332 so that the knot 
forming operation can begin. 
When the talons 400 and 401 fully open, the talon pushrod 390 will have 
backed up to its fully retracted position. Accordingly, cam feature 425 of 
cam plate 422, mounted on talon pushrod 390 will have activated the latch 
release finger cam pin 420, rotating and lifting latch release finger 416. 
Finger 416 is a pivoted finger which trips the detent latch 412 so that 
the spinner detent hub 406 can rotate away from detent roller 410. It will 
be remembered that, at step 3(b) above, the detent roller 410 had dropped 
behind the lobe on spinner detent hub 406, locking the spinner shaft 326 
into position--detent arm 408 was latched down by the engagement of the 
pin 409 on detent hub 406 with detent latch 412. Now, when the detent 
latch 412 is tripped, it will return to its unlatched position. This 
allows the detent arm 408 to lift, thereby unlocking the spinner shaft 
326. 
As the capstan 364 pulls back on the wire, tightening the loop around the 
rebar bundle to be tied, sufficient torque is transmitted to the spinner 
shaft 326 through differential 318 to rotate the spinner detent hub 406 
clockwise. "Sufficient torque" is a preset value, set to match the desired 
pull back tension (this can be anywhere from five pounds or less, to 150 
pounds or more, or any value between). This lifts the detent arm 408, 
which permits spinner detent hub 406 to rotate clockwise. As hub 406 
rotates, the wire lock release tab 352 rotates away from wire lock release 
lever 346. This allows the wire lock pawl 344 to engage wire lock wheel 
342 which then locks the wire drive. See FIG. 26A. 
At this point, the talons are fully open, the wire drive is locked, the 
spinner drive is unlocked, and the motor is running in a clockwise 
direction. 
5. Power to the Spinner Drive (knot forming operation--retracting the 
spinner shaft and extruding the knot). At this point, with the talons open 
and the wire drive locked, full drive torque is transmitted to the spinner 
shaft 326 and spinner head 332. This provides full power to the knot 
forming operation. 
As spinner head 332 starts to rotate in a clockwise direction, the wire 
starts to bend where it enters and exits the spinner head 332. The bending 
action puts kinks in the wire ends to allow the spinner head to apply 
tension to the wire ends while the wire knot is being extruded. 
At the same time, and as the spinner shaft 326 starts to rotate in a 
clockwise direction, the helper spring 424 which was previously compressed 
(see step 3(b) above), provides an additional force which pushes on the 
helper spring roller 407 of the spinner detent hub 406. 
As the kinking is being completed, wire cutting begins. The wire is cut, 
first, at the entrance to the spinner head 332 and then at the exit from 
the spinner head. This is a staggered cutting action which reduces the 
torque requirement to the spinner shaft. The cutting is powered by the 
combined torque from the drive motor 300 and helper spring 424. 
The spinner head 332 continues to rotate, completing the cut and rotating 
four turns. This extrudes the knot and returns the spinner shaft to its 
retracted position. When the spinner shaft 326 reaches the fully retracted 
position, rear limit sensor 426 (a proximity switch) signals the motor 300 
to shut off. 
6. Reset to the Starting Configuration. When motor 300 shuts off, the 
operator releases the trigger. At this point, the tool is back in the 
starting configuration--the talons 400, 401 are open, spinner shaft 326 is 
retracted, and the wire drive is locked--and the operator can move the 
tool to a new location, and place the talons around the next rebar bundle 
to be tied. When the operator pulls the trigger, the next cycle will 
commence. 
7. Reversing Button (Obstructions. Jams, Stowage & Repair). The wire tying 
tool has a reverse button 608 which allows the operator to reverse the 
direction of the drive motor 300 at any point in the cycle. The action of 
the reversing button at various points in the cycle will be explained now. 
(a) At an early part of the cycle (see the beginning of step 3(b) above), 
the talons 400 and 401 are closing, and the spinner shaft 326 is moving 
forward but is not yet locked into place. Actuating the reverse button at 
this point will open the talons and retract the spinner shaft 326. 
(b) At an intermediate part of the cycle (see step 3(d) above), the talons 
400 and 401 are closed, the spinner shaft 326 is fully forward and locked, 
and the wire drive is unlocked. The wire drive is engaged and wire is 
being fed forward through the talons. Actuating the reverse button at this 
point will open the talons and simultaneously pull back on the wire. 
(c) Later in the cycle (see step 4(b) above), the wire has been fed all the 
way through the talons 400 and 401, and the wire end is sensed. The motor 
300 now reverses (so that it is running in the clockwise direction) and 
the talons begin to open as the wire is being pulled back. Actuating the 
reverse button at this point will close the talons and feed the wire 
forward. 
(d) Still later in the cycle (see step 5), the wire has been pulled back 
tight, the talons 400 and 401 are fully opened, and the detent hub 406 has 
pulled free, unlocking the spinner shaft 326. The wire is cut, and the 
spinner is rotating and retracting as it spins the knot. Actuating the 
reverse button at this point will drive the spinner shaft forward and 
close the talons. 
The reverse button would be actuated at the foregoing points in the cycle 
as necessary and in circumstances such as the following: 
For Wire Remnant Removal. When a spool of wire has been fully used, there 
may be a remnant of wire left within the wire tying tool which should be 
removed before starting a new spool. Removal is accomplished by triggering 
the tool and advancing it just far enough in the cycle to engage the wire 
drive and begin feeding the wire into the talons. Here, the reverse button 
will interrupt the cycle, the wire drive will reverse, and the wire will 
be pulled backwards out of the capstan 364. Now the operator can start the 
new wire end of the new spool into the capstan, and can proceed with 
normal operation of the tool. 
For Clearing Talon Obstructions. If the talons 400 and 401 are placed 
around a bundle too large to be fully enclosed by the talons so that the 
talons will not close (of if the talons are obstructed for any reason and 
do not close), the reverse button will stop and reverse the talons. The 
talons will open, and the spinner shaft 326 will retract. Now the tool is 
reset and the operator may resume normal operation. 
For Clearing Wire Jams. If there is a wire jam during feeding, the operator 
may use the reverse button to reverse the wire feed. This usually clears 
the jam. If the jam is not cleared, the operator can alternately drive the 
wire forward and backwards using the trigger 606 and reverse button 608 to 
clear the jam as necessary. When the wire jam is cleard, the operator may 
then start the cycle over. 
After Tool Stowage. Before the tool is stowed, the operator will pull the 
trigger 606 to close the talons 400 and 401. Before reusing the tool after 
storage, the operator must actuate the reverse button 608 to open the 
talons to the initial configuration. 
For Maintenance and Repair. For maintenance and repair, the reverse button 
can be used as needed, and in conjunction with the trigger 606, for 
positioning the spinner and talons, testing the mechanical logic, testing 
the various clutches and differentials and the like. 
The foregoing description has explained the tool, with reference to the 
embodiment of FIGS. 1-12 and the embodiment of FIGS. 13-32. The various 
assemblies, including the talons and spinner, for enclosing a rebar joint 
or any other object to be tied and for forming a knot by looping a length 
of wire around the object, keeping the loop under tension, and then 
spinning and extruding the knot, have been explained. Likewise, the 
various drives, including the talon drive, wire drive and spinner drive 
for transmitting power from a single motor to the talons, the wire 
pusher/puller mechanism and the spinner have been explained, together with 
a control system for sequencing the various operations. 
The method of using the tool has been explained in the course of desribing 
its components and their operation. It should be clear that an operator 
simply places the talons around the object to be tied, pulls the trigger, 
and then pulls the tool away, leaving a twisted knot behind. The machine 
can tie several knots per minute (variables affecting the number of ties 
include the thickness of the material to be tied, and the distance between 
ties--under controlled conditions of thickness and closeness a prototype 
of the device has tied about 20 knots per minute). 
Once the concept of this invention is understood, it should be apparent 
that any number of variations or substitutions may be made, still within 
the scope of the invention. Beyond the obvious substitution of electronic 
logic control devices for the mechanical logic devices already described, 
some of the other additions and variations will be briefly described 
below. 
Additions and Variations 
Among the additions and variations are these: 
(a) An Elongated Handle. The handle 602 as shown in FIG. 13 is close to the 
tool itself. An elongated handle 603 is shown in FIG. 30. The elongated 
handle extends the reach of the operator, and support handle 604 might be 
moved towards the rear of the tool as necessary to facilitate the 
extension. An operator's use of the machine in certain applications (as 
in, for example, tying a rebar grid at the operator's feet; or in tying 
certain overhead objects) might be greatly facilitated by the longer reach 
afforded by the elongated handle. A trigger 606A and a reverse button 608A 
place the necessary controls within easy reach of the operator on the 
elongated handle 603. 
(b) Talon Modifications. It has already been explained that the talon sets 
(or jaw sets) may help define a wire path which is fully enclosed (the 
embodiment of FIGS. 1-12) or partially enclosed (the embodiment of FIGS. 
13-32), and that the wire-enclosing channel might open by way of swinging 
doors, trap doors or floating plates. Other variations are readily 
grasped. In addition, all that is required is an encircling enclosure. It 
should be readily apparent that the pair of talons shown and described 
herein could be replaced by a single hook-shaped talon. Such a single 
talon could be placed over the object to be tied and then pulled back, 
latched, or otherwise secured around the object. 
(c) The Object to be Tied. The most obvious example of an object to be tied 
with the tool of this invention is a rebar cross joint. The tool is, 
however, not limited to a single application, but is appropriate for any 
object to be tied. It is also useful for any object that needs to be 
twisted. For example, the tool could be readily adopted to the use of 
forming the ties in metal clothes-hangers, in product wraps, in bag 
closures, in attaching wire to fence posts, and in any of an almost 
unlimited number of uses involving a twist-tie knot. 
(d) The Wire or Other Material Forming the Knot. While the tool of this 
invention is especially suited for use with a heavy duty wire, it is not 
so limited. Any sort of material which can be twisted could be used. Thus, 
the expressions, "wire," "wire drive" and the like, when used in this 
specification, or in the claims, should be understood to include not only 
wire, but any material used to form the knot, the drive which pushes or 
pulls such material, and so on. 
When a wire or other material is used, it should be clear that certain 
further advantages can be specified. Among them are these: (1) the wire 
could be coated with a sheath, coated (or treated) with a fusion bonded 
thermoplastic, or treated with a "slip agent" of polyethylene, and/or (2) 
the wire could be marked with one or more marks or stripes. 
The coating or treatment is designed to vary the tack, and permits the 
coefficient of friction to be closely controlled (that is, the wire can be 
made more or less "slippery" by a coating or a treatment which decreases 
or increases the coefficient of friction relative to uncoated or untreated 
wire). The marking could be one or more stripes (perhaps a stripe every 
six inches, more or less) with the stripes readible by an optical or 
electromagnetic or other such sensing or reading device. Among other 
things, such a system could be: keyed to coated or treated wires to 
prevent wrongly coated or treated (or noncoated or nontreated) wire from 
being used, thereby preventing damage to the machine; keyed to count the 
number of marks to monitor usage of the machine and proper maintenance (or 
to monitor usage for purposes of charging for use of the machine); or any 
of several other purposes. 
(e) The Spool. The spool, as shown and described in the various drawings of 
the several embodiments shown here, is variously clutched, spring-loaded 
and otherwise driven so that the wire is held under sufficient pressure to 
prevent its expansion on the spool. It should be readily understood that 
there are many equivalent mechanisms to prevent the expansion of the wire 
on the spool. 
In addition, it should be understood that the spool is, or can be, 
removable (for reloading with wire) and/or replaceable (with preloaded 
spools). In these cases, the spool will be keyed specially to the tool so 
that it will mate and lock in place. Further, appropriate sensors may be 
used to sense when the spool is properly locked in place so that operation 
of the device cannot proceed without a proper spool in locked in place. 
Thus, in conjunction with the coated or treated wire and/or the use of 
marked wire, the keying system can be important to prevent the use of 
standard spools, and/or prevent the usage of spools not loaded with the 
properly coated, treated or marked wire, thereby preventing improper usage 
of the machine. Thus, it can be important that the spool of this invention 
not be a spool of standard or general design, but that the spool be 
specially keyed and/or sized so as to prevent improper usage. 
Moreover, it should be understood that the spool might be moved away from 
the tool (to a remote location, including an operator's belt, backpack or 
other holder; and including a place removed from both the tool and the 
operator, such as a work-bay configuration, in any event, with appropriate 
feed channels). A wire may be fed, for example from an overhead feed 
channel directly to the tool in an appropriately designed work station. 
Such work stations are well known in the building trades and will not be 
further described here. 
(f) Independent Features. The features of this invention are best enjoyed 
in combination, but there is no necessity that all of them always be 
employed together in any particular application. While it is generally an 
advantage to have but a single reversible motor powering all three of the 
wire drive, talon drive and spinner drive, it can readily be appreciated 
that there may be circumstances and applications in which there is a 
separate motor for each drive, or for any combination of two of the 
drives. There may be, as well, applications calling for a "forward" motor 
and a separate "reverse" motor. 
Finally, the conceptually separate steps of feeding wire, and pulling wire; 
opening and closing talons; and spinning and retracting (and then spinning 
and advancing back to the start position) have made it convenient to 
discuss three corresponding drives (wire drive, talon drive, and spinner 
drive) and mechanisms (capstan or other feed system, talon, spinner and 
associated parts) as if they were three completely separate facilities. 
Although in the preferred embodiment, there is some physical separation 
among the wire drive, talon drive, spinner drive and their related 
mechanisms, there is nothing to prevent them from being combined into 
integrated units. 
It should be readily understood, therefore, that it is not essential to 
this invention that there be any given number of discrete drives, or that 
all three of the particularly named drives be present. This invention is 
designed for use with all three drives working together as described in 
connection with the preferred embodiments, but it is by no means limited 
to the entire combination for all purposes.