Abstract:
The cycle counter is incorporated in a cable tie tool and provides an accurate count of the number of cable ties cut by the tool. The cycle counter includes a sensor which detects the displacement of the blade of the cable tie tool required to sever the strap of the cable tie. Alternatively, the sensor detects the condition of a component of the cable tie tool which indicates that the tool has cut the strap of a cable tie. The sensor generates a cut signal indicating that the strap of a cable tie has been cut. The cycle counter further includes summing devices for processing the cut signals and generating additional signals for transmission to a display device. The display device communicates to an operator the total number of cable ties severed by the cable tie tool. The display device also communicates to the operator the total number of selected cable ties severed by the cable tie tool.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
   This patent application claims priority to and the benefit of U.S. Provisional Patent Application No. 60/544,472 filed in the U.S. Patent and Trademark Office (USPTO) on Feb. 13, 2004. 

   BACKGROUND OF THE INVENTION 
   The present invention relates generally to a tension and anti-recoil mechanism for a cable tie tool, and more specifically, to such a mechanism for limiting the tension applied to the cable tie by the tool and limiting the re-coil of the tool when the cable tie is cut. 
   Cable ties are used to bundle or secure a group of articles such as electrical wires or cables. Cable ties of conventional construction include a cable tie head and an elongate strap extending therefrom. The strap is wrapped around a bundle of articles and thereafter inserted through a passage in the head. The head of the cable tie typically supports a locking element which extends into the head passage allowing the strap to be inserted through the passage but preventing retraction of the strap through the passage in the head. Two longitudinally separated portions of the strap are thereby secured to the head to define a loop for holding together the group of articles. 
   In use, the installer manually places the tie about the articles to be bundled, inserts the strap through the head passage and then manually tightens the tie about the bundle. Further tightening of the cable tie, which increases the tension in the strap thereof, may be provided by a cable tie tool. 
   One type of such a cable tie tool includes a housing which is generally pistol-shaped where the housing has a barrel into which the strap may be inserted for application of the tension. The housing has a grip which depends from the barrel. 
   Typically, cable tie tool are most effective when new and during a reasonable period of use thereafter. After prolonged use of a cable tie tool, the effectiveness thereof normally decreases. Such decreased effectiveness may result from a reduction in the quality of the blade which is supported, typically within the cable tie tool, and displaced to cut the strap of the cable tie. Such a reduction in the quality of the blade normally results in decreased quality of the severing of the strap. 
   Decreased effectiveness of the cable tie tool from prolonged use thereof may also result in increased force being required to close the trigger mechanism of the cable tie tool. The trigger mechanism is mechanically coupled to the blade such that closure of the trigger mechanism is required to displace the blade sufficiently to cut the strap of the cable tie. Such closure of the trigger mechanism is typically provided by grasping of the trigger mechanism and grip of the cable tie tool within the hand of the operator and the hand being squeezed or closed to pivot the trigger mechanism toward, and possibly into direct engagement with, the grip. If such closure or squeezing is significantly resisted by trigger mechanism, which may result from the quality of the blade being reduced or from other factors, then the closing force required to be applied by the hand of the operator is increased. If the force required to be provided by the hand of the operator is sufficiently large, undesirable consequences to the hand of the operator may result, such as strain or fatigue thereof. 
   The amount of use of a cable tie tool is primarily dependent upon the number of cable ties which have been tensioned and cut by the tool. The actual number of such cable ties which have been tensioned and cut by a specific cable tie tool is normally not apparent from the tool itself. The date of manufacture of a specific cable tie tool will not necessarily provide an indication of the amount of use of the tool since a relatively new tool may have been extensively used to tension and cut a large number of cable ties. Conversely, a relatively old cable tie tool may have been rarely used to tension and cut a small number of cable ties. Accordingly, an accurate determination of the amount of actual use of a specific cable tie tool is normally difficult. Typically, a determination of the actual number of cable ties which have been tensioned and cut by a specific cable tie tool is made by estimate or not at all. 
   SUMMARY OF THE INVENTION 
   The cycle counter of the present invention is incorporated in a cable tie tool and provides an accurate count of the number of cable ties cut by the tool. The cycle counter includes a sensor which detects the displacement of the blade of the cable tie tool required to sever the strap of the cable tie. Alternatively, the sensor detects the condition of a component of the cable tie tool which indicates that the tool has cut the strap of a cable tie. The sensor generates a cut signal indicating that the strap of a cable tie has been cut. 
   The cycle counter includes a total summing device which communicates with the sensor such that the total summing device receives all of the cut signals generated by the sensor. The total summing device has a total adding device for adding all of the cut signals received from the sensor. The total summing device generates a total signal indicating the total number of all cut signals received from the sensor. 
   The cycle counter further includes a discrete summing device which communicates with the sensor such that the discrete summing device receives a selected portion of the cut signals generated by the sensor. The discrete summing device has a discrete adding device for adding all of the selected cut signals received from the sensor. The discrete summing device generates a discrete signal indicating the total number of the selected cut signals received from the sensor. 
   The cycle counter further includes a display device which communicates with the total and discrete summing devices such that the display device receives the total and discrete signals generated by the total and discrete summing devices, respectively. The display device generates a total display signal for communicating to an operator the total number of cable ties severed by the cable tie tool. The display device generates a discrete display signal for communicating to the operator the total number of selected cable ties severed by the cable tie tool. 
   The total display signal generated by the display device provides an indication of the total actual usage of the cable tool by showing the total number of cable ties which have been cut by the tool. This may be useful, for example, for determining the applicability of a warranty. The total actual usage may also be used for maintenance, for example, by indicating when the blade is due for replacement. 
   The discrete display signal generated by the display device provides an indication of the actual usage of the cable tool over a specific time period by showing the total number of cable ties which have been cut by the tool during such a time period. This information may be useful to the operator since it will provide the number of cable ties cut by the operator during the shift and assist the management of the production in the factory to determine the efficiency of the operator. 
   Actual cutting of a cable tie is normally required for the sensor to generate a cut signal. Movements of one or more components of the cable tie tool which may be associated with the cutting of a cable tie, such as pivoting or closure of the trigger mechanism, will normally not cause the sensor to generate a cut signal absent an actual cutting of a cable tie. This increases the accuracy of the total and discrete display signals since they normally provide the number of cable ties which were actually cut. 
   These and other features of the invention will be more fully understood from the following description of specific embodiments of the invention taken together with the accompanying drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     In the drawings: 
       FIG. 1  is a rear perspective view of a cable tie tool which incorporates the cycle counter of the present invention; 
       FIG. 2  is a side elevation view of the cable tie tool which incorporates the cycle counter of  FIG. 1 ; 
       FIG. 3  is a top plan view of the cable tie tool which incorporates the cycle counter of  FIG. 2 ; 
       FIG. 4  is a rear elevation view of the cable tie tool which incorporates the cycle counter of  FIG. 2 ; 
       FIG. 5  is an enlarged view of the display panel of the cycle counter of  FIG. 1 ; 
       FIG. 6  is a schematic view of the components of the cycle counter of  FIG. 1 ; 
       FIG. 7  is a rear perspective view of an alternative second embodiment of the cable tie tool which incorporates the cycle counter of  FIG. 1 ; 
       FIG. 8  is a side elevation view of the cable tie tool which incorporates the cycle counter of  FIG. 7 ; 
       FIG. 9  is a top plan view of the cable tie tool which incorporates the cycle counter of  FIG. 8 ; and 
       FIG. 10  is a rear elevation view of the cable tie tool which incorporates the cycle counter of  FIG. 8 . 
   

   Corresponding reference characters indicate corresponding parts throughout the several views of the drawings. 
   DETAILED DESCRIPTION OF THE INVENTION 
   Referring to the drawings and more particularly to  FIGS. 1 to 6 , a cycle counter  10  is shown incorporated in a cable tie tool  12  for counting the severing of a cable tie  14 , having a strap  16  and head  18 , to a bundle of articles, such as wires or cables. The cable tie tool  12  includes a barrel  20  and a grip  22  depending therefrom. The cable tie tool  12  includes a trigger mechanism  24  which is connected by a mechanical linkage to a cutting mechanism  26  located within the barrel  20  adjacent to the front end thereof. The cutting mechanism  26  typically includes a blade which is forcibly displaced to sever a portion of the strap  16  which is inserted into the barrel  20  through the front end thereof. 
   The cycle counter  10  includes a sensor mounted within the cable tie tool  12 . The sensor is coupled to the blade for detection of the complete displacement thereof for severing the strap of a cable tie. The sensor generates a cut signal indicating each displacement of the blade which is detected by the sensor. The sensor is constructed to sense, and thereby generate a corresponding cut signal, specific cuts made by the blade and not pivoting of the trigger mechanism  24 , such as by squeezing thereof. 
   The cycle counter  10  further includes a total summing device mounted within the cable tie tool. The total summing device communicates with the sensor such that the total summing device receives all of the cut signals generated by the sensor. The total summing device has a total adding device for adding all of the cut signals received from the sensor. The total summing device generates a total signal indicating the total number of all of the cut signals received from the sensor. The total summing device may include a micro switch. Preferably, the total summing device may not be reset to zero so that the total number of straps  16  severed by the cable tie tool  12  may be determined. This information may be used to determine the amount of actual use of a specific cable tie tool  12 . 
   The cycle counter  10  further includes a discrete summing device mounted within the cable tie tool. The discrete summing device communicates with the sensor such that the discrete summing device receives a selected portion of the cut signals generated by the sensor. The discrete summing device has a discrete adding device for adding all of the selected cut signals received from the sensor. The discrete summing device generates a discrete signal indicating the total number of the selected cut signals received from the sensor. The discrete summing device may include a micro switch. 
   The discrete summing device includes a reset device which communicates with the discrete adding device. The reset device is able to eliminate the total number of selected cut signals recorded by the discrete adding device such that the discrete summing device may total a subsequent number of selected cut signals and generate a discrete signal indicative thereof. The discrete summing device may thereby be reset to zero by the reset device. This enables determination of the total number of straps  16  severed by the cable tie tool  12  for a specific continuous period of time, such as during use of the cable tie tool by a specific operator. This information may be used to determine the amount of cable ties  14  severed by the operator or the rate at which the cable ties were severed. Also, this information may be used to determine the total number of cable ties  14  severed by the cable tie tool  12  during a specific shift. This capability of the cycle counter  10  may be referred to as a shift counter. 
   The cycle counter  10  includes a display device  29  mounted on the rear of the barrel  20 , as shown in  FIG. 1 . The display device  29  communicates with the total and discrete summing devices such that the display device receives the total and discrete signals generated by the total and discrete summing devices, respectively. The display device  29  generates a total display signal for communicating to a user the total number of cable ties severed by the cable tie tool. The display device  29  generates a discrete display signal for communicating to a user the total number of selected cable ties severed by the cable tie tool. The display device  29  may include an LCD display  30  for displaying the total and discrete display signals as digits, such as by having a maximum number of 6. 
   The display device  29  includes a control button  31 , which may be actuated by forcible depression thereof. Alternatively, the control button  31  may be heat sensitive and thereby actuated by contact thereof by the finger of the user. Actuation of the control button  31  causes the display device  29  to replace the display signal shown when the button is actuated, such as the total display signal, with the display signal not shown when the button is actuated, such as the discrete display signal. This provides for control of the cycle counter  10  by the control button  31  and a micro controller chip. The control button  31  may be actuated by a momentary push thereof for flip flop between the total summing device and discrete summing device. 
   The control button  31  is also connected to the reset device. Actuation of the control button in specific manner, such as by depressing the button for a minimum period of time when the display device  29  is showing the discrete display signal, causes the reset device to eliminate the total number of selected cut signals recorded by the discrete adding device. Actuating the control button  31 , such as by pushing it, continuously will reset the cycle counter  10  to zero. 
   The control logic for the cycle counter  10  is shown in  FIG. 6 . The actuator control  33  and push button  35  are coupled to a micro controller  37 . Adjacent to the actuator control  33  in  FIG. 6  is an indication that the sensor may detect the displacement of the blade of the cable tie tool (such as by a MICRO-SWITCH), or the load in a component of the cable tie tool which indicates that the tool has cut the strap of a cable tie (such as by a LOAD SENSOR). Also, the actuator control  33  may receive a signal from a component which displaces the blade of the cable tie tool to cut the strap of a cable tie. Such displacement of the blade may be in the upward direction when the cable tie tool is in an upright orientation. The push button  35  corresponds to the control button  31  in  FIGS. 4 and 5 . The micro controller  37  is supplied by a power control  39  which, in turn, is supplied by a battery  41  such as a lithium battery. The micro controller  39  is coupled to an LCD driver  43  which controls an LCD display  30 . The control logic illustrated in  FIG. 6  provides electronic control of the cycle counter  10 . 
   In an alternative embodiment of the sensor, the sensor may detect the tension in the strap of the cable tie instead of the displacement of the blade of the cutting mechanism  26 . Such a load-sensitive sensor may be used with a device which produces a specific tension in the strap  16  of the cable tie  14  before severing thereof. Such a device is disclosed in U.S. Provisional Patent Application filed in the USPTO on even date herewith and entitled “Tension and Anti-Recoil Mechanism for Cable Tie Tool”, having as the inventors Joey D. Magno, Jr., Johan Tapper, Anders Fahlen, Joakim Norin, Goran Paulsson, and Sven Wadling, and identified by the Attorney Docket No. 577-613. A sensor which is load sensitive would generate the cut signal when the specific tension indicative of severing of the strap  16  is detected therein. 
   In an alternative embodiment of the cycle counter  10 , a mechanical counter may be coupled to the blade or another component of the cable tie tool  12  which translates when the strap  16  is severed. Such a mechanical counter may require more than one cable, linkage or other parts, any or all of which may require machining and assembly. 
   An alternative embodiment of the cable tie tool  10   a  is shown in  FIGS. 7 to 10 .  FIGS. 7 to 10  are views which correspond to the views of  FIGS. 1 to 4 , respectively. Parts shown in  FIGS. 7 to 10  which correspond to parts shown in  FIGS. 1 to 4  have the same reference numeral as in  FIGS. 1 to 4  with the addition of the suffix “a” in  FIGS. 7 to 10 . The tool head  12   a  is generally the same as the tool head  12  shown in  FIGS. 1 to 4 . The tool handle  15   a  shown in  FIGS. 7 to 10  includes a trigger mechanism  45  as shown in  FIGS. 7 and 8 . 
   The entire disclosure of U.S. Pat. No. 5,915,425 issued Jun. 29, 1999 is hereby incorporated by reference herein. The entire disclosures of U.S. patent application Ser. No. 10/614,435 filed in the USPTO on Jul. 7, 2003, U.S. patent application Ser. No. 29/185,985 filed in the USPTO on Jul. 7, 2003 and U.S. patent application Ser. No. 29/185,986 filed in the USPTO on Jul. 7, 2003 are each hereby incorporated by reference herein. The entire disclosures of U.S. Provisional Patent Application No. 60/544,361 filed in the USPTO on Feb. 13, 2004, U.S. Provisional Patent Application No. 60/544,362 filed in the USPTO on Feb. 13, 2004, and U.S. Provisional Patent Application No. 60/544,472 filed in the USPTO on Feb. 13, 2004 are each hereby incorporated by reference herein. The entire disclosure of the U.S. patent application filed in the USPTO on even date herewith and entitled “Cable Tie Tool Having Modular Tool Head”, having as the inventor Joey D. Magno, Jr., Johan Tapper, Anders Fahlen, Joakim Norin, Goran Paulsson, and Sven Wadling, and identified by the Attorney Docket No. 577-609 is hereby incorporated by reference herein. The entire disclosure of the U.S. patent application filed in the USPTO on even date herewith and entitled “Tension and Anti-Recoil Mechanism for Cable Tie Tool”, having as the inventors Joey D. Magno, Jr., Johan Tapper, Anders Fahlen, Joakim Norin, Goran Paulsson, and Sven Wadling, and identified by the Attorney Docket No. 577-613 is hereby incorporated by reference herein. 
   While the invention has been described by reference to certain preferred embodiments, it should be understood that numerous changes could be made within the spirit and scope of the inventive concept described. Accordingly, it is intended that the invention not be limited to the disclosed embodiments, but that it have the full scope permitted by the language of the following claims.