Abstract:
The present disclosure relates to applicator counters and assemblies for counting, recording and transmitting cycles of machines, tools and the like. An applicator counter assembly for operative association with an applicator or the like is provided. The applicator counter assembly includes an applicator counter for counting, recording and transmitting cycles of the applicator. The applicator counter includes a magnetically responsive switch capable of being actuated in response to a magnetic force, whereby the applicator counter registers a count for each actuation of the switch.

Description:
BACKGROUND 
   1. Technical Field 
   The present disclosure relates to electronic devices and, more particularly, to electronic applicator counters for counting, recording and transmitting cycles of machines, tools and the like. 
   2. Background of Related Art 
   Current devices and/or equipment operatively connected to applicators (e.g., machines and the like), used to count cycles and the like, are typically simple mechanical counters or electromechanical counters. Information and records regarding the maintenance of the applicator are kept at a location and/or in a device which is separate from the applicator counter itself. In other words, various numbers of cables and/or wires may extend from the applicator counter to a separate storing and/or recording device, where the cycles counted are kept and stored. Alternatively, an individual must inspect the applicator counter, at regular intervals, and manually record the information collected (e.g., cycles) and either enter that information into a separate device at that moment or enter that information into a separate device at a later time. 
   Repetitive use of machines and tools results in machine or tooling wear. Accordingly, if continuous and meticulous records are kept and analyzed for the usage of the machine and/or tool, a user may be better able to predict and/or forecast when machine and/or tool maintenance or replacement will be necessary. In this manner, all the necessary replacement machines and/or tools may be acquired ahead of time, or all of the necessary repair equipment may be readied ahead of time in order to reduce the time the machine and/or tool is kept idle, i.e., downtime. 
   The need exists for devices and/or equipment capable of counting cycles and other data associated with the operation of machines, tools and the like, as well as being capable of recording and/or storing the data for manipulation at the time the data is taken or at a later time. 
   The need also exists for devices and/or equipment capable of transmitting the data to a remote processing unit either instantly or at a later time. 
   SUMMARY 
   The present disclosure relates to electronic devices and applicator counters for counting, recording and transmitting cycles of machines, tools and the like. 
   According to one aspect of the present disclosure, an applicator counter for counting, recording and transmitting cycles of machines, tools and the like is provided. The applicator counter includes a housing defining at least one window; a display operatively disposed within the housing and visible through the window formed in the housing; and a circuit board assembly operatively disposed within the housing and in electrical contact with the display. 
   The circuit board assembly includes a printed circuit board; a microchip supported on the printed circuit board for processing and manipulating information; an energy source supported on the printed circuit board for powering at least the display and the microchip; a storage element supported on the printed circuit board for storing information; and a magnetically responsive switch supported on the printed circuit board. The switch is configured to actuate in response to a magnetic force, whereby the circuit board assembly registers a count for each actuation (e.g., closing) of the switch. 
   It is envisioned that the magnetically responsive switch is a reed switch. Desirably, the circuit board assembly includes at least a pair of reed switches positioned at opposing sides thereof. 
   The circuit board may further include a data transmitting controller supported on the printed circuit board for transmitting information to a remote location. The data transmitting controller is desirably an IrDA® controller. 
   In an embodiment, the display is a liquid crystal display. 
   According to another aspect of the present disclosure, an applicator counter assembly for operative association with an applicator or the like is provided. The applicator counter assembly includes an applicator counter for counting, recording and transmitting cycles of the applicator. The applicator counter includes a switch configured to actuate in response to a magnetic force, whereby the applicator counter registers a count for each actuation of the switch. 
   The applicator counter assembly further includes a counter mounting kit for mounting the applicator counter to the applicator. The counter mounting kit includes a bracket configured to interconnect the applicator counter and the applicator; and a magnet operatively supportable on a working element of the applicator. In one embodiment, the magnet has a first position, corresponding to when the working element is in an idle condition, in which the magnet does not cause the magnetically responsive switch to actuate. In the same embodiment, the magnet has a second position, corresponding to when the working element is in an active condition, in which the magnet causes the magnetically responsive switch to actuate. The circuit board assembly in turn registers each count. 
   The applicator counter desirably includes a housing defining at least one window; a display operatively disposed within the housing and visible through the window formed in the housing; and a circuit board assembly operatively disposed within the housing and in electrical contact with the display. The circuit board assembly includes a printed circuit board; a microchip supported on the printed circuit board for processing and manipulating information; an energy source supported on the printed circuit board for powering at least the display and the microchip; and a storage element supported on the printed circuit board for storing information. 
   In an embodiment, the magnetically responsive switch is a reed switch. Desirably, at least a pair of reed switches is provided with each reed switch being supported at opposite ends of the printed circuit board. 
   The circuit board desirably includes a data transmitting controller supported on the printed circuit board for transmitting information to a remote location. Desirably, the data transmitting controller is an IrDA® controller. 
   The display is desirably a liquid crystal display. 
   The counter mounting kit may further include a guide selectively mountable to the bracket; and a rod extending through the guide and configured to support the magnet thereon. The rod is selectively connectable to the working element of the machine, wherein movement of the working element results in movement of the rod. It is envisioned that the bracket is configured to enable adjustment of the location of the applicator counter. In an embodiment, the guide is a clevis and the rod extends through arms of the clevis. 
   In use, when the working element of the machine is in an active condition, the magnet is positioned at a magnetically effective distance relative to the magnetically responsive switch. 
   For a better understanding of the present invention and to show how it may be carried into effect, reference will now be made by way of example to the accompanying drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view, with parts separated, of an application counter assembly according to an embodiment of the present disclosure; 
       FIG. 2  is a perspective view of the application counter assembly of  FIG. 1  shown operatively connected to a side feed applicator; 
       FIG. 3  is a perspective view of the application counter assembly of  FIG. 1  shown operatively connected to an end feed applicator; 
       FIG. 4  is a front elevational view of the side feed applicator of  FIG. 2  including the application counter assembly of  FIG. 1 ; 
       FIG. 5  is a side elevational view of the side feed applicator of  FIGS. 2 and 4  including the application counter assembly of  FIG. 1 ; 
       FIG. 6  is a rear elevational view of the side feed applicator of  FIGS. 2 ,  4  and  5  including the applicator counter assembly of  FIG. 1 ; 
       FIG. 7  is an enlarged top plan view illustrating the connection of the applicator counter assembly of  FIG. 1  to the applicator; 
       FIG. 8  is a bottom, perspective view illustrating the connection of the applicator counter assembly of  FIG. 1  to the applicator; 
       FIG. 9  is a perspective view, with parts separated, of an applicator counter assembly according to another embodiment of the present disclosure; 
       FIG. 10  is a perspective view of the applicator counter assembly of  FIG. 9  shown operatively connected to an end air feed applicator; 
       FIG. 11  is a perspective view of the applicator counter assembly of  FIG. 9  shown operatively connected to a side air feed applicator; 
       FIG. 12  is an exploded, perspective view of the counter of the assembly of  FIG. 1 ; 
       FIG. 13  is a schematic illustration of the counter of  FIG. 12 ; and 
       FIG. 14  is a schematic illustration of a reed switch. 
   

   DETAILED DESCRIPTION OF EMBODIMENTS 
   Embodiments of the presently disclosed applicator counter assembly will now be described in detail with reference to the drawing figures wherein like reference numerals identify similar or identical elements. As used herein and as traditional, the term “distal” refers to that portion which is furthest from the user while the term “proximal” refers to that portion which is closest to the user. 
   The applicator counter assembly of the present disclosure is a simple and inexpensive computer control device capable of storing information for terminal setup and capable of collecting data for a scheduled maintenance and calibration program. 
   Referring initially to  FIGS. 1-8 , an applicator counter assembly, in accordance with an embodiment of the present disclosure and for operative engagement with a machine and/or tool (e.g., an applicator or the like), is generally designated as  100 . Applicator counter assembly  100  includes a counter  200 , and a counter mounting kit  110  configured and adapted to selectively operatively connect counter  200  to a machine and/or tool “M”. Desirably, counter mounting kit  110  and counter  200  are configured for side attachment to machine and/or tool “M”, as seen in  FIG. 2 , and/or end attachment to machine and/or tool “M”, as seen in  FIG. 3 . 
   As seen in  FIG. 1 , counter mounting kit  110  includes a counter mounting bracket  112  including at least one hole  114  formed therein for receiving a corresponding securing element  116  (e.g., a screw or the like) therethrough. Desirably, a pair of holes  114  is provided for receiving a pair of screws  116  for securing counter  200  thereto. Bracket  112  further includes at least one elongate slot  118  formed therein and extending at least substantially across the entire rear portion of bracket  112 . Desirably, a pair of substantially parallel elongate slots  118  is formed in bracket  112 . While a pair of parallel elongate slots  118  are shown and described, it is envisioned that any configuration of apertures may be provided. Slots  118  enable the adjustment of and desired placement of counter  200  relative to machine “M”. Each slot  118  is configured and dimensioned to receive a respective mounting element  120  (e.g., a screw) or the like. 
   Counter mounting kit  110  further includes a guide  122  selectively mountable to bracket  112 . Guide  122  includes at least one aperture formed in an upper surface thereof for receiving corresponding screws  120  extending through nuts  121  and elongate slots  118 . Guide  122  further includes at least one mounting hole  124  formed therethrough for receiving a mounting screw  126  (see  FIGS. 5-8 ). Desirably, a pair of mounting holes  124  is provided. Mounting holes  124  and mounting screws  126  are used to secure guide  122  to machine and/or tool “M”. Desirably, screws  120  extend through slots  118  and engage complementary holes  123  formed in a top surface of guide  122 . 
   Counter mounting kit  110  further includes an adjustment rod  130  slidably extending through an appropriately sized aperture  128  formed in guide  122 . Desirably, adjustment rod  130  extends orthogonally through guide  122 . Adjustment rod  130  includes a first end  130   a  and a second end  130   b . First end  130   a  of adjustment rod  130  extends through aperture  128  formed in guide  122 , and second end  130   b  of adjustment rod  130  is configured for operative engagement to a working element “W” of machine “M” (see  FIG. 6 ). 
   Adjustment rod  130  includes a threaded opening  132  formed in first end  130   a  thereof for receiving an adjustment screw  134 . A magnet  136  (i.e., a ring magnet) is positioned on shaft portion  134   b  of adjustment screw  134 , against head portion  134   a  of adjustment screw  134 . A first locking element  138   a  (i.e., a nut) may be used to secure ring magnet  136  against head portion  134   a  of adjustment screw  134 . A second locking element  138   b  (i.e., a nut) may be used fix the location of ring magnet  136  relative to adjustment rod  130 . More particularly, as will be described in greater detail below, second locking element  138   b  functions to fix the location of ring magnet  136  to counter  200  when working element “W” of machine “M” is in an idle condition. Desirably, when working element “W” of machine “M” is in the idle condition, ring magnet  136  is disposed proximate a predetermined location of counter  200  (see  FIGS. 6-8 ). 
   As seen in  FIG. 1 , a pair of spaced apart annular grooves  140  is formed in adjustment rod  130 , between first end  130   a  and second end  130   b . Annular grooves  140  are each configured and dimensioned to operatively receive a respective retaining ring  142 . Desirably, second end  130   b  of adjustment screw  130  extends through working element “W” of machine “M” and retaining rings  142  are disposed on either side of working element “W”. In this manner, adjustment rod  130  will axially translate in the direction of movement of working element “W”. Desirably, a compression spring  144  is positioned about adjustment rod  130  and between guide  122  and a retaining ring  142 . In this manner, compression spring  144  will bias adjustment rod  130 , and in turn ring magnet  136  into magnetic engagement with counter  200  when working element “W” returns to the idle condition. 
   In use, as will be described in greater detail below, when working element “W” of machine “M” is in an idle or first condition (see  FIGS. 2-8 ), ring magnet  136  is positioned at a location for magnetic operative engagement with counter  200 , i.e., ring magnet  136  magnetically draws or repels a complementary magnet or magnetically responsive material (not shown) in a first direction. When working element “W” of machine “M” is in a second or working condition (not shown), ring magnet  136  is positioned at a location to have no magnetic operative engagement with counter  200 , i.e., ring magnet  136  does not magnetically draw or repel a complementary magnet or magnetically responsive material (not shown) in the first direction. 
   Turning now to  FIGS. 9-11 , counter mounting kit  110  is configured and adapted for connecting counter  200  to a machine “M” having an end air feed, as seen in  FIG. 10 , or a machine “M” having a side air feed, as seen in  FIG. 11 . Counter mounting kit  110  includes an L-shaped bracket  150  having a back wall portion  152  and a bottom wall portion  154 . Back wall portion  152  of L-shaped bracket  150  includes at least one aperture  152   a  formed therein for receiving a mounting element  153 , e.g., a screw (see  FIGS. 10 and 11 ). Bottom wall portion  154  of L-shaped bracket  150  includes a plurality of holes  154   a  formed therein. Holes  154   a  are formed at locations which align with elongate slots  118  formed in bracket  112 . Holes  154   a  are configured and sized to receive screws  120 . In use, bracket  112  is disposed on top of bottom wall portion  154  of L-shaped bracket  150 . 
   Counter mounting kit  110  further includes a clevis  160  which is securable to machine “M” and which is configured and adapted to support a pin or rod  162 . Pin or rod  162  includes a magnet  164  disposed at an end thereof. Desirably, pin or rod  162  extends through holes  160   b  formed in arms  160   a  of clevis  160 . A retaining ring  166  may be provided and used to engage an annular groove  162   a  formed in pin or rod  162  and preventing pin or rod  162  from sliding out of holes  160   b  of clevis  160 . 
   Desirably, when counter mounting kit  110  is used to mount counter  200  to a machine “M” having an end air feed, as seen in  FIG. 10 , or a machine “M” having a side air feed, as seen in  FIG. 11 , mounting kit  110  is configured to position magnet  164  proximate a predetermined location of counter  200  when machine “M” is in the idle condition. In use, when working element “W” of machine “M” is in the idle of first condition, magnet  164  is positioned at a location for magnetic operative engagement with counter  200  (i.e., magnet  164  magnetically draws or repels a complementary magnet or magnetically responsive material in a first direction. When working element “W” of machine “M” is in a second or working condition (not shown), magnet  164  is positioned at a location to have no magnetic operative engagement with counter  200 , i.e., magnet  164  does not magnetically draw or repel a complementary magnet or magnetically responsive material in the first direction. 
   Turning now to  FIGS. 12 and 13 , a detailed discussion of counter  200  is provided. Counter  200  includes a housing  202  having a rear-half portion  202   a  and a front-half portion  202   b . Rear-half portion  202   a  and front-half portion  202   b  are joined together using any method or technique known by one having skill in the art, such as, for example, spot welding, adhering, fastening and the like. Front-half portion  202   b  of housing  202  defines a window  204  formed therein for exposing a display  206  disposed within housing  202 . Desirably, display  206  is an LCD (liquid crystal display) or any other graphic producing display available in the art. 
   At least one connector  208  is provided for electrically connecting display  206  to a circuit board assembly  210 . Preferably, a pair of connectors  208  is used to electrically connect display  206  to circuit board assembly  210 . It is envisioned that connectors  208  are “zebra-type” connectors. 
   Counter  200  includes a circuit board assembly  210  mounted within housing  202  having half-sections  202   a ,  202   b  using mounting elements  203  (e.g., screws or the like). Circuit board assembly  210  includes a printed circuit board  212  supporting at least a microchip  214 , a battery  216  or other energy source, a display controller  218 , at least one reed or Hall effect switch  220  or any other magnetically responsive switch, an IrDA® controller  222  or any other data transmitting controller, and a storage element  224 . 
   Reed switches  220  are configured and adapted to activate and/or function upon exposure to magnetic forces and the like. For example, as seen in  FIG. 14 , reed switch  220  includes two identical flattened ferromagnetic reeds  220   a , sealed in a dry inert-gas atmosphere within a capsule  220   b , thereby protecting reeds  220   a  from contamination. Reeds  220   a  are sealed in capsule  220   b  in cantilever form so that their free ends overlap (as indicated by arrow “B”) and are separated by a small gap  220   c.  In operation, when a magnetic force is generated parallel to reed switch  220 , reeds  220   a  become flux carriers in the magnetic circuit. The overlapping ends of reeds  220   a  become opposite magnetic poles, which attract each other. If the magnetic force between the poles is strong enough to overcome the restoring force of reeds  220   a  (as indicated by arrows “A”), reeds  220   a  will be drawn together and complete an electrical circuit. In the case of counter  200 , each contacting of reeds  220   a  with one another represents a single count of operation of machine “M”. 
   It is envisioned that microchip  214  and storage element  224  may retain the following data fields: total count; permanent data; and tooling data. The permanent data may include information about the machine and/or tool “M”, such as, for example, the date manufactured; the serial number; the part number; and the customer data. The tooling data may include information such as the part number, date, and cycle count for wire crimpers, insulation crimpers, anvils, sheer tools, maintenance data and the like. 
   IrDA® controller  222  uses an IrDA® built into circuit board assembly. IrDA® controller  222  enables creation of a wireless interface to a separate computer for data transfer. 
   To conserve power, display  206  and IrDA® controller  222  are desirably normally in an “off ” condition. To activate display  206  and IrDA® controller  222 , a push-button  226 , supported in front-half portion  202   b  of housing  202  is depressed. 
   In use, as magnet  136  or  164  is approximated toward reed switch  220 , the magnetic force generated by magnate  136  or  164  is strong enough to overcome the restoring force of reeds  220   a  and will draw reeds  220   a  together to complete an electrical circuit and register a single count of operation for machine “M”. In one embodiment, all of the counts registered are stored in storage element  224  of counter  200  and, if desired, processed and/or manipulated by microchip  214 . The processes information is later transmitted, via IrDA® controller  222  to an external, remote computer “C” (see  FIG. 13 ). Alternatively, in another embodiment, all of the counts are transmitted immediately to computer “C” for storage and/or further processing and manipulating. 
   By using applicator counter assembly  100  to monitor, store and process data regarding the usage of machine and/or tool “M” (e.g., the count or number of times the machine and/or tool is used), the user is better able to predict and/or forecast when machine and/or tool maintenance or replacement will be necessary. In this manner, all the necessary replacement machines and/or tools may be acquired ahead of time, or all of the necessary repair equipment may be readied ahead of time in order to reduce the time machine and/or tool “M” is kept idle, i.e., downtime. 
   It is to be understood that the foregoing description is merely a disclosure of particular embodiments and is no way intended to limit the scope of the invention. Other possible modifications will be apparent to those skilled in the art and all modifications will be apparent to those in the art and all modifications are to be defined by the following claims.