Battery powered flat tensioner tool

Abstract

A tool for tensioning a strap around a load and a method of operating the tool are provided. The tool includes a housing having a gripping portion, a power supply, a motor disposed within the housing, a tensioner head having a drive shaft driven by the motor, a tension feed wheel rotatable with the drive shaft and a nosepiece rotatably mounted to the tensioner head. The nosepiece includes a strap feed path and a tension foot having a substantially planar load engaging surface. A clutch plug is secured to the tension foot opposed from the feed wheel. A biasing element urges the nosepiece in a predetermined direction relative to the tensioner head. An operating handle is coupled to the tensioner head and nosepiece and is configured to rotate the tensioner head and nosepiece relative to one another in a first direction against a force from the biasing element.

What is claimed is: 
     
         1 . A tool for tensioning a strap around a load, the tool comprising:
 a housing having a gripping portion formed on an exterior surface;   a power supply;   a motor disposed within the housing and operably connected to the power supply;   a tensioner head positioned at one end of the housing, the tensioner head having a drive shaft operably connected to and configured to be driven by the motor;   a tension feed wheel mounted on and configured to rotate with the drive shaft;   a nosepiece rotatably mounted to the tensioner head having a strap feed path configured to receive overlapping plies of a strap, the nosepiece comprising a tension foot having a substantially planar load engaging surface configured to engage a substantially flat surface of the load;   a clutch plug secured to the tension foot, wherein a portion of the strap feed path is formed between the tension feed wheel and the clutch plug;   a biasing element configured to urge the nosepiece in a predetermined direction relative to the tensioner head; and   an operating handle coupled to the tensioner head and nosepiece, the operating handle configured to rotate the tensioner head and nosepiece relative to one another in a first direction against a force from the biasing element to increase a gap between the tension feed wheel and the clutch plug to receive overlapping plies of the strap.   
     
     
         2 . The tool of the  claim 1 , wherein the strap feed path is substantially parallel to the load engaging surface. 
     
     
         3 . The tool of  claim 1 , further comprising a powertrain disposed in the housing and interconnected between the motor and the tensioner head. 
     
     
         4 . The tool of  claim 1 , further comprising a side plate secured to the tensioner head. 
     
     
         5 . The tool of  claim 1 , further comprising a trigger to actuate the motor to drive the tension feed wheel. 
     
     
         6 . The tool of  claim 1 , further comprising a controller operably connected to the motor and configured to control the motor to selectively operate the tension feed wheel. 
     
     
         7 . The tool of  claim 6 , further comprising a tension control knob operably connected to the controller, the tension control knob configured to set a desired level of tension and communicate the desired level of tension to the controller. 
     
     
         8 . The tool of  claim 6 , further comprising a strap position sensor, operably connected to the controller, configured to detect the presence or absence of the strap in the strap feed path and communicate the presence or absence of the strap the controller. 
     
     
         9 . The tool of  claim 6 , further comprising an operating lever position switch operably connected to the controller and configured to detect movement of the operating lever to a predetermined position and communicate movement of the operating lever to the predetermined position to the controller. 
     
     
         10 . The tool of  claim 6 , wherein the trigger is operably connected to controller and is configured to change between different operating modes. 
     
     
         11 . The tool of  claim 6 , further comprising a home position switch operably connected to the controller, the home position switch configured to detect a position of the nosepiece and communicate a signal to the controller indicating the position of the nosepiece. 
     
     
         12 . The tool of  claim 1 , further comprising a strap guide positioned at a rear portion of the strap feed path, the strap guide having a tab configured to laterally guide and the maintain the strap under the tension feed wheel. 
     
     
         13 . The tool of  claim 1 , further comprising a module cutter secured to the nosepiece, the modular cutter having a cutting blade configured to cut the strap. 
     
     
         14 . A method of operating a tool for tensioning a strap around a load, the tool comprising nosepiece having a tension foot with a substantially planar load engaging surface, the method comprising:
 receiving, at a controller, a first signal from a strap sensing sensor that a strap is positioned in a strap feed path of the tension foot;   receiving, at the controller, a second signal from a home position switch indicating that the home position switch has changed from a first state to a second state; and   operating, by the controller, the motor to drive a drive shaft and rotate the tension feed wheel to tension the strap around the load in response to receipt of the first and second signals.   
     
     
         15 . The method of  claim 14 , further comprising receiving, at the controller, a predetermined tension level from a tension control knob. 
     
     
         16 . The method  claim 15 , wherein operating the motor further includes operating the motor until the predetermined tension has been reached. 
     
     
         17 . The method of  claim 14 , wherein operating the motor further includes operating the motor for a predetermined length of time. 
     
     
         18 . The method of  claim 14 , further comprising receiving, at the controller, a third signal from an operating lever position switch indicating movement of an operating lever, and the operating of the motor further includes operating the motor in response to receipt of the third signal. 
     
     
         19 . The method of  claim 14 , further comprising receiving, at the controller, a tension cycle start signal from a trigger, and operating of the motor further includes operating motor in response to receipt of the tension cycle start signal. 
     
     
         20 . A nosepiece for a strap tensioning tool having a housing, a power supply, a motor disposed in the housing, a tensioner head having a drive shaft and a tension feed wheel mounted on the drive shaft, the nosepiece comprising:
 a pivot pin configured to rotatably couple the nosepiece to the tensioner head;   a tension foot having a strap feed path configured to receive overlapping plies of a strap and a substantially planar load engaging surface; and   a clutch plug positioned in the tension foot substantially opposed to the tension feed wheel, the clutch plug configured to engage a strap to be tensioned.