U.S. patent application number 13/963718 was filed with the patent office on 2014-02-13 for band tensioning tool insert.
This patent application is currently assigned to Band-It-IDEX, Inc.. The applicant listed for this patent is Band-It-IDEX, Inc.. Invention is credited to Miklos Balazs Marelin.
Application Number | 20140041747 13/963718 |
Document ID | / |
Family ID | 50065272 |
Filed Date | 2014-02-13 |
United States Patent
Application |
20140041747 |
Kind Code |
A1 |
Marelin; Miklos Balazs |
February 13, 2014 |
Band Tensioning Tool Insert
Abstract
A band tensioning tool is provided that employs a replaceable
insert juxtaposed to a tensioning wheel. The insert is made of
low-friction material wherein band galling and tension wheel
slippage is drastically reduced. The tool employing the
contemplated insert can tension bands of various material
properties with predictable repeatability.
Inventors: |
Marelin; Miklos Balazs;
(Aurora, CO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Band-It-IDEX, Inc. |
Denver |
CO |
US |
|
|
Assignee: |
Band-It-IDEX, Inc.
Denver
CO
|
Family ID: |
50065272 |
Appl. No.: |
13/963718 |
Filed: |
August 9, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61682014 |
Aug 10, 2012 |
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Current U.S.
Class: |
140/93.2 |
Current CPC
Class: |
B21F 15/04 20130101;
B65B 13/22 20130101; B25B 25/00 20130101 |
Class at
Publication: |
140/93.2 |
International
Class: |
B65B 13/22 20060101
B65B013/22; B21F 15/04 20060101 B21F015/04 |
Claims
1. A band tensioning tool comprising: a pneumatically-powered
tension wheel; a foot spaced from said tension wheel, said foot
having a recess; a lever associated with said foot that selectively
moves said foot away from said tension wheel; and an insert
positioned in said insert, said recess being made of a low-friction
material.
2. The tool of claim 1, wherein said low-friction insert has a room
temperature tensile strength of between about 20,000 to 32,000 psi,
room temperature tensile modulus of between about 3-4 Mpsi, room
temperature flexural strength of between about 30,000 to 50,000
psi, room temperature flexural modulus of between about 4.9 to 4.12
Mpsi, room temperature compressive strength of between about
40,000-75,000 psi, and room temperature coefficient of friction of
between about 0.15 to 0.20.
3. The tool of claim 1, wherein said low friction insert has a
coefficient of friction of between about 0.15 to 0.20.
4. The tool of claim 1, wherein said low friction insert has a
coefficient of friction of between about 0.05 to 0.40.
5. The tool of claim 1, wherein said low friction insert is made of
a composition comprised of a mixture of between about 40%-60%
pmr-15 polyamide resin and between about 40%-60% of at least one of
carbon fiber and graphite.
6. The tool of claim 1, wherein said insert has a circular outer
perimeter.
7. A band tensioning tool comprising a gear housing having a
tension wheel protruding from a portion thereof; a foot pivotally
coupled to said gear housing and having a band support portion
disposed generally opposite said tension wheel; a compression foot
spring having a first end portion associated with said gear housing
and a second end portion associated with said foot, said
compression foot spring adapted to pivotally bias said band support
portion of said foot toward the tension wheel; a handle having a
first end portion coupled to said foot, said handle having an
intermediate portion and a second end portion extending from said
foot generally along the axial dimension of said gear housing, said
handle being actuatable toward and away from said gear housing to
pivot said foot against the pivotal bias of said compression foot
spring, which moves said band support portion away from said
tension wheel to provide a band-receiving gap, the improvement
comprising: a low-friction insert incorporated in said foot, said
low-friction insert being generally aligned with, but spaced from,
said tension wheel when said handle is actuated toward said gear
housing.
8. The tool of claim 7, wherein said low-friction insert has a room
temperature tensile strength of between about 20,000 to 32,000 psi,
room temperature tensile modulus of between about 3-4 Mpsi, room
temperature flexural strength of between about 30,000 to 50,000
psi, room temperature flexural modulus of between about 4.9 to 4.12
Mpsi, room temperature compressive strength of between about
40,000-75,000 psi, and room temperature coefficient of friction of
between about 0.15 to 0.20.
9. The tool of claim 7, wherein said low friction insert has a
coefficient of friction of between about 0.05 to 0.40.
10. The tool of claim 7, wherein said low friction insert is made
of a composition comprised of a mixture of between about 40%-60%
pmr-15 polyamide resin and between about 40%-60% of at least one of
carbon fiber and graphite.
11. A method of securing a band about a plurality of objects,
comprising: providing a band tensioning tool comprising a
pneumatically-powered tension wheel, a foot spaced from said
tension wheel, said foot having a recess, a lever associated with
said foot that selectively moves said foot away from said tension
wheel, and an insert positioned in said insert, said recess being
made of a low-friction material; moving said lever to separate said
foot from said tension wheel; placing a band between said tension
wheel and said foot; releasing said lever which moves said insert
into engagement with said band, said band also being engaged to
said tension wheel; rotating said tension wheel, which moves said
band across said insert; achieving a predetermined band tension;
deforming a seal about said band to create a band loop; and
severing an excess portion of said band.
12. The method of claim 11, wherein said band does not
substantially gall when it moves across said insert.
13. The method of claim 11, wherein said tool is capable of
tensioning bands made of at least one of a carbon steel, a
stainless steel alloy, and a steel/nickel alloy, wherein retained
force is between about 200-400 lbf. is achieved, regardless of band
material.
14. The method of claim 11, wherein said tool is capable of
tensioning bands made of at least one of Zeron, Alloy 400,
one-quarter hard 304 stainless steel, and 316 stainless steel,
wherein retained force is between about 200-400 lbf. is achieved,
regardless of band material.
15. The method of claim 11, wherein said tool is capable of
tensioning a plurality of Zeron bands with a standard deviation
associated with applied band tension is about 30-40.
16. The method of claim 11, wherein said tool is capable of
tensioning a plurality of Zeron bands such that a standard
deviation associated with applied band tension is reduced by about
80-90% with respect to a similar tool that does not employ a
low-friction insert.
17. The method of claim 11, wherein said tool is capable of
tensioning a plurality of Alloy 400 bands with a standard deviation
associated with applied band tension is about 50-60.
18. The method of claim 11, wherein said tool is capable of
tensioning a plurality of Alloy 400 bands such that a standard
deviation associated with applied band tension is reduced by about
55-65% with respect to a similar tool that does not employ a
low-friction insert.
19. A band tensioned by the method of claim 11.
Description
[0001] This application claims the benefit of U.S. Provisional
Application Ser. No. 61/682,014, filed Aug. 10, 2012, the entire
disclosure of which is incorporated by reference herein.
FIELD OF THE INVENTION
[0002] Embodiments of the present invention are generally related
to band tensioning tools. More particularly, one embodiment is a
tool with an insert positioned beneath, and spaced from, a tension
wheel that facilitates band tensioning and reduces tool
malfunctions.
BACKGROUND OF THE INVENTION
[0003] Corrosion-resistant metallic bands are used in oil drilling
operations where exposure to seawater, chemicals, drilling fluids,
etc. is common. Carbon steel bands have been used in these
applications and have been successfully tensioned by existing
tensioning tools, such as Fromm's A480 tool. Zeron, a stainless
steel with excellent corrosion resistance and high strength
characteristics, is also commonly used. Nickel alloys are also
used, such as Inconel and Monel, which are corrosion and heat
resistant. The problem of using stainless steel or nickel alloy
bands is the existing band tools provide inadequate tension and the
tension provided varies from band-to-band.
[0004] FIGS. 1-4 show the Fromm A480 tool 2. The tool employs a
pneumatically-driven knurled tension wheel 6 that is spaced from a
replaceable insert 10 located in a breaker foot 14. A spring biases
the tension wheel 6 towards the breaker foot 14. A lever 18 is used
to separate the tension wheel 6 from the breaker foot 14, which
allows a band to be inserted therebetween. The operator releases
the lever 18 and pneumatic pressure is used to rotate the tension
wheel 6 which tensions the band. That is, as the tension wheel 6
rotates, the band is pulled across the insert 10, thereby
tensioning the band about an object(s). A user-controlled "pressure
setting" of the tool 2 is proportional to the amount of pressure
applied by the tension wheel 6 onto the band, the level of band
cutting force available, and band pull speed.
[0005] When a desired band tension is achieved, the tension wheel 6
will stall or repeatedly slip at the point of band contact because
the pneumatic pressure used to rotate the tension wheel 6 will be
insufficient to overcome the tension exerted by the band (i.e., a
force in a direction opposite from the band pull direction). When
the tension wheel 6 stalls, the operator surmises that the proper
band tension has been achieved and uses lock forming jaws of the
tool 2 to deform a buckle or seal about the band. After the band
has been locked, the excess portion of the band is severed
therefrom by a pneumatically driven knife/blade mechanism of the
tool. If the tension wheel 6 slips before the desired band tension
is achieved, because of increased friction between the band and
insert, or because the tension wheel is rendered ineffective, the
operator will mistakenly believe the desired tension has been
reached and will lock and cut the band prematurely.
[0006] Again, existing tools tension carbon steel bands
effectively, but bands made out of stainless steel, for example,
often pose problems. For instance, compression of stainless steel
bands against existing inserts cause the band and/or insert to gall
as the band moves relative to the insert. Galling can occur after a
small number of bands are tensioned. Galling, i.e., adhesive wear
of the tension wheel or the insert, adversely affects tool
performance because it can cause material to be removed from the
band which can clog spaces in the knurled surface of the tension
wheel. As one of skill will appreciate, altering the tension wheel
in this fashion causes slippage and, thus, ineffective tensioning.
Tension wheel slipping also causes the tension wheel to wear
prematurely. Further, galling often alters the shape of the band,
which may render adding additional band seals to a severed end of a
band coil difficult.
[0007] Galling is addressed in some ways by coating the band with
wax, which adds cost and complexity to band manufacturing.
Alternatively, tool operators choose to accept some level of
galling and compensate for slipping by modifying the pressure
setting to increase the pressure the tension wheel applies on the
band. Regardless of the techniques used to address the slippage,
studies have shown that a given number of stainless steel bands
tensioned with an existing tool often deviate in band tension
performance, which indicates inconsistent and unpredictable tool
performance.
[0008] Another way to address galling is to employ a pinch wheel
opposite the tension wheel, which is disclosed in U.S. Pat. No.
6,073,664, the entirety of which is incorporated herein. Changing
existing tools to incorporate a pinch wheel would require major
modifications.
[0009] Thus is a long felt need to provide a band clamping tool
that provides accurate and repeatable tension from band to band. It
is also desirable to provide a band tensioning tool that prevents
or reduces the amount of slippage between the pinch wheel and the
band and, thus, prolongs life of the tension wheel.
SUMMARY OF THE INVENTION
[0010] It is one aspect of embodiments of the present invention to
provide a tool that addresses galling and performance issues
commonly experienced by existing band tensioning tools. More
specifically, one embodiment of the present invention employs a
low-friction insert that works in conjunction with a tensioning
wheel. The contemplated insert has a room temperature tensile
strength between about 20,000 to 32,000 psi, room temperature
tensile modulus of between about 3-4 Mpsi, room temperature
flexural strength of between about 30,000 to 50,000 psi, room
temperature flexural modulus of between about 4.9 to 4.12 Mpsi,
room temperature compressive strength of between about
40,000-75,000 psi, and room temperature coefficient of friction of
between about 0.15 to 0.20. In one embodiment of the present
invention, Wearcomp.RTM. manufactured by Hycomp.RTM. was used, but
one of skill in the art will appreciate that any material that
meets these or similar material properties may be used without
departing from the scope of the invention. Wearcomp.RTM. is
comprised primarily of pmr-15 polyamide resin (40%-60%) and carbon
fiber or graphite (40%-60%).
[0011] The contemplated low-friction insert is placed within a foot
of the tool and is spaced from the tension wheel. In operation, a
band is compressed between the tension wheel and the insert. When
the tension wheel is rotated and the band tensioned, the
low-friction insert allows the band to slide without galling, which
increases tension wheel effectivity. As a result, the insert allows
for increased tension wheel pressure to be applied, which
influences band tension and pull speed.
[0012] It is one aspect of embodiments of the present invention to
provide a band tensioning tool comprising: a pneumatically-powered
tension wheel; a foot spaced from the tension wheel, the foot
having a recess; a lever associated with the foot that selectively
moves the foot away from the tension wheel; and an insert
positioned in the insert, the recess being made of a low-friction
material.
[0013] It is yet another aspect of embodiments of the present
invention to provide a band tensioning tool comprising a gear
housing having a tension wheel protruding from a portion thereof; a
foot pivotally coupled to the gear housing and having a band
support portion disposed generally opposite the tension wheel; a
compression foot spring having a first end portion associated with
the gear housing and a second end portion associated with the foot,
the compression foot spring adapted to pivotally bias the band
support portion of the foot toward the tension wheel; a handle
having a first end portion coupled to the foot, the handle having
an intermediate portion and a second end portion extending from the
foot generally along the axial dimension of the gear housing, the
handle being actuatable toward and away from the gear housing to
pivot the foot against the pivotal bias of the compression foot
spring, which moves the band support portion away from the tension
wheel to provide a band-receiving gap, the improvement comprising:
a low-friction insert incorporated in the foot, the low-friction
insert being generally aligned with, but spaced from, the tension
wheel when the handle is actuated toward the gear housing.
[0014] It is still yet another aspect of embodiments of the present
invention to provide a method of securing a band about a plurality
of objects, comprising: providing a band tensioning tool comprising
a pneumatically-powered tension wheel, a foot spaced from the
tension wheel, the foot having a recess, a lever associated with
the foot that selectively moves the foot away from the tension
wheel, and an insert positioned in the insert, the recess being
made of a low-friction material; moving the lever to separate the
foot from the tension wheel; placing a band between the tension
wheel and the foot; releasing the lever which moves the insert into
engagement with the band, the band also being engaged to the
tension wheel; rotating the tension wheel, which moves the band
across the insert; achieving a predetermined band tension;
deforming a seal about the band to create a band loop; and severing
an excess portion of the band.
[0015] The Summary of the Invention is neither intended nor should
it be construed as being representative of the full extent and
scope of the present invention. Moreover, references made herein to
"the present invention" or aspects thereof should be understood to
mean certain embodiments of the present invention and should not
necessarily be construed as limiting all embodiments to a
particular description. The present invention is set forth in
various levels of detail in the Summary of the Invention as well as
in the attached drawings and the Detailed Description of the
Invention and no limitation as to the scope of the present
invention is intended by either the inclusion or non-inclusion of
elements, components, etc. in this Summary of the Invention.
Additional aspects of the present invention will become more
readily apparent from the Detail Description, particularly when
taken together with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The accompanying drawings, which are incorporated in and
constitute a part of the specification, illustrate embodiments of
the invention and together with the general description of the
invention given above and the detailed description of the drawings
given below, serve to explain the principles of these
inventions.
[0017] FIG. 1 is a perspective view showing a band tensioning tool
of the prior art;
[0018] FIG. 2 is a front elevation view of FIG. 1;
[0019] FIG. 3 is a detailed view of FIG. 1 showing the bottom
portion of the tool;
[0020] FIG. 4 is a detailed view of FIG. 1 showing a tension wheel
spaced from an insert;
[0021] FIG. 5A is a perspective view of an insert employed by one
embodiment of the present invention;
[0022] FIG. 5B is a front elevation view of FIG. 5A;
[0023] FIG. 5C is a side elevation view of FIG. 5A;
[0024] FIG. 6 is a table showing retained force of bands of various
material compositions tensioned with a tool of one embodiment of
the present invention;
[0025] FIG. 7 is a table showing loop tensile force achieved by
bands tensioned with tools of one embodiment of the present
invention;
[0026] FIG. 8 is a table showing band pull speed provided by one
embodiment of the present invention;
[0027] FIG. 9 is a table comparing steel inserts with inserts
employed by some embodiments of the present invention;
[0028] FIG. 10A is a perspective view of a tool showing removal of
side cover screws;
[0029] FIG. 10B is a perspective view of a tool showing removal of
the tool side cover;
[0030] FIG. 10C is a perspective view of a tool showing removal of
a tension wheel;
[0031] FIG. 10D is a perspective view of a tool showing removal of
an existing insert or the replacement of a low-friction insert;
and
[0032] FIG. 10E shows the installation of the replacement insert
into a foot.
[0033] It should be understood that the drawings are not
necessarily to scale. In certain instances, details that are not
necessary for an understanding of the invention or that render
other details difficult to perceive may have been omitted. It
should be understood, of course, that the invention is not
necessarily limited to the particular embodiments illustrated
herein.
DETAILED DESCRIPTION
[0034] As briefly described above, FIGS. 1-4 show a band tensioning
tool 2 commonly used in the industry to tension a band claim. The
tool 2 includes pneumatically-driven tension wheel 6 that is spaced
from a foot 14 that accommodates a low-friction insert 10. In
operation, the user moves a lever 18 that moves the foot 14 away
from the tension wheel 6, which allows a band to be placed
therebetween. When the lever is released, the band is compressed
between the low-friction insert 10 and the tension wheel 6. A
pneumatic motor is initiated to rotate the tension wheel to tension
the band. After a predetermined tension is achieved, a locking
mechanism is employed that deforms a portion of a seal about the
band, which maintains the applied tension, and the excess band
portion, which extends beyond the seal, is severed. The components
and functionality of existing tools is described in U.S. Pat. No.
4,380,255, which is incorporated by reference herein, and the
previously-mentioned U.S. Pat. No. 6,073,644. The contemplated
low-friction insert may be incorporated into these, or similar,
tools. The Locking a seal by crimping is described in U.S. Pat. No.
7,484,274, which is incorporated by reference herein.
[0035] FIGS. 5A-5C shows a low-friction insert of one embodiment of
the present invention. Although the shape of this insert is
circular, one of skill in the art will appreciate that the insert
may have any shape so long it can be accommodated in a cavity
provided in the foot. The insert may also include a cavity that
receives a secondary insert that is removable therefrom.
[0036] FIG. 6 is a table showing retained force of bands that were
tensioned using a stock Fromm tool versus those using a Fromm tool
employing the contemplated low-friction insert. Here, bands made of
Zeron, Alloy 400, 304 stainless steel (one quarter hard), and 316
stainless steel were tensioned. A retained force (i.e., the force
exerted on the objects by the band) of about 500 pounds was
achieved when a Zeron band was tensioned with a stock Fromm tool
and a retained force of about 280 pounds achieved by a tool using a
tool with a low-friction insert. When tensioning an alloy 400 band,
the stock tool produced a retained force of about 150 pounds
compared to a retained force of about 250 pounds achieved by a tool
with a low friction insert. In the case of a 304 stainless steel
(one-quarter hard) band, the retained force was 550 pounds using
the stock tool and about 340 pounds when using a tool with a low
friction insert. Finally, when a 316 stainless steel band was
tensioned using a stock tool, 90 pounds of retained force was
attained compared to about 210 pounds using the low friction
insert. Accordingly, one of skill in the art will appreciate that a
tool employing a low-friction insert provides a more predictable
and consistent band clamp performance over a wide range of
materials compared to the stock tool.
[0037] These test results illustrate band performance
repeatability, which is important, as users will often use bands of
different materials for different applications. In the past, the
band material would dictate the amount tension applied wherein the
user would have to modify tool parameters to achieve the desired
tension. Embodiments of the present invention address this issue by
providing an insert that tensions bands of different materials to
the same level degree, thereby increasing repeatability and
reliability. For example, bands made of Zeron, Alloy 400, 304
stainless steel, and 316 stainless achieve a retained force of at
least about 200 psi. The table shows that the retained force of
bands applied by the stock Fromm tool varies depending on band
material. Repeatability is often the driving force in banding
operations, because it allows users to be confident that the
tension applied to each band meets a predefined design
criteria.
[0038] FIG. 7 shows that a tool employing a low-friction insert
clamp strength will be unchanged over a wide range of pressure
settings. More specifically, the loop tensile force provided by a
band tensioned with a tool employing a low friction insert is about
3,500 lbf regardless of the tool pressure, i.e., pressure the
tension wheel imparts on the band and insert, which is comparable
to the tool loop tensile force provided by band tensioned with the
stock tool. Thus using a low-friction insert does not adversely
affect loop tensile performance.
[0039] FIG. 8 shows bands may be tension much faster when using a
low friction insert. More specifically, tools using a low-friction
insert are capable of operating at lower torque because excess
power is not needed to counteract friction associated with the band
moving across the insert. Such tools are desirable as they can pull
band at higher speeds while applying the desired tension and while
providing sufficient pneumatic pressure to sever bands of various
materials. Employing a low-friction insert, the pull speed may be
doubled because a high speed motor may be used. Conversely, prior
art tools cannot use a high speed motor because of the detrimental
effects of tension wheel slipping and/or galling, which affects the
applied tension and which can stall the tool. Here, a tool
employing a low-friction insert has a band speed rate of about 7
in./s wherein the prior art insert allows for a band pull speed of
about 3.2 in./s (because a low-speed transmission is commonly
used). As one of skill in the art will appreciate, pull speed is
directly related to the amount of bands that can be installed in a
given amount of time.
[0040] Referring now to FIG. 9, Zeron and Alloy 400 (full hard)
bands were tensioned using a stock Fromm A480 tool and a Fromm A480
tool employing a low-friction insert. The stock tool produced bands
tensioned to about 508 lbf (Alloy 400) and 629 lbf (Zeron). The
tool employing a low friction insert performed much better,
tensioning bands to about 1196 lbf (Alloy 400) and about 1301 lbf
(Zeron). The standard deviation of band tension was also reduced
when using a modified tool by an order of magnitude, from 284 to 34
for Zeron and from 145 to 58 for Alloy 400. Use of a low-friction
insert increased tension on average about 673 lbf (Zeron) and 688
lbf (Alloy 400) over existing inserts. Further, the repeatability
in performance is desirable to operators as they can tension many
bands without having to make adjustments to the tool
configuration.
[0041] Further, embodiments of the present invention reduce galling
in stainless steel bands. In one test, 10,000 pulls were performed
without failure, i.e., tension wheel slippage. Also, the nature of
the contemplated low-friction insert allows it to be reversible
(i.e., removed, flipped over, and replaced), thereby doubling its
life and lowers tension output, which reduces the risk of damage to
the seal and band at higher pressure settings.
[0042] With reference now to FIGS. 10A-10E, modification of a stock
tool is shown. Initially, side cover screws 18 are removed and the
side cover 22 is pried from the tool, which exposes the tension
wheel 6 and insert screw 26. The tension wheel 6 and insert 10 are
then removed. The replacement insert 10 is then installed into the
foot 14 of the tool and a tension wheel 6 is placed back on its
axle 30. Minute changes can be made to the gap between the tension
wheel 6 and the insert 10. Finally, the side cover 22 and screws 18
are placed back on the tool and gap adjustment screws are used to
further maintain a predetermined gap between the tension wheel 6
and the insert 10.
[0043] Although described numerous times herein, the aspects of the
present invention are not limited to the Fromm A480 tool. That is,
one of skill in the art will appreciate that tools of other
manufacture and type can be used without departing from the scope
of the invention.
[0044] While various embodiments of the present invention have been
described in detail, it is apparent that modifications and
alterations of those embodiments will occur to those skilled in the
art. However, it is to be expressly understood that such
modifications and alterations are within the scope and spirit of
the present invention, as set forth in the following claims.
Further, the invention(s) described herein is capable of other
embodiments and of being practiced or of being carried out in
various ways. In addition, it is to be understood that the
phraseology and terminology used herein is for the purpose of
description and should not be regarded as limiting. The use of
"including," "comprising," or "having" and variations thereof
herein is meant to encompass the items listed thereafter and
equivalents thereof as well as additional items.
* * * * *