Note: Descriptions are shown in the official language in which they were submitted.
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UNITED STATES PROVISIONAL PATENT APPLICATION
FOR
TOOL AND TOOL SETTING MANAGEMENT SYSTEM AND
METHOD CONFIGURED TO PAIR WITH THE TOOL TO CHANGE
HOW THE TOOL CAN FUNCTION
INVENTORS:
JANUSZ FIGIEL
WALTER L. BOSS
WAYNE SKONIECZNY JR.
MARK RAGUSA
GUIDO SIMON LEINE
PRIORITY CLAIM
[0001] This application
claims priority to and the benefit of U.S.
Provisional Application No. 62/270,906, which was filed on December 22, 2015,
the entire contents of which are incorporated herein by reference.
CROSS-REFERENCE TO RELATED APPLICATION
[0002] This application is
related to commonly-owned co-pending U.S.
Patent Application No. 15/ __ , __ (Atty. Docket No. 026787- ______ /70028-
US),
which was filed on May 5, 2016, and is entitled "Tool Setting Management
System
and Method."
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BACKGROUND
[0003] Tools that have one or more different modifiable tool settings
are well known. For instance, one known strap tensioning tool is operable to
tension a strap until the strap tension reaches a designated strap tension
level.
The strap tension level is a tool setting of the strap tensioning tool. This
known
strap tensioning tool enables a user to modify this designated strap tension
level
if the user desires a higher or lower strap tension. For instance, the user
may
desire a strap having a width of 1/2 inch (13 millimeters) to have a different
strap tension than a strap having a width of 3/4 inch (19 millimeters). In
this
case, the user would modify the tool setting to change the defined strap
tension
level when switching between using the strap tensioning tool to tension 1/2
inch
(13 millimeter) wide straps and 3/4 inch (19 millimeter) wide straps. The fact
that these known tools have one or more modifiable tool settings renders these
tools more valuable and flexible than their counterparts having non-modifiable
tool settings because they can conform to different applications as needed.
[0004] Generally, before using a tool having modifiable tool settings, a
user ensures the tool is appropriately configured for its intended use by, for
each
tool setting, confirming that the tool setting is set to the user's desired
tool setting
value or modifying the tool setting to the desired tool setting value.
Continuing
with the above example, if the user desires to use the known strap tensioning
tool
to tension 3/4 inch (19 millimeter) wide straps, the user ensures that the
strap
tension level of the tool is set to the desired strap tension level for 3/4
inch (19
millimeter) wide straps.
[0005] Known tools having modifiable tool settings typically include
one or more mechanical or electromechanical tool setting modification devices.
A user can directly physically manipulate the tool setting modification
device(s)
to modify one or more tool settings. Put differently, to modify a tool setting
of
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one of these known tools, the user must directly physically manipulate a tool
setting modification device that is a physical part of the tool. The tool
setting
modification devices may take any of a variety of forms. For instance,
mechanical tool setting modification devices can include knobs, levers, or
dials,
and electromechanical tool setting modification devices can include button
panels or touch screen displays.
[0006] These known tool setting modification devices enable a user to
modify their respective tool settings throughout the tool settings' entire
functional ranges. For example, a tool setting modification device of a known
strap tensioning tool enables the user to set the tool's strap tension level
anywhere from a lower strap tension level limit to an upper strap tension
level
limit.
[0007] This unfettered ability to choose a particular tool setting can be
problematic. When a user desires to change the tool setting of a tool, the
user
must scroll or cycle through a number of undesired tool settings before
reaching
the desired tool setting. This wastes time and decreases the user's
production.
For example, if the user will only be using a known strap tensioning tool to
tension 1/2 inch (13 millimeter) wide straps and 3/4 inch (19 millimeter) wide
straps, whenever the user desires to switch from tensioning one size strap to
the
other, the user has to spend time scrolling through all of the undesired strap
tension levels between the desired strap tension level for 1/2 inch (13
millimeter)
wide straps and the desired strap tension level for 3/4 inch (19 millimeter)
wide
straps.
[0008] Another problem is that providing users the unchecked ability
to modify tool settings throughout their entire functional ranges increases
the
chances that the user will accidentally select an undesired tool setting,
which
results in suboptimal tool performance. For instance, a user may unknowingly
fail to turn a tool setting modification knob of a strap tensioning tool far
enough
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when setting the strap tension level of the strap tensioning device. This
results in
a lower-than-desired strap tension level. If the user does not realize that
the
tension level setting is lower than desired and continues to tension straps,
those
straps will be tensioned to a strap tension level that does not provide the
desired
performance.
[0009] There is a continuing need for new ways to modify tool settings
of a tool that solve the above problems.
SUMMARY
[0010] Various embodiments of the present disclosure are directed to
a tool and a tool setting management system and method that solve the above
problems.
[0011] Generally, the tool setting management system of the present
disclosure is configured to pair with the tool of the present disclosure to
change
how the tool can function. The tool of the present disclosure stores a set of
a
plurality of different available tool settings at which the tool can operate
to
control certain components of the tool. The tool includes a mechanical or
electromechanical tool setting selection device that a user can directly
physically
manipulate to choose the particular tool setting of the set of available tool
settings at which the user desires the tool to operate. The tool prevents the
user
from selecting any tool setting not included in the stored set of available
tool
settings, even though the tool could otherwise operate at tool settings not
included in the stored set of available tool settings. That is, the tool could
operate
at any of a first quantity of tool settings, but the tool only enables the
user to
configure the tool to operate at one of a second, lesser quantity of tool
settings.
[0012] The tool setting management system of the present disclosure
enables a user to wirelessly pair (such as via a Bluetooth connection) a user
device (such as a smartphone or a computer) with the tool to change the set of
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available tool settings that the tool stores and employs. Specifically, once
paired
with the tool, the user device enables the user to modify the set of available
tool
settings¨such as by changing one of the tool settings of the set, adding a
tool
setting to the set, or deleting a tool setting from the set¨and sends the
modified
set of available tool settings to the paired tool. Upon receipt, a controller
of the
paired tool replaces the currently-stored set of available tool settings with
the
modified set of available tool settings. Afterwards, a user can use the tool
setting
selection device of the tool to select one of the tool settings of the stored
modified set of available tool settings at which to operate the tool. The tool
prevents the user from selecting any tool setting not included in the stored
modified set of available tool settings, such as a tool setting included in
the
previously-employed set of available tool settings but not included in the
currently-employed modified set of available tool settings.
[0013] The tool and tool setting management system solve the above
problems by limiting the tool settings at which the user can configure the
tool to
operate to a particular set of available tool settings while providing a quick
and
easy way to modify that set should the need arise. Limiting the available tool
settings makes it easier for users to select a desired tool setting and less
likely that
they will accidentally select an undesired tool setting, thus increasing
productivity and reducing the potential for error.
[0014] In various embodiments, a method of operating a strapping
device setting management system comprises: receiving, by an input device of a
user device, a pair request; broadcasting, by a wireless communication device
of
the user device, a pair inquiry; receiving, by the wireless communication
device
of the user device, one or more responses to the pair inquiry, each response
received from a wireless communication device of a strapping device available
for pairing with the user device; displaying, by a display device of the user
device
and for each strapping device available for pairing that responded to the pair
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inquiry, a selectable indicator associated with said strapping device;
receiving, by
the input device of the user device, a selection of one of the displayed
indicators;
pairing the user device and the strapping device associated with the selected
indicator; receiving, by the wireless communication device of the user device
and from the wireless communication device of the paired strapping device, a
set
of a plurality of available tool settings; receiving, by the input device of
the user
device, a modification to the set of available tool settings; and
communicating,
by the wireless communication device of the user device, the modified set of
available tool settings to the wireless communication device of the paired
strapping device to cause the paired strapping device to implement the
modified
set of available tool settings.
[0015] In one such embodiment, the strapping device setting includes
a tension level setting.
[0016] In another such embodiment, the strapping device includes a
handheld strap tensioning tool.
[0017] In another such embodiment, the wireless communication
devices of the user device and the strapping device are Bluetooth devices.
[0018] In another such embodiment, the method includes receiving,
by the wireless communication device of the user device and from the wireless
communication device of the paired strapping device, confirmation that the
paired strapping device has implemented the modified set of available tool
settings.
[0019] In another such embodiment, the set of available tool settings
cannot be modified other than via receipt of the modified set of available
tool
settings from the wireless communication device of the user device.
[0020] In certain embodiments, a method of operating a strapping
device setting management system comprises: pairing a user device and a
strapping device such that wireless communication devices of the user device
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and the strapping device can communicate with one another over a network;
receiving, by an input device of the user device, a modification to a set of a
plurality of available strapping device settings of the paired strapping
device; and
communicating, by the wireless communication device of the user device, the
modification to the set of available strapping device settings to the wireless
communication device of the paired strapping device to cause the paired
strapping device to change a set of available strapping device settings in
accordance with the modification.
[0021] In one such embodiment, the strapping device setting includes
a tension level setting.
[0022] In another such embodiment, the strapping device includes a
handheld strap tensioning tool.
[0023] In another such embodiment, the wireless communication
devices of the user device and the strapping device are Bluetooth devices.
[0024] In another such embodiment, the method includes receiving,
by the wireless communication device of the user device and from the wireless
communication device of the paired strapping device, confirmation that the
paired strapping device has changed the set of available tool settings.
[0025] In another such embodiment, the set of strapping device
settings cannot be modified other than via receipt of the modification from
the
wireless communication device of the user device.
[0026] In various embodiments, a method of operating a strapping
device setting management system comprises: receiving, by a wireless
communication device of a strapping device, a pair inquiry from a wireless
communication device of a user device; if the strapping device is available
for
pairing, sending, by the wireless communication device of the strapping
device, a
response to the pair inquiry to the wireless communication device of the user
device; pairing the strapping device and the user device; receiving, by the
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wireless communication device of the strapping device, a strapping device
setting
modification from the wireless communication device of the user device; and
changing, by a controller of the strapping device, a set of a plurality of
available
strapping device settings in accordance with the received strapping device
setting
modification.
[0027] In one such embodiment, the strapping device setting includes
a tension level setting.
[0028] In another such embodiment, the strapping device includes a
handheld strap tensioning tool.
[0029] In another such embodiment, the wireless communication
devices of the user device and the strapping device are Bluetooth devices.
[0030] In another such embodiment, the includes communicating, by
the wireless communication device of the strapping device and to the wireless
communication device of the paired user device, confirmation that the
strapping
device has changed the set of available tool settings.
[0031] In another such embodiment, the set of available strapping
device settings cannot be modified other than via receipt of the strapping
device
setting modification from the wireless communication device of the user
device.
[0032] In certain embodiments, a method of operating a strapping
device setting management system comprises: receiving, by an input device of a
user device, a pair request; broadcasting, by a wireless communication device
of
the user device, a pair inquiry; for each of one or more strapping devices,
receiving, by a wireless communication device of said strapping device, the
pair
inquiry from the user device; for each of the one or more strapping devices,
if
said strapping device is available for pairing, sending, by the wireless
communication device of the strapping device, a response to the pair inquiry
to
the wireless communication device of the user device; receiving, by the
wireless
communication device of the user device, one or more responses to the pair
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inquiry from the wireless communication devices of the one or more strapping
devices available for pairing with the user device; displaying, by a display
device
of the user device and for each strapping device available for pairing that
responded to the pair inquiry, a selectable indicator associated with said
strapping device; receiving, by the input device of the user device, a
selection of
one of the displayed indicators; pairing the user device and the strapping
device
associated with the selected indicator; receiving, by the wireless
communication
device of the user device and from the wireless communication device of the
paired strapping device, a set of a plurality of available tool settings;
receiving,
by the input device of the user device, a modification to the set of available
tool
settings; communicating, by the wireless communication device of the user
device, the modified set of available tool settings to the wireless
communication
device of the paired strapping device; and changing, by a controller of the
paired
strapping device, the set of available tool settings in accordance with the
received
modification.
[0033] In one such embodiment, the strapping device setting includes
a tension level setting.
[0034] In another such embodiment, the strapping device includes a
handheld strap tensioning tool.
[0035] In another such embodiment, the wireless communication
devices of the user device and the strapping device are Bluetooth devices.
[0036] In another such embodiment, the method includes
communicating, by the wireless communication device of the strapping device
and from the wireless communication device of the paired user device,
confirmation that the strapping device has changed the set of available tool
settings.
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[0037] In another such embodiment, the set of available tool device
settings cannot be modified other than via receipt of the modified set of
available
tool settings from the wireless communication device of the user device.
[0038] In various embodiments, a strap tensioning device comprises: a
body; a tensioner supported by the body and including a tensioning motor; a
battery supported by the body and configured to power the tensioning motor; a
strap tension level selection device supported by the body; a first wireless
communication device pairable with a second wireless communication device of
a user device such that the first wireless communication device can send data
to
and receive data from the second wireless communication device; and a
controller including a memory device storing a set of a plurality of available
strap tensioning device settings each associated with a tension level, the
controller configured to: (1) designate one of the strap tensioning device
settings
following receipt of an actuation of the strap tension level selection device;
(2)
control the tensioning motor in accordance with the designated strap
tensioning
device setting to tension a strap until a strap tension of the strap reaches
the first
tension level, and (3) after the first wireless communication device is paired
with
the second wireless communication device and the first wireless communication
device receives a request to modify the set of available strap tensioning
device
settings from the second wireless communication device, modify the set of
available strap tensioning device settings.
[0039] In one such embodiment, the set of available strap tensioning
device settings cannot be modified other than via receipt of the request to
modify
from the second wireless communication device.
[0040] In another such embodiment, the strap tensioning device of
claim 25, which includes a power device actuatable to power the strap
tensioning
device on and off.
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[0041] In another such embodiment, the controller is configured to
pair the first wireless communication device with the second wireless
communication device upon receiving a pair request from the second wireless
communication device.
[0042] In another such embodiment, the first and second wireless
communication devices are Bluetooth devices.
[0043] In another such embodiment, the controller is configured to
cause the first wireless communication device to, after modifying the set of
available strap tensioning device settings, send confirmation to the second
wireless communication device that the set of available strap tensioning
device
settings has been modified.
[0044] In another such embodiment, the strap tensioning device is a
handheld strap tensioning tool.
[0045] Additional features and advantages are described herein, and
will be apparent from, the following Detailed Description and the Figures.
BRIEF DESCRIPTION OF THE FIGURES
[0046] Figure 1 is a block diagram of one embodiment of the tool
setting management system of the present disclosure including a user device
and
a tool configured to communicate over a wireless communication network.
[0047] Figure 2 is a perspective view of one embodiment of a tool of
the tool setting management system of the present disclosure.
[0048] Figure 3 is another perspective view of the tool of Figure 2.
[0049] Figure 4 is another perspective view of the tool of Figure 2.
[0050] Figure 5 is another perspective view of the tool of Figure 2
similar to the view shown in Figure 3 with portions of the housing removed for
clarity.
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[0051] Figure 6 is an enlarged perspective view of the tool of Figure 2
showing various components and features of the tool.
[0052] Figure 7 is another perspective view of the tool of Figure 2
similar to the view shown in Figure 4 with portions of the housing removed for
clarity.
[0053] Figure 8 is an illustration of the interlocking key arrangement
formed in the overlapping courses of strap by the tool of Figure 2.
[0054] Figure 9 is an illustration of portions of the sealing and
tensioning sections of the tool of Figure 2.
[0055] Figure 10 illustrates the positioning of the strap around a load.
[0056] Figures 11A and 11B are top plan and bottom plan views of an
example circuit board of the tool of Figure 2.
[0057] Figure 12 is a flowchart of an example process or method of
operating the tool of Figure 2.
[0058] Figures 13A and 13B are top plan views of one embodiment of
a user device of the tool setting management system of the present disclosure
during initialization of the tool setting management software application.
[0059] Figure 14 is a flowchart of an example process or method of
pairing the user device and the tool via the tool setting management software
application.
[0060] Figures 15A, 15B, 15C, 15D, 15E, and 15F are top plan views
of the user device of Figures 13A and 13B during the pairing process of Figure
14.
[0061] Figures 16A, 16B, and 16C are block diagrams of the user
device and a plurality of tools during the pairing process of Figure 14.
[0062] Figure 17 is a flowchart of an example process or method of
modifying a set of available tool settings of a tool paired with a user device
via
the tool management software application.
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[0063] Figures 18A, 18B, 18C, and 18D are top plan views of the user
device of Figures 13A and 13B during the process of modifying the set of
available tool settings of Figure 17.
[0064] Figures 19A and 19B are top plan views of the user device of
Figures 13A and 13B during a statistics viewing process.
[0065] Figures 20A and 20B are top plan views of the user device of
Figures 13A and 13B during a diagnostics viewing process.
DETAILED DESCRIPTION
[0066] Various embodiments of the present disclosure are directed to
a tool and a tool setting management system and method that solve the above
problems.
[0067] Generally, the tool setting management system of the present
disclosure is configured to pair with the tool of the present disclosure to
change
how the tool can function. The tool of the present disclosure stores a set of
a
plurality of different available tool settings at which the tool can operate
to
control certain components of the tool. The tool includes a mechanical or
electromechanical tool setting selection device that a user can directly
physically
manipulate to choose the particular tool setting of the set of available tool
settings at which the user desires the tool to operate. The tool prevents the
user
from selecting any tool setting not included in the stored set of available
tool
settings, even though the tool could otherwise operate at tool settings not
included in the stored set of available tool settings. That is, the tool could
operate
at any of a first quantity of tool settings, but the tool only enables the
user to
configure the tool to operate at one of a second, lesser quantity of tool
settings.
[0068] The tool setting management system of the present disclosure
enables a user to wirelessly pair (such as via a Bluetooth connection) a user
device (such as a smartphone or a computer) with the tool to change the set of
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available tool settings that the tool stores and employs. Specifically, once
paired
with the tool, the user device enables the user to modify the set of available
tool
settings¨such as by changing one of the tool settings of the set, adding a
tool
setting to the set, or deleting a tool setting from the set¨and sends the
modified
set of available tool settings to the paired tool. Upon receipt, a controller
of the
paired tool replaces the currently-stored set of available tool settings with
the
modified set of available tool settings. Afterwards, a user can use the tool
setting
selection device of the tool to select one of the tool settings of the stored
modified set of available tool settings at which to operate the tool. The tool
prevents the user from selecting any tool setting not included in the stored
modified set of available tool settings, such as a tool setting included in
the
previously-employed set of available tool settings but not included in the
currently-employed modified set of available tool settings.
[0069] The tool setting management system of the present disclosure
can be used in conjunction with to any suitable machine, such as a strapping
machine, or any suitable tool, such as a handheld strapping tool configured to
cut, tension, seal, and/or otherwise apply steel or plastic straps. For
clarity and
brevity, any and all of these machines and tools are referred to herein as
"tools."
1. Tool setting management system components
[0070] Figure 1 illustrates one example embodiment of the tool
setting management system 10 of the present disclosure. In this embodiment,
the
tool setting management system 10 includes a user device 200 and a tool 300
configured to send data to and receive data from one another over a wireless
communication network 150, such as a Bluetooth network, a WiFi network, a
cellular network, or other suitable data network.
[0071] The user device 200 may be any suitable computing device
including components configured to send data to and receive data from the tool
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300 such as, but not limited to: a desktop computer, a laptop computer, a
tablet
computer, a personal digital assistant, or a smartphone. In various
embodiments,
the user device 200 includes: (1) a controller 210 that includes a processing
device 212 and a memory device 214, (2) one or more output devices 220 in
communication with the controller 210, (3) one or more input devices 230 in
communication with the controller 210, and (4) one or more wireless
communication components 240 in communication with the controller 210.
[0072] The processing device 212 may be any suitable processing
device, such as a microprocessor, a microcontroller-based platform, a suitable
integrated circuit, or one or more application-specific integrated circuits.
The
memory device 214 may be any suitable memory device, such as such as one or
more volatile memory elements (e.g., random access memory (RAM, such as
DRAM, SRAM, SDRAM, etc.)) and/or one or more nonvolatile memory
elements (e.g., ROM, hard drive, tape, CDROM, etc.).
[0073] The one or more output devices 220 include at least one
display device 222. The at least one display device may include, without
limitation: a monitor, a plasma display, a liquid crystal display (LCD), a
display
based on light emitting diodes (LEDs), a display based on a plurality of
organic
light-emitting diodes (OLEDs), a display based on polymer light-emitting
diodes
(PLEDs), a display based on a plurality of surface-conduction electron-
emitters
(SEDs), a display including a projected and/or reflected image, or any other
suitable electronic device or display mechanism. The at least one display
device
222 may be of any suitable size, shape, and configuration. In certain
embodiments, the one or more output devices 220 include a sound generating
device, such as one or more speakers.
[0074] The one or more input devices 230 may include any suitable
device(s) that enables an input signal to be produced and received by the
controller 210. In various embodiments, the one or more input devices 230
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include a plurality of buttons that are programmable to, when actuated, cause
the user device to perform particular functions. For instance, these buttons
may
be hard keys, programmable soft keys, or icons displayed on the display device
222 of the user device 200 that are actuatable via a touch screen of the user
device 200 (described below) or via use of a suitable input device of the user
device 200 (such as a mouse or a stylus).
[0075] In certain embodiments, the one or more input devices 230
include a touch-screen coupled to a touch-screen controller or other touch-
sensitive display overlay to enable interaction with any images displayed on
the
display device. One such input device is a conventional touch-screen button
panel. The touch-screen and the touch-screen controller are connected to a
video
controller. In these embodiments, signals are input to the user device 200 by
touching the touch screen at the appropriate locations.
[0076] The one or more wireless communication components 240
include one or more communication interfaces having different architectures
and
utilizing a variety of protocols such as, but not limited to: 802.11 (WiFi);
802.15
(including Bluetooth); 802.16 (WiMax); 802.22; cellular standards such as
CDMA, CDMA2000, and WCDMA; Radio Frequency (e.g., RFID); infrared;
and Near Field Communication (NFC) protocols. The one or more wireless
communication components 240 transmit electrical, electromagnetic, or optical
signals that carry digital data streams or analog signals representing various
types of information.
[0077] The controller 210 is configured to operate one or more
separate programs. The separate programs comprise ordered listings of
executable instructions for implementing logical functions. For example, the
controller 210 may be configured to operate a suitable operating system such
as,
but not limited to: (1) a Windows operating system available from Microsoft
Corporation; (2) a Macintosh operating system available from Apple Computer,
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Inc.; (3) a UNIX operating system, which is available for purchase from many
vendors, such as the Hewlett-Packard Company, Sun Microsystems, Inc., and
AT&T Corporation; (4) a LINUX operating system, which is freeware that is
readily available on the Internet; (5) a run time Vxworks operating system
from
Intel, Inc.; or (6) an appliance-based operating system, such as that
implemented
in smartphones, tablet computers, and personal digital assistants (e.g., iOS
available from Apple Computer, Windows Mobile available from Microsoft
Corporation, and Android available from Google). The operating system
essentially controls the execution of other programs, and provides scheduling,
input-output control, file and data management, memory management, and
communication control and related services.
[0078] The tool 300 may be any suitable tool including components
configured to send data to and receive data from the user device 200. In
various
embodiments, the tool 300 includes: (1) a controller 310 that includes a
processing device 312 (such as any of those described above) and a memory
device 314 (such as any of those described above), and (2) one or more
wireless
communication components 340 (such as any of those described above) in
communication with the controller 310.
2. Example tool
[0079] Figures 2, 3, 4, 5, 6, 7, 8, 9, 10, 11A, 11B, and 12 illustrate
the
components, features, and operation of one example embodiment of a tool 300a
of the tool setting management system of the present disclosure.
[0080] In this embodiment, the tool 300a is a steel strap tensioning,
sealing, and cutting tool configured to, as best shown in Figures 8, 9, and
10,
tension a steel strap S or strapping material around an object or load L, seal
overlapping portions of the strap S to itself at a seal or joint J to form a
tensioned loop around the load L, and cut the tensioned loop from the strap
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supply P. Generally, the strap S includes a feed or supply end P and a free
end F
that is fed around the load L and reinserted into the tool 300a to overlap the
supply end P.
[0081] For purposes of the present disclosure, the term "sealless"
refers to the configuration or type of seal or joint that is made in the
overlapping
portions of the strap. Although a "seal" is made in the strap courses, the
sealless
joint is made by cutting or punching interlocking keys K or sections of the
courses, as illustrated in Figure 8. The term sealless is intended to define
this
type of joint or seal J as compared to a joint that is made using a separate
element such as a crimp seal that is applied over and crimped onto the
overlapping strap courses.
[0082] The tool 300a includes a body 12, a tensioning section 14, and
a sealing section 16. The tensioning section 14 includes a housing 18 and a
first
or tensioner motor assembly 20 operably mounted to the body 12. The sealing
section 16 includes a sealer 21, a housing 22, and a second or sealer motor
assembly 24 operably mounted to the body 12. The body 12 includes a foot 26, a
housing 28, and one or more handles 30 and 32 to facilitate handling and using
the tool 300a. One handle can be a tool opening handle 30 above the tensioner
motor assembly 20 and the other an operating handle 32 mounted above the
body 12. A receiver 34 is formed as part of or mounted to the body 12 for
receiving a battery 36 or other power source. A temporary hold-down finger 38
can be positioned on the foot 12, opposite the tensioner motor assembly 20.
The
hold-down finger can be biased toward the foot 26.
[0083] The tensioning section 14 includes the tensioner motor
assembly 20, which has a motor 40, such as a DC motor, and a gear housing 42
including a gear set 44 to convert the motor 40 output drive to a usable
speed.
The gear set 44 can include a planetary gear set (not shown) to reduce the
output
speed and to increase the output power or torque from the motor 40. The gear
set
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44 includes a final drive (not shown) that meshes with a gear (not shown) on a
tension wheel 46. The tension wheel 46 is mounted normal to the final drive.
The gear set 44 and final drive are housed in the gear housing 18 mounted to
the
tool body 12. A gripping pad 48 can be positioned in the foot 26, opposite the
tension wheel 46.
[0084] The tensioner motor assembly 20, gear housing 42, and tension
wheel 46 are movably mounted to the body 12 to move the tension wheel 46
toward and away from the foot 26. This enables the tool 300a to be opened to
position the strap S between the foot 26 and the tension wheel 46. In an
embodiment, the tensioner motor assembly 20, gear housing 42, and tension
wheel 46 are pivotably mounted to the body 12 to pivot the tension wheel 46
toward and away from the foot 26. The tensioner motor assembly 20, gear
housing 42, and tension wheel 46 can be biasedly mounted to the body 12, such
as by a spring (not shown), to bias the tension wheel 46 toward the foot 26
and
into contact with the strap S in the closed position.
[0085] The sealing section 16 includes the sealer motor assembly 24
which has a motor 50 (such as a DC motor) and a drive 52. In one embodiment,
the drive 52 is a gear set 54 that includes a planetary gear set (not shown)
that
drives a cam shaft 56 through a final drive gear (not shown). The planetary
gear
set reduces the output speed and increases the output power or torque from the
motor 50. Other drives can be used to transfer power from the motor 50 to the
cam shaft 56, such as belts, chains, and the like.
[0086] Cams 58 on the cam shaft 56 contact and move a set of dies 60
in the sealing section 16. The dies 60 reciprocate toward and away from a
punch
62 located on the foot 26 to bring the dies 60 into and out of contact with
the
overlapping course of strap S positioned between the dies 60 and the punch 62.
When the dies 60 engage the strap S (in a sealing portion of the cycle), the
dies
60 and punch 62 form keys K in the strap S that, when shifted longitudinally,
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lock into one another. An example of a sealer section 16 is illustrated in
Figure 9
and an example of an interlocking key K seal or joint J is illustrated in
Figure 8.
The sealing section 16 also includes a cutter 64 to cut the looped and sealed
strap
S from the strap supply P during the sealing cycle. Similar to the dies 60,
the
cutter 64 is driven by the rotation of the cam shaft 56.
[0087] The tool 300a is configured to permit operation in fully
automatic and manual modes. To this end, the tool 300a includes a control
system, shown generally at 66, to control operation of the tool 300a. In one
embodiment, the tool 300a includes an actuation switch 68, the controller 310
(described above), and one or more circuits 70 and 72 to control the tensioner
motor 40 and the sealing motor 50. In an embodiment, the tensioner motor and
sealing motor circuits 70 and 72 are provided on separate boards within the
tool
300a. In this embodiment, the controller 310 is a Bluetooth Low Energy (BLE)
microcontroller that includes a Bluetooth radio. The BLE microcontroller 310
is
configured to control both the operation of the tool 300a and its components
and
the Bluetooth radio to pair and communicate with one or more user devices, as
described below
[0088] In other embodiments, the tool includes a single board
including the controller, the tensioner circuit, and the sealer circuit.
Figures 11A
and 11B illustrate one such board 1000. The board 1000 includes: (1) a metal¨
oxide¨semiconductor field-effect transistor (MOSFET) 1001 configured to
activate the dynamic brake, (2) MOSFETs 1002 and 1006 configured to control
the tensioner motor in a forward or first direction, (3) MOSFET 1003
configured
to control the sealer motor in a forward or first direction, (4) MOSFETs 1004
and 1005 configured to control the tensioner motor in a reverse or second
direction, (5) a current sensor 1007 configured to sense the current level in
both
the tensioner motor and the sealer motor, (6) a power resistor 1008 configured
to
slow down and stop sealer motor rotation, (7) an integrated circuit 1010
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configured to control the tensioner motor, and (8) a BLE microcontroller 1009
communicatively connected to the MOSFETs 1001, 1002, 1003, 1004, 1005,
1006; the current sensor 1007, the power resistor 1008, and the integrated
circuit
1010.
[0089] The BLE microcontroller 310 includes a memory device 314 as
described above. The memory device 314 stores one or more sets of a plurality
of available tool parameters or tool settings at which the tool 300a can
operate to
control certain components of the tool. Specifically, in this example
embodiment, the memory device of the tool 300a stores a set of two or more
available strap tension levels (i.e., tool settings in this example
embodiment) at
which the tool 300a can operate to tension a strap. In operation, a user
selects
one of the strap tension levels of the set of two or more available strap
tension
levels. The BLE microcontroller of the strap tensioning tool controls the
tensioner motor 40 such that the tool 300a tensions a strap to that selected
strap
tension level. As described in detail below, the tool setting management
system
of the present disclosure enables a user to change the set of available strap
tension levels (such as by modifying one of the strap tension levels of the
set,
adding another strap tension level to the set, or deleting a strap tension
level from
the set) via the tool setting management software application on the user
device.
[0090] The tool prevents the user from selecting any tool setting not
included in the stored set of available tool settings, even though the tool
could
otherwise operate at tool settings not included in the stored set of available
tool
settings. That is, the tool could operate at any of a first quantity of tool
settings,
but the tool only enables the user to configure the tool to operate at one of
a
second, lesser quantity of tool settings. For instance, the strap tensioning
tool
could operate according to any of ten different strap tension levels, but the
strap
tensioning tool only enables the user to configure the strap tensioning tool
to
operate at three of those strap tension levels.
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[0091] The tool includes a mechanical or electromechanical tool
setting selection device (not shown) that a user can directly physically
manipulate to choose the particular tool setting of the set of available tool
settings at which the user desires the tool to operate. In certain
embodiments, the
tool setting selection device includes one or more buttons that the user can
press
to select the desired tool setting. In one such embodiment, different tool
settings
are associated with different button-press sequences. In this embodiment, the
user presses the button according to the sequence associated with the desired
tool
setting to select that tool setting. In another such embodiment, the tool
includes
a display device, such as an LED display, and the user can press the button to
cycle through the tool settings of the set of available tool settings, which
the
display device displays, until the user finds the desired tool setting. In
another
embodiment, the tool setting selection device includes a knob or dial that a
user
can rotate to select the desired tool setting. In another embodiment, the tool
setting selection device includes a touch screen that the user can manipulate
to
select the desired tool setting.
[0092] In certain embodiments, one or more existing devices on the
tool¨such as devices that would otherwise be included a similar tool without
the new functionality described herein¨are configured such that a user may use
this device or these devices to select the desired tool setting. For instance,
the
tool may include a power button configured to power the tool on and off and a
home button usable to return one or more components of the tool to its(their)
initial or home position(s). In one embodiment, actuating these buttons in a
particular way (e.g., holding the home switch while pressing the power button)
enables the user to select the desired tool setting. Put differently, certain
of the
switches, buttons, or other devices of the tool may be dual-purpose switches
usable to control the tool to both select the desired tool function and carry
out
one or more other different functions.
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[0093] In this embodiment, during operation of the tool 300a, the
controller 310 compiles and stores in the memory device 314 any of a variety
of
different data associated with operation of the tool 300a. In this embodiment,
the controller 310 compiles and stores: the average operating time of the
tensioner motor, the total quantity of tension/seal/cut cycles performed by
the
tool, the amount of battery life remaining, the average quantity of
tension/seal/cut cycles performed by the tool per day, the serial number of
the
tool, the quantity of tension/seal/cut cycles remaining before the tensioning
wheel should be replaced, and the quantity of tension/seal/cut cycles
remaining
before the punch and die components should be replaced. As described in detail
below, once the tool 300a is paired with a user device, the tool is configured
to
send the stored data to the user device, which enables display of the
operating
data via the tool setting management software application.
[0094] The control system 66 can further include a cam position
switch or sensor 74 to sense the position of the cam shaft 56 in the sealing
section 16, a strap size adjustment device 76, an anti-jam device 78, and a
dynamic brake 80. The cam position switch 74 is positioned to determine the
position of the cam shaft 56 and thus the position of the cam lobes 58 (or
cams),
and consequently the dies 60 and cutter 64. The strap size adjustment device
76
can be, for example, a knob-type dial adjustment provided on the tool body 12.
Control of the anti-jam device 78 can be incorporated within the tension/strap
size adjustment dial 76. The dynamic brake 80 is associated with the sealing
motor 50 to brake or stop the motor 50 when the cam shaft 56 is at a home
position and to bleed power from the motor 50 at the completion of the sealing
cycle. The tool 300a can further include one or more indicators, such as LEDs,
to provide indication of certain functions and states of the tool. An LED
indicator 82 can be positioned within or around the actuation switch 68.
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[0095] Referring to Figure 12, in an operating scenario, the tool 300a
is in a home position in which the spring biases the tension wheel 46 into
contact
with the foot 26. When the battery is installed, as at step 102, the tool 300a
turns
on and runs a self-test, as at step 104. An indicator, such as the LED 84 in
the
actuation switch 68, can be configured to flash in a predetermined sequence to
indicate the operating state of the tool 300a. For example, the LED 84 can
flash
once to indicate that the tool 300a is in an automatic operating mode and
twice
to indicate that the tool 300a is in a manual operating mode. Once the tool
300a
completes the self-test it is in a ready/sleep state as at step 106. In the
ready/sleep state, the tensioner and sealer motors 40 and 50 are off (no power
to
the motors), the tool 300a is ready for operation in an automatic mode or a
manual mode, and the Bluetooth radio is listening for an inquiry broadcast by
a
user device.
[0096] To commence a strapping cycle, the tool 300a is opened by
urging or pulling the tensioner motor assembly 20 toward the tensioner handle
30 to open a gap between the tension wheel 46 and the foot 26. A lead or free
end F of the strap S is positioned around the load and a supply end P of the
strap S (from a strap dispenser) is positioned overlapping the free end F. The
overlapping courses of strap S are positioned in the tool 300a between the
tension wheel 46 and the foot 26 and between the dies 60 and punch 62 with the
supply end P entering from the rear end (the tension wheel 46 end) of the tool
300a as illustrated in Figures 9 and 10, with the strap S courses positioned
under
the hold-down finger 38.
[0097] In one scenario of an automatic mode, depressing and
releasing the actuation switch 68 commences the operating cycle. With
overlapping strap S courses positioned between the tension wheel 46 and the
foot
26 and between the dies 60 and punch 62, the tension cycle starts, as at step
108,
in which the tensioner motor 40 operates to drive the tension wheel 46 to draw
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tension in the strap S. As the tensioner motor 40 operates, the actuation
switch
LED 84 is illuminated. When the tension in the strap reaches a predetermined
tension level (stored in the memory device 314), the tensioner motor 40 stops
and the LED indicator 84 goes out.
[0098] The sealing cycle then starts, as at step 110, in which the
sealing motor 50 operates to rotate the cam shaft 56 and the cams 58 move into
contact with and move the dies 60 downward to contact the strap S. When the
sealing motor 50 starts, the actuation switch LED 84 illuminates to indicate
tool
300a operation. The interlocking keys K are cut by the force of the cams 58 on
the dies 60 forcing the dies 60 into the strap S and forcing the strap S
against the
punch 62. The strap supply P end is cut to separate the looped strap S from
the
strap supply P.
[0099] The sealing motor 50 continues to operate, and when the cam
shaft 56 completes one full (360 degree) revolution, the cam switch or sensor
74
is triggered and the sealing motor 50 turns off. The dynamic brake 80 stops
the
cam shaft 56 at the home position by absorbing excess energy from the sealing
motor 50. The hold-down finger 38 at the foot 26 holds the strap S temporarily
in
place in the tool 300a. Once sealing is complete, the tensioner motor 40
operates
in reverse for a short period (less than about 1 second) to allow the tension
in the
strap S to "pull" the keys K into an interlocking arrangement (see Figure 8),
which forms the seal or joint J.
[00100] Once the sealing cycle is completed, as at step 112, with the
dies 60 returned to the home position and the sealing motor 50 stopped, the
LED indicator 84 goes out. The tool 300a is then in the ready/sleep state.
[00101] In automatic mode, depressing and releasing the actuation
switch 68 at any time during the tension and/or sealing cycles (see steps 108
and
110), can, for example, stop the tool 300a, and depressing and holding the
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actuation switch 68, as at step 114, can operate the tensioner motor 40 in
reverse.
This functions as an emergency stop of the tool 300a.
[00102] The tool 300a can also be operated in manual mode in which,
for example, a first depression of the actuation switch 68 commences the
tension
cycle, and the tensioner motor 40 stops when a predetermined tension is
reached. In this example of manual operation, a second depression of the
actuation switch 68 may then be required to commence the sealing cycle. The
auto-stop functions (for example, depressing and/or depressing and holding the
actuation switch) can again serve to stop the tool 300a and/or reverse the
tensioner motor 10 in manual mode.
[00103] With reference to the trigger functions and events referenced in
Figure 12, Trigger Function (1) (.) when in Ready mode 106, will begin the
tensioning cycle; Trigger Function (2) (-) when in Ready mode 106, will cause
the tool to reverse until the trigger is released; and Trigger Function (3)
(.) at any
time during the tension cycle will stop the motor, where (.) indicates that
the
trigger is held for less than a specified period of time and (-) indicates
that the
trigger is held for more than a specified period of time.
[00104] (*) Automatic mode¨after tensioning tool automatically seals.
Manual mode¨after tensioning tool waits for a second trigger event to activate
sealer motor. (**) Strap size adjusting knob¨selects strap width, mode and
option to only activate sealer motor.
[00105] As noted above, the tool 300a can include an anti-jam feature
78, actuation of which can be incorporated into the strap size adjusting
device
76. When the anti-jam feature 78 is selected and the actuation switch 68 is
depressed, the tensioner motor 40 operates in reverse to clear any material
that
may be jammed in the tool 300a, between the tension wheel 46 and the foot 26.
The sealing motor 50 will cycle once, also to clear any material that may be
jammed in the tool 300a.
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[00106] The tool 300a as disclosed and described is an electrically
powered tool that uses a battery 36; it will however be appreciated that the
tool
300a can be configured to operate with a voltage converter (not shown) for
example, for use at line voltages (e.g., 120 V to 240 V). In addition,
although the
tool 300a is described as including a tensioner motor 40 and a sealing motor
50,
it is contemplated that a single motor can be used to carry out both the
tension
and sealing functions with appropriate drives in place.
[00107] It will also be appreciated by those skilled in the art that
various other automatic and manual operating scenarios are and can be
contemplated in connection with the disclosed electrically powered combination
hand-held strapping tool 300a, and that such other operating scenarios are
within the scope and spirit of the present disclosure.
3. Initializing the tool setting management software application
[00108] In various embodiments, before a user device can: (1) pair with
a tool, (2) enable a user to modify the predefined set of available tool
settings of
the paired tool, (3) display operating data associated with the paired tool,
or (4)
display diagnostic information associated with the tool setting management
software application itself and/or the tool, the user device must first
download,
install, and initialize the tool setting management software application or
program. The user device may download and install the tool setting management
software application to the memory device of the user device in any of a
variety
of manners, such as by downloading and installing the tool setting management
software application from a software application store or a website or by
installing the tool setting management software application via use of a CD, a
DVD, a USB memory device, or other computer-readable medium. In other
embodiments, the tool setting management software application is a web-based
application that is accessible via a website. In these embodiments, the user
device
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need not download and install the tool setting management software
application,
but can instead visit the website to use the web-based application.
[00109] Once the tool setting management software application is
installed on the user device, the user may initialize (i.e., instruct the user
device
to execute) the tool setting management software application in any of a
variety
of manners known in the art. Figure 13A is a top plan view of one example
embodiment of the user device 200, which is a smartphone in this embodiment,
displaying a plurality of icons each associated with a software application
installed on the user device 200. The plurality of icons include an icon 213
associated with the tool setting management software application that is
selected
via a touch screen of the user device to initialize the tool setting
management
software application.
[00110] After the tool setting management software application is
initialized, as shown in Figure 13B, the user device 200 displays a Home
screen
250 including the following four virtual buttons, which are actuatable via the
touch screen of the user device 200: (1) a Scan button 251, (2) a Parameters
button 252, (3) a Statistics button 253, and (4) a Diagnostics button 254. The
Scan button 251, when actuated, causes the user device to initiate the pairing
process to pair the user device with a tool. The Parameters button 252, when
actuated, causes the user device to display one or more tool parameters or
tool
settings of a tool paired with the user device and to enable the user to
modify at
least one of those tool settings. The Statistics button 253, when actuated,
causes
the user device to display operating data associated with a tool paired with
the
user device. The Diagnostics button 254, when actuated, causes the user device
to view diagnostic information associated with the tool setting management
software application itself and/or a tool paired with the user device. These
functions are described in detail below
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4. Pairing a user device and a tool
[00111] In various embodiments, before a user device: (1) enables a
user of the user device to modify the predefined set of two or more tool
settings
of a tool, (2) can display operating data associated with the tool, or (3) can
display diagnostic information associated with the tool, the user device and
the
tool must be paired such that the user device and the tool can transfer data
to
and receive data from one another.
[00112] Figure 14 is a flowchart of one example process or method 400
of pairing a user device and a tool. Although the process 400 is described
with
reference to the flowchart shown in Figure 14, many other processes of
performing the acts associated with this illustrated process 400 may be
employed. For example, the order of certain of the illustrated blocks may be
changed, certain of the illustrated blocks may be optional, and/or certain of
the
illustrated blocks may not be employed.
[00113] In operation of this embodiment, the user device receives a
pair input from the user, as indicated by block 402. The user device detects
any
tools within a designated range of the user device, as indicated by block 404.
The
user device receives, from each detected tool, information associated with
that
tool, as indicated by block 406. The information may include, for example, a
name of that tool, a tool type of that tool, a location of that tool, a unique
identifier of that tool (such as a serial number), and the like. The user
device
displays, for each detected tool, a selectable tool indicator associated with
that
detected tool, as indicated by block 408. The tool indicator may include all
of or
a subset of the information associated with that tool to help distinguish the
detected tools from one another. The user device receives a selection of one
of
the tool indicators from the user, as indicated by block 410. The user device
pairs
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with the tool associated with the selected tool indicator, as indicated by
block
412.
[00114] One example embodiment of the process of pairing the user
device 200 and one of a plurality of different tools 300a, 300b, ... 300z via
a
Bluetooth connection is described below with respect to Figures 15A, 15B, 15C,
15D, 15E, 15F, 16A, 16B, and 16C.
[00115] Turning to Figure 15A, the user device 200 receives an
actuation of the Scan button 251 on the Home screen 250 of the tool setting
management software application from the user via the touch screen of the user
device 200. This initiates the pairing process.
[00116] After receiving the actuation of the Scan button 251, as shown
in Figure 16A, the user device 200 broadcasts, via its Bluetooth radio, an
inquiry
receivable by all Bluetooth-enabled tools 300a, 300b, ... 300z within range of
the
Bluetooth radio of the user device 200. While doing so, as shown in Figure
15B,
the user device 200 displays a Scan screen 260 that includes a Cancel button
269.
If the user device 200 receives an actuation of the Cancel button 269, the
user
devices 200 stops the pairing process and returns to the Home screen 250.
[00117] After the Bluetooth radio of a tool 300a, 300b, ... 300z that is
"listening" for inquiries broadcast by user devices receives the inquiry from
the
Bluetooth radio of the user device 200, as shown in Figure 16B, the Bluetooth
radio of that tool 300a, 300b, ... 300z sends the user device 200 data
representing
certain information about that tool 300a, 300b, ... 300z, such as a name of
that
tool, a tool type of that tool, a location of that tool, a unique identifier
of that
tool (such as a serial number), and the like. After receiving the data from
the
Bluetooth-enabled tools 300a, 300b, ... 300z within range, the user device 200
displays, for each of those tools 300a, 300b, ... 300z, a selectable tool
indicator
associated with that tool. As shown in Figure 15C, the user device 200
displaying
a plurality of different tool indicators 261, 262, 263, and 264 on the Scan
screen
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260. Each tool indicator represents a different one of the Bluetooth-enabled
tools
300a, 300b, ... 300z within range of the user device 200 that responded to the
inquiry of the user device 200. The user device 200 also displays a Cancel
button
269 and a Re-Scan button 268. When the user device 200 receives an actuation
of the Cancel button 277, the user device 200 exits the Scan screen 260 and
returns to the Home screen 250. When the user device 200 receives an actuation
of the Re-Scan button 268, the user device 200 re-starts the pairing process
by
broadcasting another inquiry as described above.
[00118] After displaying the plurality of different tool indicators 261,
262, 263, and 264, the user device 200 enables the user to indicate which tool
300a, 300b, ... 300z (if any) the user desires the user device 200 to pair
with by
selecting the corresponding displayed tool indicator. As shown in Figure 15D,
in
this example embodiment the user device 200 receives a selection of the tool
indicator 261 from the user via the touch screen of the user device 200.
[00119] After receiving the selection of the displayed tool indicator
261, as shown in Figure 16C, the user device 200 securely pairs with the
Bluetooth-enabled tool 300a, which is associated with the selected tool
indicator
261, in a manner known in the art. Figures 15E and 15F show the Scan screen
260 of the user device 200 while the user device 200 is in the process of
pairing
with the Bluetooth-enabled tool 300a and after the user device 200 has
successfully paired with the Bluetooth-enabled tool 300a, respectively.
[00120] While the above-described example embodiment employs a
Bluetooth communication network to identify tools within range of the user
device and to pair a selected tool with the user device, the tool setting
management system may employ any suitable network to do so, such as a WiFi
network, a cellular network, and the like.
[00121] In certain embodiments, after the user device receives the data
from each detected tool within range of the user device, the user device
identifies
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which tool is located the closest to the user device and displays an
indication
identifying the closest tool. This enables the user to quickly and easily pair
a
particular tool and the user device by moving the user device close to that
tool
before initiating the pairing process.
[00122] In various embodiments, the tool and the user device include
suitable hardware that enables the user device and the tool to pair via NFC.
In
these embodiments, instead of the user device broadcasting an inquiry to
determine tools within range of the user device and the user then searching
through a list of within-range tools to select the tool the user desires to
pair with
the user device, the user simply taps the user device to (or brings the user
device
within a designated distance of) a particular area of the tool to pair the
tool and
the user device via NFC.
[00123] In certain embodiments, the tool setting management system
enables the user to provide unique identifying information associated with a
particular tool to enable the tool setting management system to quickly pair
the
user device with that tool. This saves time by eliminating the need for the
user to
search through a list of within-range tools to select the tool the user
desires to
pair with the user device. For instance, in one example embodiment, the user
device enables the user to input a unique serial number of a tool, such as by
entering the serial number using an alphanumeric keyboard or by using a camera
of the user device to take a photo of the serial number. If the tool having
this
unique serial number responds to the user device's broadcast inquiry, the user
device automatically pairs itself with that particular tool.
[00124] In another example embodiment, the user device enables the
user to take a photo of a unique quick response (QR) code, barcode, or other
indicia associated with a particular tool using the camera of the user device.
If
the tool associated with this unique QR code, barcode, or other indicia
responds
to the user device's broadcast inquiry, the user device automatically pairs
itself
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with that particular tool. In one embodiment, the user device stores a
database
that associates unique indicia with their corresponding tools, and in this
embodiment the user device uses the database to identify the tool associated
with
the indicia in the photo. In another embodiment, another device, such as a
server, stores this database. In this embodiment, the user device communicates
the photo to this other device, such as via a suitable wireless communication
network, and the other device determines the corresponding tool and sends this
information to the user device.
[00125] In various embodiments, the tool may initiate the pairing
process instead of the user device. In these embodiments, when the tool
receives
a pairing input, such as an actuation of a button, the tool broadcasts its
request
for pairing (via Bluetooth, WiFi, cellular, or any other suitable wireless
communication network) to user devices within range. Each user device within
range that receives this request then enables the user of the user device to
either
ignore the request or confirm the request, which initiates pairing of the tool
and
the user device.
[00126] In certain embodiments in which the tool includes a lighting
device, the tool illuminates the lighting device in different manners to
convey
different information associated with the pairing process to the user. For
instance, in one example embodiment: (1) the tool illuminates the lighting
device
in yellow after the tool has responded to the user device's broadcast inquiry
and
is awaiting pairing instructions, (2) the tool illuminates the lighting device
in
yellow and in a flashing manner while the user device is in the process of
securely pairing with the tool, (3) the tool illuminates the lighting device
in green
while the tool is securely paired with the user device, and (4) the tool
illuminates
the lighting device in red and in a flashing manner while the user device is
in the
process of unpairing from the tool. In another example embodiment, when the
user device receives a selection of a displayed tool indicator, the user
device
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causes the corresponding tool to illuminate the lighting device of that tool.
This
enables the user to quickly and easily visually confirm that the user selected
the
desired tool indicator to prevent an undesired tool/user device pairing.
[00127] In certain embodiments, the tool is configured to "listen" for
and respond to an inquiry broadcast by a user device whenever the tool is
powered on. For instance, in one embodiment in which the tool is a Bluetooth-
enabled battery-powered handheld strapping device, the Bluetooth radio of the
strapping tool is configured to "listen" for and respond to an inquiry
broadcast
by the user device whenever the strapping device is powered on, but not when
the strapping device is powered off.
[00128] In other embodiments, a tool must be actively configured by a
user to "listen" for and respond to inquiries broadcast by a user device
through a
series of activation steps. For instance, in one example embodiment in which
the
tool is a Bluetooth-enabled battery-powered handheld strapping device, if the
user desires the strapping device to "listen" for and respond to an inquiry
broadcast by the user device, the user must first: (1) depress and hold the
actuation (i.e., on/off) switch of the strapping device; (2) while depressing
the
actuation switch, insert the battery into the strapping device; and (3) after
inserting the battery, releasing the actuation switch. In this example
embodiment, after the user releases the actuation switch, the controller of
the
strapping device causes the Bluetooth radio to begin "listening" for and
responding to any inquiries broadcast by any user devices and illuminates an
LED light to indicate that the Bluetooth radio is doing so. The activation
steps
may be any other suitable activation steps, such as depressing the actuation
button for a designated period of time or depressing the actuation button
according to a designated sequence.
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5. Modifying the stored set of available tool settings of a paired tool
[00129] After the user device is paired with a tool, the tool setting
management software application enables a user to use the user device to
modify
the set of available tool settings the paired tool stores and employs.
[00130] More specifically, as described above, the memory device of
the paired tool stores one or more sets of a plurality of available tool
settings at
which the tool can operate to control certain components of the tool. The tool
setting management system enables a user to modify a set of tool settings
stored
in the memory device of the tool, such as by changing one of the tool settings
of
the set, adding a tool setting to the set, or deleting a tool setting from the
set.
[00131] For example, in one embodiment in which the tool is a strap
tensioning tool configured to tension a strap, the memory device of the strap
tensioning tool stores a set of a plurality of strap tension levels. In
operation, a
user uses a tool setting selection device of the strap tensioning tool to
select one
of the strap tension levels of the set of available strap tension levels, and
the
controller of the strap tensioning tool controls the tensioner of the strap
tensioning tool to operate such that the strap tensioning tool tensions a
strap to
the selected strap tension level. The strap tensioning tool thus enables
quick, on-
the-fly adjustment of the strap tension level. In this example embodiment, the
tool setting management system enables a user to modify the set of available
strap tension levels via the tool setting management software application.
[00132] Figure 17 is a flowchart of one example process or method 500
of using a user device to modify a set of a plurality of tool settings stored
in a
memory device of a tool paired with the user device. Although the process 500
is
described with reference to the flowchart shown in Figure 17, many other
processes of performing the acts associated with this illustrated process 500
may
be employed. For example, the order of certain of the illustrated blocks may
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changed, certain of the illustrated blocks may be optional, and/or certain of
the
illustrated blocks may not be employed.
[00133] In operation of this embodiment, the user device receives,
through the tool setting management software application, a tool setting set
modification from the user, as indicated by block 502. The user device sends
the
tool setting set modification to the paired tool, as indicated by block 504.
The
paired tool modifies a set of available tool settings based on the tool
setting set
modification received from the user device, as indicated by block 506.
[00134] Continuing with the example embodiment described above
with respect to Figures 15A, 15B, 15C, 15D, 15E, 15F, 16A, 16B, and 16C, one
example embodiment of the process of using the user device 200 to modify a set
of available tool settings stored by a memory device of the paired tool 300a
is
described below with respect to Figures 18A, 18B, 18C, and 18D.
[00135] Turning to Figure 18A, the user device 200 receives an
actuation of the Parameters button 252 on the Home screen 250 of the tool
setting management software application from the user via the touch screen of
the user device 200.
[00136] After receiving the selection of the Parameters button 252, the
user device 200 displays a Parameters screen 270, as shown in Figure 18B. The
Parameters screen includes a plurality of displayed tool setting indicators
271,
273, and 274. Each tool setting indicator 271, 273, and 274 is associated with
a
tool setting of the set of available tool settings the paired tool 300a
currently
stores and employs. In this illustrated embodiment in which the paired tool
300a
is a steel strap tensioning and sealing tool, each tool setting indicator 271,
273,
and 274 is associated with a different strap tension level setting of the set
of
available tension level settings the paired tool 300a stores and employs. The
strap
tension level setting indicates the tension to which the tensioning device of
the
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paired tool 300a tensions the steel strap during operation if the user selects
that
particular strap tension level setting, as described above.
[00137] In this example embodiment, the Parameters screen 270
includes a tool set setting modification slider 276 usable to modify a
selected one
of the strap tension level settings of the set of available strap tension
level
settings of the paired tool 300a. Specifically, after the user device 200
receives a
selection of one of the displayed tool setting indicators 271, 273, and 274,
the
user device 200 enables the user to manipulate the tool setting modification
slider 276 to increase or decrease the strap tension level associated with the
selected tool setting indicator. The Parameters screen 270 also includes a
Back
button 277. When the user device 200 receives an actuation of the Back button
277, the user device 200 exits the Parameters screen 270 and returns to the
Home
screen 250. In other embodiments, the Parameters screen includes different
tool
setting modification sliders for each displayed tool setting indicator, and
the user
device enables the user to manipulates the tool setting modification sliders
to
increase or decrease the strap tension levels associated with the
corresponding
tool setting indicators.
[00138] Figure 18C shows the Parameters screen 270 after the user
device 200 has received a selection of the tool setting indicator 274 and a
manipulation of the tool setting modification slider 276. The Parameters
screen
270 indicates that the manipulation of the tool setting modification slider
276
increased the strap tension level from 900 pounds (4003 Newtons) to 920 pounds
(4092 Newtons). In this example embodiment, after a strap tension setting is
modified, the user device 200 displays a Confirm Modification button 278 and a
Cancel button 279. When the user device 200 receives an actuation of the
Confirm Modification button 278, the user device 200 sends the modified set of
strap tension level settings to the paired tool 300a. When the paired tool
300a
receives the modified set of tension level settings from the user device 200,
the
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paired tool 300a replaces the set of strap tension level settings currently
employed and stored in the memory device 314 with the modified set of strap
tension level settings received from the user device 200. After doing so, the
paired tool 300a sends confirmation that the paired tool 300a is currently
employing the modified set of strap tension level settings, and as shown in
Figure 18D the user device 200 displays confirmation that the paired tool 300a
has done so. When the user device 200 receives an actuation of the Cancel
button 279, the user device 200 cancels the pending tool setting modification.
[00139] The user device may enable the user to modify the set of
available tool settings in any suitable manner instead of or in addition to
the use
of a tool setting modification slider. For instance, in one embodiment, the
user
device enables the user to modify a tool setting by entering a new value via
an
alphanumeric or numeric keyboard. In another embodiment, the user device
enables the user to modify a tool setting by selecting from one of a plurality
of
predetermined tool setting options. In another embodiment, the user device
enables the user to modify the set of available tool settings by adding
another
tool setting to the set (e.g., modifying the set of available tool settings
from
including three tool settings to four tool settings). In another embodiment,
the
user device enables the user to modify the set of available tool settings by
deleting a tool setting from the set (e.g., modifying the set of available
tool
settings from including three tool settings to two tool settings).
[00140] In various embodiments, the tool setting management software
application employs one or more security measures to ensure that only
authorized users can modify a tool's set of available tool settings via the
tool
management software application. In one embodiment, the tool setting
management software application is password-protected, and only enables users
who enter a designated password (or one of a plurality of designated
passwords)
or other particular unique identifier (e.g., fingerprint, eye scan, face
recognition,
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etc.) to modify a tool setting using the tool setting management software
application.
6. Displaying operating data and diagnostic information associated with a
paired tool
[00141] After the user device is paired with a tool, the tool setting
management software application enables a user to use the user device to
display
operating data and diagnostic information associated with the paired tool.
[00142] More specifically, as described above, during operation of a
tool, the controller of the tool compiles and stores in the memory device of
the
tool any of a variety of different data associated with tool operation. Once
the
tool pairs with a user device, the tool sends the stored operating data to the
user
device, which enables display of the operating data via the tool setting
management software application.
[00143] Continuing with the example embodiment described above
with respect to Figures 15A, 15B, 15C, 15D, 15E, 15F, 16A, 16B, 16C, 17A, 17B,
17C, and 17D, one example embodiment of the process of using the user device
200 to display operating and diagnostic data associated with the paired tool
300a
is described below with respect to Figures 18A, 18B, 19A, and 19B.
[00144] Turning to Figure 19A, the user device 200 receives an
actuation of the Statistics button 253 on the Home screen 250 of the tool
setting
management software application from the user via the touch screen of the user
device 200.
[00145] After receiving the actuation of the Statistics button 253, the
user device 200 displays a Statistics screen 280, as shown in Figure 19B. The
Statistics screen 280 displays a plurality of operating data associated with
and
received from the paired tool 300a. For instance, in this example embodiment,
the operating data includes: the average operating time of the tensioner motor
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per cycle, the total quantity of cycles performed by the paired tool 300a, the
percentage of power remaining of the battery of the paired tool 300a, the
average quantity of cycles performed by the paired tool 300a per day, the
total
time between cam position switch or sensor pulses for the last cycle, and the
average time between cam position or sensor pulses. In certain embodiments,
the
Statistics screen 280 is read-only in that the tool setting management
software
application does not enable the user to interact with any of the displayed
information aside from viewing that information.
[00146] Turning to Figure 20A, the user device 200 receives an
actuation of the Diagnostics button 254 on the Home screen 250 of the tool
setting management software application from the user via the touch screen of
the user device 200.
[00147] After receiving the actuation of the Diagnostics button 254, the
user device 200 displays a Diagnostics screen 290, as shown in Figure 20B. The
Diagnostics screen 290 displays a plurality of diagnostic data associated with
and received from the paired tool 300a. For instance, in this example
embodiment, the diagnostic data includes: the serial number of the paired tool
300a, the quantity of cycles remaining before the tensioning wheel of the
paired
tool 300a should be replaced (along with a Reset button that enables the user
to
reset that quantity to an initial quantity), a quantity of cycles remaining
before
the punch and die elements of the paired tool 300a should be replaced (along
with a Rest button), the status of the sealer and tensioner motors, the total
run
time of the tensioner motor, and the total run time of the sealer motor.
[00148] For certain consumables that require replacement from time to
time, such as tensioning wheels or punch and die elements, in certain
embodiments
the Diagnostics screen 290 displays visual indicators that indicate how "used"
a
component is and whether the component needs to be replaced. For instance, the
Diagnostics screen may display an indicator that changes color from green to
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to red as a component is used to indicate that the component is becoming "used
up"
(transitioning from green to yellow) and needs to be replaced (transitioning
from
yellow to red). Since the user can quickly and easily gauge when the tool will
need
its components replaced, the user can plan ahead accordingly and order
replacement
components in advance to minimize downtime when the components in fact need
replacement.
[00149] The user device may provide an alert (e.g., a visual output,
audible output, or tactile output) whenever a component needs replacement. In
certain embodiments, the user device is configured to automatically order a
replacement component when yellow or red status is reached.
[00150] The Diagnostics screen 290 also enables a user to request the
instruction manual corresponding to the tool by actuating a particular button,
which causes the user device 200 to automatically download the instruction
manual or causes the user device 200 to navigate to a web page from which the
user device can then download the instruction manual.
[00151] The Diagnostics screen 290 also enables a user to view a
maintenance log associated with the tool, which indicates the maintenance
history of the tool, by actuating a particular button.
[00152] The Diagnostics screen 290 also enables a user to export a file
(such as a *.csv file or any other suitable file extension) indicative of
tensioner
motor and/or sealer motor current as a function of time.
[00153] In certain embodiments, if the user device receives an
indication from the tool that a particular component of the tool is broken or
otherwise malfunctioning, the user device displays an indication that the
component is broken and needs to be repaired or replaced. Additionally or
alternatively, an indicator of the tool itself could indicate that a
particular
component of the tool is broken or otherwise malfunctioning, such as by an
LED of the tool blinking according to a certain pattern or in a certain color
to
indicate an error. Different patterns and/or colors could correspond to
different
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errors. In one embodiment, the user device enables the user to order a
replacement component or request a maintenance call via the tool setting
management software application.
[00154] In various embodiments, the tool stores data associated with
the tool itself and/or operation of the tool in persistent memory, such as a
non-
volatile memory device of a tool's Bluetooth controller. When the tool is
paired
with a user device, the controller moves certain stored data into a working
memory of the tool, which enables that data to be modified. If modified,
changes are copied back into persistent memory.
[00155] In certain embodiments, the tool setting management software
application employs one or more security measures (such as any of those
described above) to control access to the Diagnostics screen.
[00156] Various changes and modifications to the present embodiments
described herein will be apparent to those skilled in the art. Such changes
and
modifications can be made without departing from the spirit and scope of the
present subject matter and without diminishing its intended advantages. It is
therefore intended that such changes and modifications be covered by the
appended claims.
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