Motor timing off in power tools

Abstract

The present invention relates to motor timed shutdown of power tools. When the trigger of a tool is accidentally actuated, power is provided to the motor of the tool, causing the output assembly of the tool to operate. This can be problematic when the tool is being stored. To address this, the tool starts or initiates a motor timer when the motor is operating at any non-zero speed. If the trigger remains actuated and the motor is simultaneously operating at any non-zero speed and the motor timer reaches a threshold limit, the tool stops or interrupts the provision of power to the motor, thereby shutting down the motor. This reduces the probability of accidental release of power from the power source and accidental damage to the output assembly of the tool to the storage mechanism or other environment.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 165,002, filed March 23, 2021, and U.S. Patent Application No. 17 / 694,218, filed March 14, 2022, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This invention relates generally to power tools, and more specifically to a motor for timed shutdown of a power tool. Background Technology

[0004] Powered hand tools (such as electric ratchet wrenches, impact wrenches, and other actuators) are commonly used in automotive, industrial, and household applications to install and remove threaded fasteners and to apply torque and / or angular displacement to workpieces (such as threaded fasteners). Powered hand tools typically include an output component (such as a drive flange or drive chuck), a trigger switch that can be actuated by the user, an electric motor housed in a housing, and other components (such as switches, light-emitting diodes (LEDs), and batteries).

[0005] However, when power tools are stored in bags, toolboxes, vehicles, or other storage containers with batteries or other power sources inserted, the trigger switch may be accidentally actuated, causing the motor to start and the stored tool to operate. If the trigger switch is accidentally actuated, the tool's battery or other power source will release power, potentially inconveniencing a user who intends to use the tool later or damaging the tool's output components or other items stored with it. Some tools have a locking switch to prevent accidental actuation of the trigger switch. However, the locking switch requires the user to activate it before storing. If the user fails to activate the locking switch, the problem persists. Summary of the Invention

[0006] This invention relates primarily to a timed shutdown mechanism for a power tool's motor. The tool includes a tool housing, an output assembly (such as a ratchet head assembly) adapted to provide torque to a workpiece, a trigger, a motor housed within the housing, an indicator, a controller, and a power source. When the trigger is accidentally actuated (e.g., when the tool is placed in a storage bag), power is supplied to the motor, causing the output assembly to operate. In this situation, the invention determines that the motor is operating at any non-zero speed or that the trigger has been accidentally actuated under other circumstances, and causes a motor timer feature to start timing or activate it. If the trigger remains actuated and the motor is simultaneously operating at any non-zero speed, or if the trigger has been accidentally actuated under other circumstances and the motor timer reaches a preset threshold limit (e.g., 2 minutes), the tool stops or interrupts power supply to the motor, thereby shutting it off. The tool can also activate the indicator to indicate a malfunction to the user, thereby indicating that the trigger was accidentally actuated. After a period of time (e.g., 5 to 10 seconds), the indicator can be turned off to conserve power. When the trigger is released and pulled again or the power source is removed, the tool resumes normal operation, and the motor timer resets.

[0007] When the tool is stored in, for example, a bag, toolbox, tool cabinet, vehicle, or other storage facility, implementation of the present invention reduces the likelihood of accidental power release from the power source. The motor timer and shutdown also reduce the probability of the tool causing accidental damage to the storage facility or other environment due to the output components. Attached Figure Description

[0008] To facilitate understanding of the claimed subject matter, embodiments thereof are shown in the accompanying drawings. By consulting these embodiments and considering them in conjunction with the following description, the claimed subject matter, its construction and operation, and its many advantages should be readily understood and appreciated.

[0009] Figure 1 This is a perspective view of an exemplary tool according to one embodiment of the present invention.

[0010] Figure 2 and Figure 3 This is a component block diagram of the electronic components of an exemplary tool according to an embodiment of the present invention.

[0011] Figure 4 This is a block diagram of an exemplary tool operation method according to one embodiment of the present invention. Detailed Implementation

[0012] While the invention allows for many different embodiments, a preferred embodiment is shown in the accompanying drawings, which will be described in detail herein. It should be understood that this disclosure is to be considered as an example of the principles of the invention and is not intended to limit the broad aspects of the invention to the illustrated embodiments. As used herein, the term "invention" is not intended to limit the scope of the claimed invention, but is a term used solely for illustrative purposes to discuss exemplary embodiments of the invention.

[0013] This invention relates primarily to a timed shutdown mechanism for a power tool's motor. The tool includes a tool housing, an output assembly (such as a ratchet head assembly) adapted to provide torque to a workpiece, a trigger, a motor housed within the housing, an indicator, a controller, and a power source. When the trigger is accidentally actuated, power is supplied to the motor, causing the output assembly to operate. In this situation, the invention determines when the motor is operating at any non-zero speed and / or no resistance or torque is applied to the output assembly, or when the trigger is accidentally actuated under other circumstances, and starts or activates a motor timer. If the trigger remains actuated and the motor is simultaneously operating at any non-zero speed and / or no resistance or torque is applied to the output assembly, or when the trigger is accidentally actuated under other circumstances and the motor timer reaches a threshold limit (e.g., 2 minutes), the tool stops or interrupts power supply to the motor, thereby shutting it off. The tool can also activate an indicator to indicate a malfunction to the user, thereby indicating that the trigger was accidentally actuated. After a period of time (e.g., 5 to 10 seconds), the indicator can turn off to conserve power. When the trigger is released and pulled again or the power source is removed, the tool resumes normal operation, and the motor timer resets.

[0014] When the tool is stored in a bag, toolbox, tool cabinet, vehicle, or other storage facility, implementation of this invention reduces the likelihood of accidental power release from the power source. The motor timer and shutdown also reduce the probability of the tool causing accidental damage to the storage facility or other environment due to the output components.

[0015] See Figure 1 and Figure 3 Tool 100 (such as a cordless ratchet tool) includes a main tool housing 102 and an output assembly 104 (such as a ratchet head assembly). Tool housing 102 may include a first housing portion and a second housing portion joined together in a clamshell manner and securely connected to the output assembly 104. For example, tool housing 102 may house or accommodate an electric motor 114. Figure 2 and Figure 3 (shown in the image), controller 116 ( Figure 2 and Figure 3 (shown in the image), switch assembly 118 ( Figure 2and Figure 3 The tool housing 102 may include a display with buttons for configuring and setting the tool, one or more indicators 122 (such as light-emitting diodes), and other components for operating the tool. The tool housing 102 may also include a textured or knurled handle to improve the user's grip on the tool 100 during use.

[0016] For example, output assembly 104 includes a drive portion 106 that includes a drive flange 108. The drive flange 108 is adapted to apply torque to a workpiece (such as a fastener) via an adapter, drill bit, or sleeve (e.g., a two-way ratchet square or hexagonal drive) coupled to the drive flange 108. As shown, the drive flange 108 is a "male" connector designed to insert or matingly engage a female pair. However, the drive portion 106 may alternatively include a "female" connector designed to matingly engage a male pair. The drive portion 106 may also be configured to directly engage a workpiece without coupling to an adapter, drill bit, or sleeve. The rotation direction of the drive portion 106 / drive flange 108 can be selected as a first rotation direction or a second rotation direction (such as clockwise or counterclockwise) by rotating a selector switch.

[0017] Tool 100 also includes a trigger 110 that can be actuated by a user to operate tool 100. For example, a user can press the trigger 110 inward to selectively draw power from power source 120, causing motor 114 to provide torque to output assembly 104 and rotate drive flange 108 in the desired rotational direction. Trigger 110 can also be operatively coupled to switching mechanism 118, which, when triggered 110 is actuated, is adapted to provide power from power source 120 to motor 114. Any suitable trigger 110 or switch can be implemented without departing from the spirit and scope of the invention. For example, trigger 110 can also be biased such that it can be pressed inward relative to tool 100 to operate tool 100, and releasing trigger 110 can move it outward relative to tool 100 to stop tool 100 by the biasing characteristic of trigger 110. Trigger 110 and switching mechanism 118 can also be variable speed mechanisms. In this respect, when the trigger 110 is actuated or pressed, the further the trigger 110 is pressed down, the faster the motor will run.

[0018] Motor 114 may be disposed within tool housing 102 and adapted to operatively engage output assembly 104, and may provide torque to tool 100, thereby providing torque to drive section 106 / drive flange 108. Motor 114 may be a brushless or brushed motor or any other suitable motor. Power source 120 may be associated with tool 100 to provide electrical or other forms of power (e.g., electro-, hydraulic, or pneumatic) to tool 100 to operate the motor. In one embodiment, power source 120 may be housed in an end 112 of tool housing 102 opposite output assembly 104, in the middle of tool 100, or in any other part of tool 100 / tool ​​housing 102. Power source 120 may also be an external component not housed in tool 100 but operatively coupled to tool 100 via, for example, wired or wireless means. In one embodiment, the power source 120 is a removable rechargeable battery adapted to be disposed in the end of the tool housing 102 and electrically connected to a corresponding terminal of the tool 100.

[0019] The controller 116 may be operatively coupled to one or more of the power source 120, the switching mechanism 118, the indicator 122, and the motor 114, and is adapted to control the power supplied by the power source 120 to the motor 114. The controller 116 may include a central processing unit (CPU) for processing data and computer-readable instructions, and memory for storing data and instructions. The memory may include volatile random access memory (RAM), non-volatile read-only memory (ROM), and / or other types of memory. It may also include data storage components for storing data and controller / processor-executable instructions (e.g., instructions for the operation and running of tool 100). The data storage components may include one or more non-volatile solid-state storage devices (such as flash memory, read-only memory (ROM), magnetoresistive RAM (MRAM), ferroelectric RAM (FRAM), phase-change memory, etc.).

[0020] Computer instructions for operating tool 100 and its various components can be executed by controller 116 using memory as temporary "working" memory during runtime. The computer instructions can be stored in non-volatile memory, storage devices, or external devices in a non-transitory manner. Alternatively, in addition to software or as a replacement for software, some executable instructions can be embedded in hardware or firmware.

[0021] For example, controller 116 may implement the method described herein. When trigger 110 is accidentally actuated, power is supplied to motor 114, causing output component 104 to operate. In this case, controller 116 determines when motor 114 is operating at any non-zero speed and / or no resistance or torque is applied to output component 104, or the trigger is accidentally actuated under other circumstances, and causes a motor timer to start or activate. If trigger 110 remains actuated and motor 114 is simultaneously operating at any non-zero speed and / or no resistance or torque is applied to output component 104, or the trigger is accidentally actuated under other circumstances, and the motor timer reaches a threshold limit (such as 2 minutes), controller 116 interrupts the supply of power to motor 114, thereby shutting down motor 114. Controller 116 may also activate indicator 122 and indicate a fault to the user, thereby indicating that trigger 110 was accidentally actuated. After a period of time (such as 5 to 10 seconds), controller 116 may deactivate indicator 122 to conserve power. When the trigger 110 is released and pulled again or the power source is removed, the controller 116 can restore the tool to normal operation and reset the motor timer. The indicator 122 can be any type of indicator (such as a light-emitting diode (LED), haptic actuator, display, etc.) that can indicate a fault to the user.

[0022] See Figure 4 The method of operation 200 of tool 100 is described. As shown in step 202, the method begins to execute when the trigger is actuated. As shown in step 204, when the trigger is not actuated, the motor timer can be reset (if the motor timer is at a non-zero time). As shown in step 206, when the trigger is actuated, the tool (such as via controller 116) determines whether the motor is operating at any non-zero speed or whether the trigger was accidentally actuated under other circumstances.

[0023] When the motor is not running, the method returns to step 202 to determine whether the trigger has been actuated. As shown in step 208, when the motor is running at any non-zero speed or the trigger is accidentally actuated under other circumstances, the tool (such as via controller 116) starts or causes the motor timer to begin timing or continue timing. As shown in step 210, the tool (such as via controller 116) determines whether the motor timer is greater than or equal to a threshold (such as 2 minutes). When the motor timer is less than the threshold (such as 2 minutes), the method returns to step 202 to determine whether the trigger has been actuated. As shown in step 212, when the motor timer is greater than or equal to the threshold (such as 2 minutes), the tool (such as via controller 116) resets and / or stops the motor timer. The tool (such as via controller 116) stops or terminates power supply to the motor, as shown in step 214, and may also activate an indicator and cause the indicator timer to begin timing, as shown in step 216.

[0024] As shown in step 218, once the tool (e.g., via controller 116) stops or terminates power supply to the motor, the tool (e.g., via controller 116) can determine whether the trigger has been released or the power source has been removed. As shown in step 220, when the trigger is released or the power source is removed, the tool (e.g., via controller 116) can determine whether the indicator is activated. As shown in step 222, when the indicator is activated, the tool (e.g., via controller 116) can deactivate the indicator, and the method can return to step 202. When the indicator is not activated (e.g., after a period of time (e.g., 5 to 10 seconds), the indicator deactivates to conserve power), the method can return to step 202.

[0025] However, as shown in step 224, when the trigger has been released or the power source has been removed, the tool (such as via controller 116) can determine whether the indicator is activated. When the indicator is not activated or deactivated, the tool (such as via controller 116) can return to step 218. As shown in step 226, when the indicator is activated, the tool (such as via controller 116) can determine whether the indicator timer has finished counting or has reached a time threshold (such as 5 to 10 seconds). When the indicator timer has not finished counting or has not reached the time threshold, the tool (such as via controller 116) can keep the indicator activated and return to step 218. As shown in step 228, when the indicator timer has finished counting or has reached the time threshold, the tool (such as via controller 116) deactivates the indicator, and the method can return to step 218.

[0026] When the tool is stored in a bag, toolbox, vehicle, or other storage facility, the implementation of a motor timer and shutdown reduces the likelihood of accidental power source discharge. The motor timer and shutdown also reduce the probability of the tool causing accidental damage to the storage facility or other environment due to output components.

[0027] As described herein, tool 100 is a ratchet wrench. However, tool 100 can be any type of handheld motorized tool, including but not limited to electric or motorized tools (such as electric drills, planers or impact wrenches, ratchet wrenches, screwdrivers or other power tools) powered by an external power source (such as a wall socket and / or generator socket) or batteries.

[0028] As used herein, the term "connection" and its functional equivalents are not intended to be limited to a direct mechanical connection of two or more parts. Rather, the term "connection" and its functional equivalents are intended to refer to any direct or indirect mechanical, electrical, or chemical connection between two or more objects, features, workpieces, and / or environmental substances. In some instances, "connection" is also intended to indicate that one object is integral with another. As used herein, unless otherwise specified, the terms "a" or "some" may include one or more items.

[0029] The description and figures above are provided by way of example only and not as a limitation. While specific embodiments have been shown and described, it will be apparent to those skilled in the art that changes and modifications can be made without departing from the broader aspects of the inventors' contributions. The actual scope of protection claimed is intended to be defined by the following claims when viewed from the proper perspective of the prior art.

Claims

1. A method for controlling the operation of a tool, the tool comprising a motor, a power source adapted to provide power to the motor, an output assembly adapted to apply torque to a workpiece, and a trigger, wherein when the trigger is actuated, the trigger causes the power source to provide power to the motor, the method comprising: The motor timer starts counting when the trigger is actuated, when power is being supplied to the motor, and when the output component is not applying torque to the workpiece; as well as When the motor timer reaches or exceeds the motor timer threshold, the power being supplied to the motor is stopped.

2. The method according to claim 1, further comprising: When the motor timer reaches or exceeds the motor timer threshold, the indicator of the tool is activated; as well as Start the indicator timer.

3. The method according to claim 2, further comprising: After stopping the power being supplied to the motor, determine whether the trigger remains actuated.

4. The method of claim 3, further comprising: When the trigger remains actuated, the indicator is turned off if the indicator timer reaches or exceeds the indicator timer threshold.

5. The method of claim 3, further comprising: When the trigger is not activated, the indicator is turned off.

6. The method of claim 2, further comprising: After stopping the power supplied to the motor, determine whether the power source is disconnected from the tool.

7. The method of claim 6, further comprising: The indicator is turned off when the power source is connected to the tool and when the indicator timer reaches or exceeds the indicator timer threshold.

8. The method of claim 6, further comprising: When the power source is disconnected from the tool, the indicator is turned off.

9. A tool comprising: motor; A power source adapted to provide power to the motor; Output component, which is adapted to apply torque to the workpiece; A trigger, when actuated, causes the power source to supply power to the motor; as well as Controller, which is suitable for: The motor timer starts counting when the trigger is actuated, when power is being supplied to the motor, and when the output component is not applying torque to the workpiece; as well as When the motor timer reaches or exceeds the motor timer threshold, the power being supplied to the motor is stopped.

10. The tool of claim 9, further comprising an indicator, wherein the controller is further adapted to: The indicator is activated when the motor timer reaches or exceeds the motor timer threshold; and Start the indicator timer.

11. The tool of claim 10, wherein the controller is further adapted to: After stopping the power being supplied to the motor, determine whether the trigger remains actuated.

12. The tool of claim 11, wherein the controller is further adapted to turn off the indicator if the indicator timer reaches or exceeds an indicator timer threshold while the trigger remains actuated.

13. The tool of claim 11, wherein the controller is further adapted to turn off the indicator when the trigger no longer remains actuated.

14. The tool of claim 10, wherein the controller is further adapted to: After stopping the power supplied to the motor, determine whether the power source is disconnected from the tool.

15. The tool of claim 14, wherein the controller is further adapted to turn off the indicator if the indicator timer reaches or exceeds an indicator timer threshold when the power source is connected to the tool.

16. The tool of claim 14, wherein the controller is further adapted to turn off the indicator when the power source is disconnected from the tool.

17. The tool of claim 9, wherein the controller includes a data storage component for storing executable instructions.

18. The tool of claim 17, wherein the data storage component is a ferroelectric random access memory.

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