Firmware control for providing soft stop on compression drive nailers

Abstract

A method for controlling a motor of a power tool includes performing a load test on a battery pack of the power tool, determining, via a first controller, a first mechanism control scheme based on the load test, receiving, via the first controller, a user input indicating a start of an operating cycle of the power tool, and isolating the first controller from a second controller. The method further includes controlling, via the first controller, the motor based on the first mechanism control scheme, sensing a data set indicating a result of the operating cycle based on the first mechanism control scheme, receiving, via the second controller, the data set, connecting the first controller to the second controller upon completion of the operating cycle, transmitting, via the second controller, the data set to the first controller, and determining, via the first controller, a second mechanism control scheme based on the data set.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 391,620, filed July 22, 2022, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This disclosure relates to power tools, and more particularly to power fastener drives. Summary of the Invention

[0004] Fastener actuators, or powered fastener actuators, can be used to drive fasteners (e.g., nails, thumbtacks, staples, etc.) into a workpiece. Fastener actuators can be operated using various energy sources (e.g., compressed air from an air compressor, electrical energy, flywheel mechanisms, etc.), but these designs often encounter limitations in power, size, and cost.

[0005] In one aspect, this disclosure provides a method for controlling the motor of a power tool. The method may include: performing a load test on the battery pack of the power tool via a first controller; determining a first mechanism control scheme via the first controller based on the load test; receiving user input instructing the start of an operation cycle of the power tool via the first controller; and isolating the first controller from a second controller. The method further includes: controlling the motor of the power tool via the first controller based on the first mechanism control scheme while the first controller is isolated from the second controller; sensing a dataset indicating the result of the operation cycle of the power tool based on the first mechanism control scheme via one or more sensors; receiving the dataset via the second controller; connecting the first controller to the second controller upon completion of the operation cycle; transmitting the dataset back to the first controller via the second controller upon completion of the operation cycle; and determining a second mechanism control scheme via the first controller based on the dataset.

[0006] In another aspect, a method for controlling a motor of a power tool may include: electrically braking the motor based on a first mechanism control scheme via a command from a first controller; and detecting the completion of an operating cycle of the motor via the first controller. The method may further include: transmitting a dataset indicating the position of a first piston of the power tool to the first controller via a second controller upon completion of the operating cycle; and determining a second mechanism control scheme via the first controller based on the dataset, wherein the first controller and the second controller are isolated during the operating cycle.

[0007] On the other hand, this disclosure provides a power fastener actuator comprising: a first cylinder; a first piston positioned within the first cylinder and movable between a top dead center (TDC) position and a bottom dead center (BDC) position; a second cylinder in fluid communication with the first cylinder; a second piston positioned within the second cylinder and movable between the TDC position and the BDC position to initiate a fastener drive cycle; and a control system. The control system can: electrically brake a motor based on a first mechanism control scheme via commands from a first controller; drive the motor based on the first mechanism control scheme via commands from the first controller; detect the completion of an operating cycle of the motor via the first controller; transmit a dataset indicating the position of the first piston of the power tool to the first controller via a second controller upon completion of the operating cycle; and determine a second mechanism control scheme via the first controller based on the dataset, wherein the first controller and the second controller are isolated during the operating cycle.

[0008] Other aspects of this disclosure will become clear by considering the specific implementation and the accompanying drawings. Attached Figure Description

[0009] Figure 1 This is a perspective view of a power fastener driver according to an embodiment of this disclosure.

[0010] Figure 2 Examples based on this disclosure Figure 1 Powered fastener driver along Figure 1 The section view taken from line 2-2 shows the airborne compressor.

[0011] Figure 3 Examples based on this disclosure Figure 1 A perspective view of a portion of a power fastener driver, with part of the cylinder removed to reveal the crank arm assembly and latch.

[0012] Figure 4 Examples based on this disclosure Figure 3 An enlarged stereoscopic view of a portion of a power fastener actuator, showing the latch in the locked position.

[0013] Figure 5 Examples based on this disclosure Figure 1 A perspective view of a portion of a power fastener actuator, in which a portion of the cylinder has been removed to show the cylinder head that forms a channel between the compression cylinder and the drive cylinder of the onboard compressor.

[0014] Figure 6Examples based on this disclosure Figure 1 A top-view perspective view of a portion of the crank arm assembly of a power fastener driver, showing the cam cam angle formed on the cam of the crank arm assembly.

[0015] Figure 7 Examples based on this disclosure Figure 1 A bottom-view perspective view of the crank arm assembly of a power fastener driver, showing the fingers and hub formed on the crank arm of the crank arm assembly.

[0016] Figure 8 Examples based on this disclosure Figure 1 Top-view perspective of the structural housing of the power fastener driver.

[0017] Figure 9 Examples based on this disclosure Figure 1 A perspective view of the structural housing of the power fastener actuator, showing the back pressure adjustment mechanism and check valve.

[0018] Figure 10A Examples based on this disclosure Figure 1 A partial perspective view of the structural housing of a power-driven fastener actuator, showing the check valve in the closed position.

[0019] Figure 10B Examples based on this disclosure Figure 1 A partial perspective view of the structural housing of the power fastener actuator, showing the check valve in the open position.

[0020] Figure 11 This is a block diagram of a power tool system including a power tool and a battery pack, according to embodiments of this disclosure.

[0021] Figure 12 This is a flowchart of a method for controlling an electric motor of a power tool according to an embodiment of this disclosure.

[0022] Figure 13 This is a flowchart of a method for collecting data from the motor of a power tool, according to an embodiment of this disclosure.

[0023] Figure 14 This is a block diagram of a power tool system including a power tool and a battery pack, according to embodiments of this disclosure.

[0024] Figure 15 This is a flowchart of a method for controlling an electric motor of a power tool according to an embodiment of this disclosure.

[0025] Figure 16This is a flowchart of a method for collecting data from the motor of a power tool, according to an embodiment of this disclosure.

[0026] Before explaining any embodiment of this disclosure in detail, it should be understood that the subject matter is not limited in its application to the construction details and component arrangements set forth in the following description or shown in the following figures. The subject matter can have other embodiments and can be practiced or implemented in various ways. Detailed Implementation

[0027] Unless the context of their usage explicitly indicates otherwise, the articles “a” and “the” should not be interpreted as referring to “one” or “only one.” Rather, these articles should be interpreted as referring to “at least one” or “one or more.” Similarly, when the terms “the” or “the” are used to refer to a noun previously introduced by the indefinite article “a” or “an,” unless the context explicitly indicates otherwise, “the” and “the” refer to “at least one” or “one or more.”

[0028] It should also be understood that while some of the accompanying drawings illustrate hardware and software located within a particular device, these depictions are for illustrative purposes only. In some embodiments, the components shown may be combined or divided into separate software, firmware, and / or hardware. For example, logic and processing may be distributed among multiple electronic processors rather than residing within and being executed by a single electronic processor. Regardless of how the hardware and software components are combined or divided, they may reside on the same computing device or be distributed among different computing devices connected via one or more networks or other suitable communication links.

[0029] Therefore, in the claims, if a device or system is claimed, for example, including an electronic processor or other element configured in a certain way to make, for example, multiple decisions, then the claim or claim element should be interpreted as referring to one or more electronic processors (or other elements), wherein any one of the one or more electronic processors (or other elements) is configured, as claimed, to make, for example, some or all of the multiple decisions. Again, those electronic processors or processes can be distributed.

[0030] refer to Figure 1The powered fastener driver 10 is operable to drive fasteners (e.g., nails, thumbtacks, staples, etc.) housed within a cartridge 14 into a workpiece. The powered fastener driver 10 includes a housing having a handle portion 18, a structural housing 24, and a user-actuated trigger 26 mounted on the handle portion 18. Notably, the powered fastener driver 10 does not require an external air pressure source; instead, it includes an onboard air compressor 30. This reduces the tool's weight and / or size. The onboard air compressor 30 is powered by a power source (e.g., a battery pack 20) ​​connected to a battery attachment portion 22 of the housing.

[0031] refer to Figure 2 The powered fastener driver 10 includes a drive vane 34 actuated by an onboard air compressor 30 to drive a fastener into a workpiece. The compressor 30 includes a compression cylinder 38, a compressor piston 42 disposed within the compression cylinder 38, and a drive mechanism 44 that applies reciprocating motion to the compressor piston 42 to perform one or more consecutive fastener drive cycles. The drive mechanism 44 includes a motor 46 (e.g., a brushed or brushless DC motor), a transmission 50 (e.g., a multi-stage planetary transmission), and a crank arm assembly 54 configured to convert the rotational output of the transmission 50 into a reciprocating input to the compressor piston 42. The fastener driver 10 may additionally include a drive cylinder 58 and a drive piston 62 slidably disposed within the drive cylinder 58. The drive piston 62 is movable between a top dead center (TDC) position and a bottom dead center (BDC) position. Similarly, the compressor piston 42 is movable between the TDC position and a position near or close to the BDC position. For example, in the illustrated embodiment, the drive cylinder 58 may additionally include a stop member 60 (e.g., an elastic damper) that is positioned to engage and absorb energy from the drive piston 62 when the drive piston 62 reaches the BDC position.

[0032] like Figure 2 and Figure 5 As shown, the smaller drive cylinder 58 extends at least partially into the larger compression cylinder 38, such that the compressor piston 42 surrounds the entire drive cylinder 58. By fully or partially nesting the drive cylinder 58 within the compression cylinder 38, the size and / or weight of the fastener driver 10 can be advantageously reduced to achieve improved handling, manufacturability, etc. The drive cylinder 58 and the compression cylinder 38 are in fluid communication via a channel 64. Figure 3 and Figure 5Channel 64 allows pressure to be transmitted between the two cylinders 38, 58. In the illustrated embodiment, cylinder head 66 is coupled to the distal end (e.g., the upper end) of compression cylinder 38 and includes a plurality of orifices defining channel 64, which allows continuous fluid communication between the two cylinders 38, 58. In other words, there is no valve within channel 64.

[0033] like Figure 3 , Figure 4 and Figure 5 As shown, the powered fastener actuator 10 may additionally include a latch 68 supported within the structural housing 24, extending between the drive mechanism 44 and the drive blade 34. The latch 68 is movable between a locked position and an unlocked position. In the locked position, the latch 68 engages the drive blade 34 to hold the drive piston 62 in a TDC position. In the unlocked position, the latch 68 disengages from the drive blade 34, thus enabling the drive piston 62 to move from the TDC position to the BDC position to perform fastener driving operations. In the illustrated embodiment, the drive blade 34 includes a slot 70, a biasing member 74 is configured to bias the latch 68 toward the locked position, and the latch 68 includes a recess 72. When the latch 68 is in the unlocked position, the recess 72 is aligned with the drive blade 34. When the latch 68 is in the locked position, the slot 70 formed in the drive blade 34 is configured to receive a portion of the latch 68 to limit movement of the drive blade 34. When the crank arm assembly 54 moves the compressor piston 42 toward the TDC position, the crank arm assembly 54 moves the latch 68 to the unlocked position, which releases the blade 34 to initiate fastener drive operation.

[0034] like Figure 3 , Figure 4 and Figure 6 As shown, the crank arm assembly 54 includes a crank arm 76 and a connecting rod 80, the crank arm having a pin 78, the connecting rod being pivotally connected at one end to the pin 78 and at the opposite end to a piston pin 82. Figure 2 Piston pin 82 may include a portion located near the compression cylinder 38. Figure 3 and Figure 5 The printed circuit board assembly (PCBA) 83 on the exterior of the compressor piston 42 has an end-mounted magnet (not shown). The PCBA 83 may include one or more sensors 85 (e.g., Hall switches, Hall effect sensors, optical sensors, ultrasonic sensors, photoelectric sensors, and / or any other suitable position sensors) that electronically communicate with the control system 300 described in more detail below and are configured to be activated by the end-mounted magnet of the piston pin 82. Once activated by the end-mounted magnet of the piston pin 82, each of the one or more sensors 85 may be further configured to generate an indication of the compressor piston 42 ( Figure 3 and Figure 5The position signal (based on activation) of the compressor piston 42 is transmitted to the control system 300. In some embodiments, the signal may be a dataset indicating the result of an operating cycle based on the position of the compressor piston 42.

[0035] refer to Figure 7 The crank arm 76 may include a hub 84, which is coupled for co-rotating with the output shaft of the transmission 50 (e.g., arranged via a key and keyway). (See reference...) Figure 6 The crank arm assembly 54 also includes a cam 86, which is coupled for rotating together with the crank arm 76. The cam 86 includes a first side 88, a second side 90 opposite to the first side 88, and a cam cam lob 92 formed on the first side 88. In the illustrated embodiment, the cam lob 92 is formed as a protrusion on the first side 88 of the cam 86, extending axially and parallel to the rotational axes of the crank arm 76 and the cam 86. Furthermore, the crank arm 76 is coupled to the second side 90 of the cam 86, and the cam lob 92 is formed on the opposing first side 88. In other words, the first side 88 and the cam lob 92 face the drive unit 50, while the second side and the crank arm 76 face the drive cylinder 58.

[0036] As explained in further detail below, one end of latch 68 is biased against a first side 88 of cam 86, causing sliding between latch 68 and cam 86 as cam 86 rotates. As latch 68 slides onto cam cam lobe 92, latch 68 moves toward the unlocked position. At this point, latch 68 acts as a follower in response to rotation of cam 86. It should be understood that a complete fastener drive cycle can be defined as compressor piston 42 starting at a position near BDC, moving to TDC, and ending at or near BDC, while drive piston 62 starts at TDC, moves to BDC when compressor piston 42 reaches TDC, and ends at TDC. For compressor piston 42 to perform a complete fastener drive cycle, crank arm assembly 54 rotates 360 degrees. To initiate a subsequent complete fastener drive cycle, rotation of crank arm assembly 54 can continue in the same direction of rotation. In other embodiments, rotation of crank arm assembly 54 can be reversed by motor 46 to initiate a subsequent complete fastener drive cycle. To achieve this, motor 46 can cause crank arm 76 and cam 86 to rotate alternately in a clockwise and counterclockwise manner (e.g., clockwise and then counterclockwise) to complete a continuous fastener drive cycle.

[0037] like Figures 8 to 10BAs shown, the fastener actuator 10 includes a back pressure adjustment mechanism 106 supported within the structural housing 24. The back pressure adjustment mechanism 106 is configured to change the amount of air discharged from below the drive piston 62 in the drive cylinder 58 (i.e., on the side of the drive piston 62 opposite to the cylinder head 66) during a fastener drive cycle. Because the fastener actuator 10 does not include any pressure valves, the pressure of the compressed air generated in the compression cylinder 38 is the same as the pressure acting on the drive piston 62. Therefore, as the drive piston 62 moves from the TDC position to the BDC position, the back pressure adjustment mechanism 106 can selectively increase or decrease the amount of air discharged from below the drive piston in the drive cylinder 58, thereby correspondingly decreasing or increasing the back pressure acting on the drive piston 62 during the fastener drive cycle. In this way, the force acting on the drive piston 62 can be increased or decreased to drive fasteners of different sizes (e.g., 16-gauge, 18-gauge, 1-inch, 2-inch, etc.) into the workpiece by an appropriate distance, making the fastener actuator 10 suitable for a variety of fastening applications.

[0038] The back pressure adjustment mechanism 106 includes a bracket 108 rotatably supported within a structural housing 24, an adjustment member 110 extending from the bracket 108 through the structural housing 24, and an opening 112 formed in the bracket 108 to expose a central hole within the bracket 108. The opening 112 in the bracket 108 is selectively aligned with a window 114 formed in the structural housing 24, which is in fluid communication with the external atmosphere. Rotation of the bracket 108 (e.g., via the adjustment member 110) adjusts the position of the opening 112 relative to the window 114, and thus adjusts the effective cross-sectional area of ​​the opening 112 exposed to the atmosphere. Therefore, adjusting the size of the exposed opening 112 regulates the volumetric flow rate of air discharged from below the drive piston 62 in the drive cylinder 58 through the exposed opening 112 and the window 114. For example, reducing the size of the exposed opening 112 reduces the flow rate of air that can be discharged through the opening 112, which generates a greater back pressure acting on the drive piston 62, and thus reduces the net force acting on the drive piston 62 during the fastener drive cycle. Increasing the size of the exposed opening 112 increases the amount of air that can be exhausted through the opening 112, which produces a smaller back pressure on the drive piston 62 and thus increases the net force acting on the drive piston 62 during the fastener drive cycle.

[0039] Continue to refer to Figure 9 , Figure 10A and Figure 10B The fastener driver 10 may additionally include a check valve 116 and a biasing member 118 (e.g., a torsion spring, etc.) that biases the check valve 116 toward the closed position. Figure 10A The bias prevents the second window 120 ( ) from passing through the bracket 108. Figure 10B(e.g., air) flow. In the closed position, in response to the movement of the drive piston 62 from the TDC position toward the BDC position, the second window 120 is closed and atmospheric air is prevented from leaving the drive cylinder 58 via the bracket 108. The check valve 116 can be positioned adjacent to the back pressure regulating mechanism 106 and can be moved to the open position, in which, in response to the movement of the drive piston 62 from the BDC position toward the TDC position, the second window 120 in the bracket 108 is opened to allow atmospheric air to enter the drive cylinder 58 via the bracket 108. More specifically, during the movement of the drive piston 62 from the BDC position toward the TDC position, a vacuum is created below the drive piston 62 within the drive cylinder 58, which, as the drive piston 62 moves toward the TDC position, pulls the check valve 116 to the open position via a force generated by the pressure difference. When the check valve 116 is in the open position, the entire opening 112 of the bracket 108 is exposed to the atmosphere (via the first window 114 and the second window 120 in the structural housing 24) to allow replacement air to enter below the drive piston 62 in the drive cylinder 58. Once the drive piston 62 returns to the TDC position, the vacuum acting on the check valve 116 to hold it in the open position can dissipate, causing the biasing member (e.g., a spring) 118 to spring back and return the check valve 116 to the closed position, thereby closing the second window 120 and resetting the driver 10 for the subsequent fastener drive cycle. As the drive piston 62 and drive blade 34 return to the TDC position, the biasing member 74 pushes the latch 68 to engage with the slot 70 of the drive blade 34, locking the drive blade 34 in the position for the subsequent fastener drive cycle.

[0040] At the start of the fastener drive cycle, latch 68 is configured to hold drive piston 62 in the TDC position, while compressor piston 42 is in the BDC position. As described further in detail below, control system 300 can determine the position of compressor piston 42 based on the activation of one or more sensors 85 to ensure that compressor piston 42 is in the BDC position and crank arm 76 is in the starting position at the start of the fastener drive cycle. If it is determined based on the activation of one or more sensors 85 that compressor piston 42 is not near the BDC position at the end of the fastener drive cycle (i.e., an abnormal cycle), control system 300 can control motor 46 to rotate in a certain direction (e.g., clockwise or counterclockwise) to drive compressor piston 42 toward its BDC position before the start of a subsequent fastener drive cycle.

[0041] In some embodiments, an abnormal cycle may occur if the trigger 26 and / or the operating contact switch (not shown) is released before the fastener drive cycle ends. In other embodiments, an abnormal cycle may occur if the battery pack 20 is disconnected from the power tool, or if the battery pack 20 is turned off during the fastener drive cycle. In response to determining an abnormal cycle, the subsequent operating cycle may be a recovery cycle. In some embodiments, the recovery cycle may be initiated by actuation of the user-actuated trigger 26 and / or the operating contact switch (not shown). In other embodiments, the recovery cycle may be initiated by other suitable user input. In some embodiments, when a recovery cycle is initiated, a flag may be set in the memory of the control system 300 to indicate the previously abnormally ended operating cycle. Once the compressor piston 42 is reset to the BDC position, the control system 300 may clear the flag. Once a subsequent drive cycle is initiated, the control system 300 may check the memory for the flag before completing the subsequent operating cycle. In some embodiments, the control system 300 may perform additional checks based on the state of one or more sensors 85 to determine whether the starting position of the compressor piston 42 is acceptable relative to the BDC position. In some embodiments, if the position of the compressor piston 42 relative to the BDC position cannot be detected within the timeout period, a timer can be used to determine the timeout period to end the recovery cycle. The motor 46 can then rotate in the opposite direction to drive the compressor piston 42 upward toward its TDC position via the crank arm assembly 54. In some embodiments, if an abnormal cycle is identified and the compressor piston 42 stops at the cycle position or the TDC position, the recovery cycle can be divided into at least two or more recovery cycles.

[0042] As the compressor piston 42 moves upward, the air in and above the compressor piston 42 in the compression cylinder 38 is compressed, while the latch 68 holds the drive piston 62 in the TDC position. Once the crank arm 76 and cam 86 reach a predetermined angular position corresponding to the TDC position of the compressor piston 42, the cam 86 moves the latch 68 to its unlocked position, releasing the drive vane 34 as described above. After the drive vane 34 is released by the latch 68, the compressed air in the compression cylinder 38 causes the drive piston 62 to accelerate downward within the drive cylinder 58, causing the drive vane 34 to strike the fastener housed in the housing 14 and drive the fastener into the workpiece until the drive piston 62 reaches the stop member 60 located at the BDC position within the drive cylinder 58.

[0043] As the drive piston 62 reaches its BDC position, half of the fastener drive cycle is completed, and the compressor piston 42 is driven downward toward the BDC position by the motor 46 and crank arm assembly 54 to complete the fastener drive cycle and prepare the fastener driver 10 for the subsequent fastener drive cycle. As the compressor piston 42 is driven through the retraction stroke (i.e., from the TDC position toward the BDC position), a vacuum is created in the compression cylinder 38 and the drive cylinder 58, resulting in a pressure imbalance and ultimately an upward force on the drive piston 62, causing it to return to its TDC position. During the movement of the drive piston 62 to the TDC position, the check valve 116 opens, allowing replacement air to enter below the drive piston 62 in the drive cylinder 58 to facilitate the return of the drive piston 62 to the TDC position, as described above. As the drive piston 62 and drive vane 34 return to the TDC position, the biasing member 74 pushes the latch 68 into the slot 70 of the drive vane 34, locking the drive vane 34 in the appropriate position for the subsequent fastener drive cycle.

[0044] In the illustrated embodiment, the rotational speed of motor 46 can be reduced after the fastener drive operation occurs, such that the control system 300, described in more detail below, implements a mechanical control scheme to electrically brake motor 46 (e.g., via multiple FETs). In some embodiments, the mechanical control scheme can control the timing and / or position of compressor piston 42 and drive piston 62 during the operating cycle. Electrically braking motor 46 allows compressor piston 42 to return to the BDC position at a controlled speed for subsequent fastener drive cycles. During the operating cycle, one or more sensors 85 can detect signals indicating the position of compressor piston 42. Control system 300 can receive signals indicating the position of compressor piston 42 and implement the mechanical control scheme based on the received signals. In some embodiments, a timer can be used to set a timer duration for a complete fastener drive operation (e.g., a timer duration for compressor piston 42 returning to the BDC position). Thus, for a complete fastener drive cycle, control system 300 is configured to instruct motor 46 to drive during one or more cycles of motor drive time and brake during one or more cycles of motor braking time. In some embodiments, the control system 300 ensures that the compressor piston 42 returns to the vicinity of the BDC position before the subsequent fastener drive cycle.

[0045] Figure 11 This is a block diagram of a control system 300 for a power fastener driver 10 according to some embodiments. In other embodiments, the control system 300 may be used with other power tools (e.g., drill bits, saws, vibratory tools, etc.). The control system 300 may include a first controller 305a and a second controller 305b, and Figure 11 Other components not depicted, such as motor 46, solenoid, or other mechanical and / or electrical components described above. In other embodiments, the first controller 305a may include a greater number of components than the second controller 305b, or a smaller number of components. For example, the first controller 305a and the second controller 305b may include an IC chip, a PID controller, a programmable logic controller, etc.

[0046] In some embodiments, the first controller 305a may include a processing unit 310a, which includes a control unit 315a, an arithmetic logic unit 320a, and one or more registers 325a. The first controller 305a may further include a memory 330a comprised of a program storage device 335a and / or a data storage device 340a. The memory 330a may be flash memory, random access memory, solid-state memory, another type of memory, or a combination of these types. The first controller 305a may further include one or more input units 345a and / or output units 350a. In some embodiments, one or more input units 345a may be configured to receive multiple inputs from one or more output units 350b, such as shark fin switch signals, operating contact switch signals, mode switch signals, load voltage signals, trigger signals, or control signals. In some embodiments, one or more output units 350a may be configured to transmit multiple outputs, such as a battery load test signal, a signal for controlling multiple light-emitting diodes (LEDs), or a signal for controlling multiple FETs of the motor 46.

[0047] The first controller 305a can communicate electronically with the second controller 305b via a communication line 322. For example, the communication line 322 can be a wire, link, or other communication method. The first controller 305a can be further configured to transmit and / or receive data indicating the state of the fastener drive cycle with the second controller 305b via the communication line 322. The second controller 305b may include a processing unit 310b, which includes a control unit 315b, an arithmetic logic unit 320b, and one or more registers 325b. The second controller 305b may further include a memory 330b consisting of a program storage device 335b and / or a data storage device 340b. The memory 330b may be flash memory, random access memory, solid-state memory, another type of memory, or a combination of these types. The second controller 305b may further include one or more input units 345b and / or output units 350b, such as one or more input / output interfaces, various connectors of the connection components (e.g., system bus), etc. In some embodiments, one or more input units 345b can be configured to receive multiple inputs, such as signals from one or more sensors 85 or battery voltage signals. In some embodiments, one or more output units 350b may be configured to transmit multiple outputs, such as control signals, to one or more input units 345a. Processing units 310a, 310b may include a microprocessor, a microcontroller, or other suitable programmable device.

[0048] Memory 330a, 330b are non-transitory computer-readable media that include, for example, a program storage area and a data storage area. The program storage area and data storage area may include combinations of different types of memory, such as read-only memory (“ROM”), random access memory (“RAM”) (e.g., dynamic RAM [“DRAM”], synchronous DRAM [“SDRAM”], etc.), electrically erasable programmable read-only memory (“EEPROM”), flash memory, hard disk, SD card, or other suitable magnetic storage device, optical storage device, physical storage device, or electronic storage device. Processing units 310a, 310b are connected to memory 330a, 330b and execute software instructions that can be stored in the RAM of memory 330a, 330b (e.g., during execution), the ROM of memory 330a, 330b (e.g., on a generally permanent basis), or another non-transitory computer-readable medium such as another memory or disk. The software included in embodiments of fastener driver 10 may be stored in the memory 330a, 330b of controller 305a, 305b. The software includes, for example, firmware, one or more applications, program data, filters, rules, one or more program modules, and other executable instructions. Controllers 305a and 305b are configured to retrieve from memory and execute instructions particularly relevant to the control of the fastener driver 10 described herein. In other configurations, controllers 305a and 305b may include additional, fewer, or different components.

[0049] Battery pack 355 (e.g., battery pack 20) ​​may include a stack 360 consisting of one or more battery cells 365. In some embodiments, the one or more battery cells 365 are electrically connected to each other in series. In other embodiments, the one or more battery cells 365 are electrically connected to each other in parallel. In still other embodiments, the one or more battery cells 365 are electrically connected to each other in a combination of series and parallel connections. Battery pack 355 may further include a battery pack controller 370 consisting of a battery processor 375 and a battery memory 380. Battery pack 355 may further include a positive battery terminal 385 and a negative battery terminal 390. The positive battery terminal 385 and the negative battery terminal 390 may be configured to be electrically and / or mechanically coupled to corresponding terminals of the power fastener driver 10. In some embodiments, battery pack 355 includes a communication terminal 395, which may be configured to be electrically, mechanically, and / or communicatively coupled to one or more communication terminals of the power fastener driver 10.

[0050] In some embodiments, such as, Figure 11In the block diagram, one or more battery cells 365 are connected to a battery pack controller 370. The battery pack controller 370 controls the power delivered to the positive battery terminal 385 and the negative battery terminal 390 (e.g., via a control discharge field-effect transistor (FET), a charge FET, and / or other FETs located within the battery pack). In some embodiments, the battery pack controller 370 controls power by enabling or disabling power. Furthermore, in some embodiments, the battery pack controller 370 controls power by allowing a percentage of the power generated by one or more battery cells 365 to be output. In some embodiments, the amount of power delivered between battery terminals 385, 390 is approximately 100% of the power that one or more battery cells 365 may generate.

[0051] Figure 12 This is an exemplary flowchart illustrating a method 400 for controlling a motor (e.g., motor 46) of a power tool (e.g., a power fastener driver 10) according to some embodiments. It should be understood that the order of the steps disclosed in method 400 can vary. For example, additional steps can be added to the process, and not all steps may be required, or steps shown in one order may occur in a second order. Method 400 begins at step 405, where a first controller 305a receives a signal for initiating operation of the power tool (e.g., energizing the power tool). Method 400 then proceeds to step 410.

[0052] In step 410, the first controller 305a performs a battery load test on the battery pack 355 prior to the fastener drive cycle. The battery load test may include determining whether the battery pack 355 is electrically, mechanically, and / or communicatively connected to a power tool when the first controller 305a determines that the battery pack 355 includes a communication terminal 395. If the first controller 305a determines that the battery pack 355 does not include a communication terminal 395, the first controller 305a performs a load test on the battery pack 355 by measuring the voltage of the battery pack 355 prior to the fastener drive cycle. Method 400 may further include determining the internal resistance of the battery pack 355 via the first controller 305a. The internal resistance may be determined by measuring the voltage and / or current of the battery pack 355 prior to the fastener drive cycle. In some embodiments, the internal resistance may be determined based on one or more battery cells 365 and / or FETs and / or other electronic or physical components of the battery pack 355. Method 400 may further include determining the type of battery pack based on the determined internal resistance via the first controller 305a. If the first controller 305a determines that the battery pack 355 does indeed include the communication terminal 395, then method 400 may include determining the type of the battery pack by receiving a signal from the battery pack communication terminal. Method 400 then proceeds to step 415.

[0053] In step 415, the first controller 305a determines a first mechanism control scheme. The first mechanism control scheme may include determining the timing of a fastener drive cycle of the motor 46 (consistent with a fastener drive cycle of the fastener driver 10). The first mechanism control scheme includes electrically controlling the motor 46 to drive the crank arm assembly 54. In some embodiments, the motor 46 drives the crank arm assembly 54 in a first direction. The first mechanism control scheme may further include determining the duty cycle of a pulse width modulation (PWM) signal applied to the motor 46 and connected to one or more output units 350a to drive the crank arm assembly 54. The first mechanism control scheme may further include determining the duty cycle of a PWM signal applied to the multiple FETs of the motor 46 to electrically brake the crank arm assembly 54. Once the first mechanism control scheme is determined, method 400 proceeds to step 420.

[0054] In step 420, the first controller 305a receives a signal indicating the start of a fastener drive cycle (e.g., the start of an operation cycle) from a first user input via one or more input units 345a. In some embodiments, the signal for starting the fastener drive cycle of the motor 46 may be based on the actuation of trigger 26 or another switch of the power tool. In some embodiments, the first controller 305a may receive a signal indicating the mode of the fastener driver 10 from a mode switch (not shown) prior to the actuation of trigger 26. In other embodiments, the power tool may start the fastener drive cycle in response to the actuation of trigger 26 in conjunction with the actuation of a working contact element and / or the actuation of a second trigger (e.g., a shark fin switch). The actuation of the working contact element and / or the actuation of the second trigger may transmit a signal to the first controller 305a indicating the start of fastener drive operation. Method 400 then proceeds to step 425.

[0055] In step 425, the first controller 305a may be isolated from the second controller 305b via communication line 322. In some embodiments, communication line 322 is an electrical connection between one or more output units 350b and one or more input units 345a. For example, during an operation cycle, one or more output units 350b may be temporarily disconnected from one or more input units 345a. The first controller 305a generates a signal in response to actuation of trigger 26 to initiate the isolation of the first controller 305a from the second controller 305b via hardware (i.e., via communication line 322 or the electrical connection between one or more output units 350b and one or more input units 345a). Isolating the first controller 305a from the second controller 305b prevents the communication transmission of data indicating the state of the fastener drive cycle during the fastener drive cycle, as further described below. In some embodiments, isolating the first controller 305a from the second controller 305b initiates a timer of the first controller 305a corresponding to the timing of a fastener drive cycle of the motor. This fastener drive cycle can be the time between when the motor 46 starts driving the crank arm assembly 54 from a starting position (e.g., when the compressor piston 42 is in or near the BDC position) and when the crank arm assembly 54 drives the compressor piston 42 to complete the fastener drive cycle (e.g., when the compressor piston 42 returns to the BDC position). Once method 400 isolates the first controller 305a from the second controller 305b, method 400 proceeds to step 430.

[0056] In step 430, the first controller 305a controls the motor 46 via one or more output units 350a based on a first control scheme determined in step 415 (in some embodiments, the first controller 305a is isolated from the second controller 305b). At least one of the one or more output units 350a is electrically connected to the motor 46. Based on the timing of the fastener drive cycle, the first controller 305a determines multiple time intervals (e.g., a first time, a second time, a third time, a fourth time, etc.). The first mechanism control scheme further includes driving and electrically braking the motor 46 at multiple determined time intervals within multiple durations corresponding to the duty cycle of the PWM signal. Electrically braking the motor 46 may include electrically shorting the wires of the motor 46 together for a predetermined duration. Method 400 further includes applying a series of voltage pulses to the motor 46. For example, the voltage pulses may correspond to the duty cycle of the PWM signal. For example, in a complete fastener drive cycle, the first controller 305a applies a PWM signal at a first time (e.g., a first drive interval) to drive the motor 46 for a first duration (e.g., at a first duty cycle) (i.e., compressing air via the compressor piston 42 and releasing the drive piston 62); at a second time (e.g., a first braking interval) to electrically brake the motor 46 for a first duration (i.e., slowing down or stopping the motor 46 and allowing residual pressure to be released); at a third time (e.g., a second drive interval) to drive the motor 46 for a third duration (e.g., at a second duty cycle) (i.e., causing the compressor piston 42 to return to the BDC position and creating a vacuum to reset the drive piston 62 to the TDC position); and at a fourth time (e.g., a second braking interval) to electrically brake the motor 46 for a second duration (i.e., stopping the compressor piston 42 at or near the BDC position for subsequent fastener drive cycles). This ensures that the compressor piston 42 returns to the BDC position before subsequent fastener drive cycles.

[0057] In some embodiments, motor 46 drives crank arm assembly 54 in a first fastener drive cycle in a first direction, wherein a fastener drive cycle is the time between when motor 46 begins driving crank arm assembly 54 from a starting position (e.g., when compressor piston 42 is in or near the BDC position) and when crank arm assembly 54 drives compressor piston 42 to the TDC position. Then, in a second fastener drive cycle, motor 46 may drive crank arm assembly 54 in a second direction opposite to the first direction. Motor 46 may drive crank arm assembly 54 alternately in alternating cycles in this manner. For example, in the first, third, fifth, and so on cycles, motor 46 may drive crank arm assembly 54 in a clockwise direction, while in the second, fourth, sixth, and so on cycles, motor 46 may drive crank arm assembly 54 in a counterclockwise direction. Method 400 then proceeds to step 435.

[0058] In step 435, the first controller 305a determines the completion of the fastener drive cycle based on the completion of the first mechanism control scheme. The completion of the mechanism control scheme is determined by the return of the compressor piston 42 to the vicinity of the BDC position. In some embodiments, the completion of the fastener drive cycle may correspond to the end of the actuation of the trigger 26. In other embodiments, the completion of the fastener drive cycle may correspond to the end of a timer of the first controller 305a. Upon completion of the fastener drive cycle, the first controller 305a terminates the signal indicating hardware isolation between the first controller 305a and the second controller 305b via communication line 322, thereby allowing data communication between the first controller 305a and the second controller 305b. The method then proceeds to step 440.

[0059] In step 440, the first controller 305a receives data from the second controller 305b indicating a fastener drive cycle corresponding to the first mechanism control scheme. In some embodiments, the second controller 305b transmits data via communication line 322 only after the fastener drive cycle is completed. Method 400 then proceeds to step 445. In step 445, the first controller 305a determines a second mechanism control scheme based on the data received from the second controller 305b. In some embodiments, the first mechanism control scheme is adjusted based on the received data indicating the fastener drive cycle to determine the second control scheme. In other embodiments, the second control scheme may be determined solely based on the data received by the first controller 305a. After determining the second control scheme, method 400 returns to step 420, where the first controller 305a waits for a signal indicating the start of the second fastener drive cycle. In some embodiments, the fastener driver 10 may wait for the start of the second fastener drive cycle until a second actuation of the trigger 26 or other switch occurs. Method 400 can be advantageous over existing designs because battery load testing and adjusting the mechanism control scheme based on previous operating cycles result in a more reliable user experience across a range of battery packs. By performing battery load tests and adjusting the mechanism control scheme based on previous operating cycles, each mechanism control scheme can be individually and precisely changed based on the results of each operating cycle of the fastener driver 10.

[0060] Figure 13 This is a flowchart illustrating a method 500 for collecting data indicative of the results of a fastener drive cycle via a second controller 305b, according to some embodiments. It should be understood that the order of the steps disclosed in method 500 can vary. For example, additional steps can be added to the process, and not all steps may be required, or steps shown in one order may occur in a second order. Method 500 begins at step 505, where the second controller 305b receives a signal for initiating operation of the power tool (e.g., energizing the power tool). Method 500 then proceeds to step 510.

[0061] In step 510, similar to step 425 of method 400, the first controller 305a is isolated from the second controller 305b via communication line 322. In some embodiments, communication line 322 is an electrical connection between one or more output units 350b and one or more input units 345a. The first controller 305a generates a signal in response to actuation of trigger 26 to initiate the hardware isolation of the first controller 305a from the second controller 305b. Isolating the first controller 305a from the second controller 305b prevents the communication transmission of data indicating the state of the fastener drive cycle and allows for changes in the control scheme for each mechanism based on the results of previous operating cycles of the fastener driver. Method 500 then proceeds to step 515. In step 515, the second controller 305b clears any previous data stored in memory 330b (including, but not limited to, data storage device 340b) indicating data collected during a previous fastener drive cycle. The method then proceeds to step 520.

[0062] In step 520, the second controller 305b receives multiple signals from one or more sensors 85 via one or more input units 345b, indicating the position of the compressor piston 42 during a fastener drive cycle. The multiple signals indicate when each of the one or more sensors 85 is activated by an end-mounted magnet of the piston pin 82 corresponding to the position of the compressor piston 42 throughout the operating cycle. For example, the multiple signals may include data indicating when the compressor piston 42 is in the BDC position, when the compressor piston 42 reaches the peak torque position, and when the compressor piston 42 reaches the TDC position. When the second controller 305b receives one or more of the multiple signals, the second controller 305b initiates a data collection control timer corresponding to the duration of a timer used for a complete fastener drive operation (e.g., the duration for which the compressor piston 42 returns to the BDC position). Method 500 then proceeds to step 525.

[0063] In step 525, the second controller 305b stores data indicating the activation of one or more sensors 85 in memory 330b during the fastener drive cycle. When each of the one or more sensors 85 is activated (indicating when the compressor piston 42 reaches the peak torque position and when the compressor piston 42 reaches the TDC position), the second controller 305b measures the voltage of the battery pack 355 and stores the measured voltage in memory 330b during the fastener drive cycle. Method 500 then proceeds to step 530. In step 530, similar to step 435 of method 400, the first controller 305a terminates the signal indicating hardware isolation between the first controller 305a and the second controller 305b via communication line 322, thereby allowing data communication between the first controller 305a and the second controller 305b. Method 500 then proceeds to step 535.

[0064] In step 535, after the fastener drive cycle is completed, the second controller 305b transmits data stored in memory 330b indicating the activation of one or more sensors 85 to the first controller 305a via communication line 322. Method 500 returns to step 510, in which the second controller 305b awaits a signal from the first controller 305a to initiate hardware isolation between the first controller 305a and the second controller 305b. In some embodiments, if the compressor piston 42 has not fully returned to the BDC position upon completion of the fastener drive cycle, the first controller 305a can use data indicating the position of the compressor piston 42 and a measured battery voltage from the second controller 305b to control the motor 46 to automatically return the compressor piston 42 to the BDC position. In some embodiments, the first controller 305a may apply PWM signals to a plurality of FETs connected to the motor 46 to drive the crank arm assembly 54 in the direction that returns the compressor piston 42 to the BDC position.

[0065] Figure 14 This is a block diagram of a control system 300 for a power fastener driver 10 according to some embodiments. In other embodiments, the control system 300 can be used with other power tools. The control system 300 may include a controller 305c and... Figure 14Other components not depicted, such as motor 46, solenoid, and / or other mechanical and / or electrical components described above. Controller 305c may include a processing unit 310c, which includes a control unit 315c, an arithmetic logic unit 320c, and one or more registers 325c. Controller 305c may further include a memory 330c comprising a program storage device 335c and / or a data storage device 340c. Memory 330c may be flash memory, random access memory, solid-state memory, another type of memory, or a combination of these types. Controller 305c may further include one or more input units 345c and / or output units 350c. In some embodiments, one or more input units 345c may be configured to receive multiple inputs, such as shark fin switch signals, operating contact element switch signals, mode switch signals, load voltage signals, trigger signals, signals from one or more sensors 85, or battery voltage signals. In some embodiments, one or more output units 350c may be configured to transmit multiple outputs, such as a battery load test signal, a signal for controlling multiple light-emitting diodes (LEDs), or a signal for controlling multiple FETs connected to the motor 46. For example, the controller 305c may include an IC chip, a PID controller, a programmable logic controller, etc. The processing unit 310c may include a microprocessor, a microcontroller, or other suitable programmable device.

[0066] Memory 330c is a non-transitory computer-readable medium that includes, for example, a program storage area and a data storage area. The program storage area and data storage area may include combinations of different types of memory, such as read-only memory (“ROM”), random access memory (“RAM”) (e.g., dynamic RAM [“DRAM”], synchronous DRAM [“SDRAM”], etc.), electrically erasable programmable read-only memory (“EEPROM”), flash memory, hard disk, SD card, or other suitable magnetic storage device, optical storage device, physical storage device, or electronic storage device. Processing unit 310c is connected to memory 330c and executes software instructions that can be stored in the RAM of memory 330c (e.g., during execution), the ROM of memory 330c (e.g., on a generally permanent basis), or another non-transitory computer-readable medium such as another memory or disk. Software included in embodiments of fastener driver 10 may be stored in memory 330c of controller 305c. This software includes, for example, firmware, one or more application programs, program data, filters, rules, one or more program modules, and other executable instructions. The controller 305c is configured to retrieve from memory and execute instructions, particularly those relating to the control of the fastener driver 10 described herein. In other configurations, the controller 305c may include additional, fewer, or different components.

[0067] Battery pack 355 may include a stack 360 consisting of one or more battery cells 365. In some embodiments, one or more battery cells 365 (e.g., lithium-ion battery cells or battery cells with similar chemistry) are electrically connected to each other in series. In other embodiments, one or more battery cells 365 are electrically connected to each other in parallel. In still other embodiments, one or more battery cells 365 are electrically connected to each other in a combination of series and parallel connections. Battery pack 355 may further include a battery pack controller 370 consisting of a battery processor 375 and a battery memory 380. Battery pack 355 may further include a positive battery terminal 385 and a negative battery terminal 390. The positive battery terminal 385 and the negative battery terminal 390 may be configured to be electrically and / or mechanically coupled to corresponding terminals of the power fastener driver 10. In some embodiments, battery pack 355 includes a communication terminal 395, which may be configured to be electrically, mechanically, and / or communicatively coupled to one or more communication terminals of the power fastener driver 10.

[0068] In some embodiments, such as, Figure 14 In the block diagram, one or more battery cells 365 are connected to a battery pack controller 370. The battery pack controller 370 controls the power delivered to the positive battery terminal 385 and the negative battery terminal 390 (e.g., via a control discharge field-effect transistor (FET), a charge FET, and / or other FETs located within the battery pack). In some embodiments, the battery pack controller 370 controls power by enabling or disabling power. Furthermore, in some embodiments, the battery pack controller 370 controls power by allowing a percentage of the power generated by one or more battery cells 365 to be output. In some embodiments, the amount of power delivered between battery terminals 385, 390 is approximately 100% of the power that one or more battery cells 365 may generate.

[0069] Figure 15 This is a flowchart illustrating a method 600 for controlling a motor (e.g., motor 46) of a power tool (e.g., a power fastener driver 10) according to some embodiments. It should be understood that the order of the steps disclosed in method 600 can vary. For example, additional steps can be added to the process, and not all steps may be required, or steps shown in one order may occur in a second order. Method 600 begins at step 605, where controller 305c receives a signal for initiating operation of the power tool (e.g., energizing the power tool). Method 600 then proceeds to step 610.

[0070] In step 610, controller 305c performs a battery load test on battery pack 355 prior to the fastener drive cycle. The battery load test may further include determining whether battery pack 355 is electrically, mechanically, and / or communicatively connected to a power tool when first controller 305a determines that battery pack 355 includes communication terminal 395. If controller 305c determines that battery pack 355 does not include communication terminal 395, controller 305c performs a load test on battery pack 355 by measuring the voltage of battery pack 355 prior to the fastener drive cycle. Method 600 may further include determining the internal resistance of the battery pack via controller 305c. The internal resistance can be determined by measuring the voltage and / or current of battery pack 355 prior to the fastener drive cycle. Method 600 may further include determining the type of battery pack based on the determined internal resistance via controller 305c. If controller 305c determines that battery pack 355 does indeed include communication terminal 395, method 600 includes determining the type of battery pack by receiving a signal from the battery pack communication terminal. Method 600 then proceeds to step 615.

[0071] In step 615, controller 305c determines a first mechanism control scheme. The first mechanism control scheme may include determining the timing of a fastener drive cycle of motor 46 (consistent with a fastener drive cycle of fastener driver 10). The first mechanism control scheme may include electrically controlling motor 46 to drive crank arm assembly 54. In some embodiments, motor 46 drives crank arm assembly 54 in a first direction. The first mechanism control scheme may further include determining the duty cycle of a PWM signal applied to a plurality of FETs connected to motor 46 to drive crank arm assembly 54. The first mechanism control scheme may further include determining the duty cycle of a PWM signal applied to a plurality of FETs connected to motor 46 to electrically brake crank arm assembly 54. Once the first mechanism control scheme is determined, method 600 proceeds to step 620.

[0072] In step 620, controller 305c receives a signal indicating the start of a fastener drive cycle (e.g., the start of an operation cycle) from a first user input via one or more input units 345c. In some embodiments, the signal for starting the fastener drive cycle of motor 46 may be based on the actuation of trigger 26 or another switch of the power tool. In some embodiments, controller 305c may receive a signal indicating the mode of fastener driver 10 from a mode switch (not shown) prior to actuation of trigger 26. In other embodiments, the power tool may start the fastener drive cycle in response to actuation of trigger 26 in conjunction with actuation of a working contact element switch (not shown) and / or actuation of a second trigger (e.g., a shark fin switch). Actuation of the working contact element switch transmits a signal to controller 305c indicating the start of fastener drive operation. Method 600 then proceeds to step 625.

[0073] In step 625, the software of controller 305c isolates the sensor inputs received from one or more sensors 85 from the determination of the subsequent mechanism control scheme. Controller 305c generates a signal in response to the actuation of trigger 26 to initiate the isolation of the sensor inputs received from one or more sensors 85 from the subsequent mechanism control scheme via the software of controller 305c. For example, during software isolation, one or more input units 345c receive multiple signals from one or more sensors 85 during a fastener drive cycle and store the multiple signals from one or more sensors 85 in memory 330c. Isolating the multiple signals from one or more sensors 85 from the determination of the subsequent mechanism control scheme during a fastener drive cycle (e.g., during a first mechanism control scheme) prevents the determination of a second mechanism control scheme, as described further below. In some embodiments, the isolation of the multiple signals from one or more sensors 85 from the determination of the second mechanism control scheme actuates a timer of controller 305c corresponding to the timing of a fastener drive cycle of the motor. This fastener drive cycle can be the time between when the motor 46 starts driving the crank arm assembly 54 from a starting position (e.g., when the compressor piston 42 is in or near the BDC position) and when the crank arm assembly 54 drives the compressor piston 42 to complete the fastener drive cycle (e.g., when the compressor piston 42 returns to the BDC position). Once method 600 isolates the controller 305c from the memory 330c, method 600 proceeds to step 630.

[0074] In step 630, controller 305c controls motor 46 via one or more output units 350c based on a first control scheme determined in step 615. At least one of the one or more output units 350c is electrically connected to motor 46. Based on the timing of the fastener drive cycle, controller 305c determines multiple time intervals (e.g., a first time, a second time, a third time, a fourth time, etc.). The first mechanism control scheme further includes driving and electrically braking motor 46 at multiple determined time intervals within multiple durations corresponding to the duty cycle of a PWM signal. Electrically braking motor 46 may include electrically shorting the wires of motor 46 together for a predetermined duration. Method 600 further includes applying a series of voltage pulses to motor 46. For example, the voltage pulses may correspond to the duty cycle of a PWM signal. For example, in a complete fastener drive cycle, controller 305c applies a PWM signal at a first time (e.g., a first drive interval) to drive motor 46 for a first duration (e.g., a first duty cycle) (i.e., compressing air via compressor piston 42 and releasing drive piston 62); at a second time (e.g., a first braking interval) to electrically brake motor 46 for a first duration (i.e., slowing down or stopping motor 46 and allowing residual pressure to dissipate); at a third time (e.g., a second drive interval) to drive motor 46 for a third duration (e.g., a second duty cycle) (i.e., returning compressor piston 42 to the BDC position and creating a vacuum to reset drive piston 62 to the TDC position); and at a fourth time (e.g., a second braking interval) to electrically brake motor 46 for a second duration (i.e., stopping compressor piston 42 at or near the BDC position for subsequent fastener drive cycles). This ensures that compressor piston 42 returns to the BDC position before subsequent fastener drive cycles.

[0075] In some embodiments, the motor 46 drives the crank arm assembly 54 in a first direction during a first fastener drive cycle of the motor 46, wherein a fastener drive cycle is the time between when the motor 46 begins to drive the crank arm assembly 54 from a starting position (e.g., when the compressor piston 42 is in or near the BDC position) and when the crank arm assembly 54 drives the compressor piston 42 to the TDC position and continues to the vicinity of the BDC position, thus completing the fastener drive cycle. Then, in a second fastener drive cycle of the motor 46, the motor 46 may drive the crank arm assembly 54 in a second direction opposite to the first direction. The motor 46 may drive the crank arm assembly 54 alternately in this manner in alternating cycles. For example, in the first, third, fifth, and so on cycles, the motor 46 may drive the crank arm assembly 54 in a clockwise direction, while in the second, fourth, sixth, and so on cycles, the motor 46 may drive the crank arm assembly 54 in a counterclockwise direction. Method 600 then proceeds to step 635.

[0076] In step 635, controller 305c determines the completion of the fastener drive cycle based on the completion of the first mechanism control scheme. The completion of the mechanism control scheme is determined by a timer that times the return of compressor piston 42 to the BDC position. In some embodiments, the completion of the fastener drive cycle may correspond to the end of actuation of trigger 26 or other switches. In other embodiments, the completion of the fastener drive cycle may correspond to the end of a timer in controller 305c. Upon completion of the fastener drive cycle, controller 305c terminates the indication via its software that the sensor inputs received from one or more sensors 85 are isolated from the subsequent mechanism control scheme determination software, thereby allowing controller 305c to process multiple signals from one or more sensors 85 stored in memory 330c. The method then proceeds to step 640.

[0077] In step 640, controller 305c receives data from memory 330c indicating a fastener drive cycle corresponding to the first mechanism control scheme, as described in more detail below. Only after the fastener drive cycle is completed does memory 330c transmit data via electronic communication with controller 305c. Method 600 then proceeds to step 645. In step 645, controller 305c determines a second mechanism control scheme based on the data received from memory 330c. In some embodiments, the first mechanism control scheme is adjusted based on the received data indicating the fastener drive cycle to determine the second control scheme. After determining the second control scheme, method 600 returns to step 620, where controller 305c waits for a signal indicating the start of the second fastener drive cycle. In some embodiments, fastener driver 10 may wait for the start of the second fastener drive cycle until a second actuation of trigger 26 or other switch occurs.

[0078] Figure 16 This is a flowchart illustrating a method 700 for collecting data indicating the results of a fastener drive cycle via memory 330c, according to some embodiments. It should be understood that the order of the steps disclosed in method 700 can vary. For example, additional steps can be added to the process, and not all steps may be necessary, or steps shown in one order may occur in a second order. Method 700 begins at step 705, where memory 330c receives a signal for initiating operation of a power tool (e.g., powering on the power tool). Method 700 then proceeds to step 710.

[0079] In step 710, similar to step 625 of method 600, sensor inputs received from one or more sensors 85 are isolated from the determination of a subsequent mechanism control scheme via software isolation. For example, software isolation can prevent the determination of a second mechanism control scheme during a fastener drive cycle. Controller 305c generates a signal in response to actuation of trigger 26 to initiate software isolation via controller 305c of multiple signals from one or more sensors 85 from the determination of a subsequent mechanism control scheme. Isolating multiple signals from one or more sensors 85 from the determination of a subsequent mechanism control scheme prevents processing of data indicating the state of the fastener drive cycle. Method 700 then proceeds to step 715. In step 715, memory 330c clears any previously stored data indicating data collected during a previous fastener drive cycle. The method then proceeds to step 720.

[0080] In step 720, memory 330c receives multiple signals from one or more sensors 85 indicating the position of compressor piston 42 during a fastener drive cycle via one or more input units 345c. The multiple signals indicate when each of the one or more sensors 85 is activated by an end-mounted magnet of piston pin 82 corresponding to the position of compressor piston 42 throughout the operating cycle. For example, the multiple signals may include data indicating when compressor piston 42 is in the BDC position, when compressor piston 42 reaches the peak torque position, and when compressor piston 42 reaches the TDC position. When memory 330c receives one or more of the multiple signals, memory 330c initiates a data collection control timer corresponding to the duration of a timer used for a complete fastener drive operation (e.g., the duration for which compressor piston 42 returns to the BDC position). Method 700 then proceeds to step 725.

[0081] In step 725, memory 330c stores data indicating the activation of one or more sensors 85 during the fastener drive cycle. When each of the one or more sensors 85 is off (indicating when the compressor piston 42 reaches the peak torque position and when the compressor piston 42 reaches the TDC position), memory 330c measures the voltage of battery pack 355 and stores the measured voltage during the fastener drive cycle. Method 700 then proceeds to step 730. In step 730, similar to step 635 of method 600, controller 305c terminates the indication via software of controller 305c to isolate multiple signals from one or more sensors 85 from the subsequent determination software of mechanism control scheme, thereby allowing controller 305c to process the multiple signals from one or more sensors 85 stored in memory 330c. Method 700 then proceeds to step 735.

[0082] In step 735, memory 330c transmits data indicating the activation of one or more sensors 85 to controller 305c only after the fastener drive cycle is completed. Method 700 returns to step 710, where memory 330c awaits a signal from controller 305c to initiate software via controller 305c to determine the isolation of multiple signals from one or more sensors 85 from subsequent mechanism control schemes. In some embodiments, if compressor piston 42 has not fully returned to the BDC position upon completion of the fastener drive cycle, controller 305c may use data indicating the position of compressor piston 42 and a measured battery voltage from memory 330c to control motor 46 to automatically return compressor piston 42 to the BDC position. In some embodiments, controller 305c may automatically apply PWM signals to multiple FETs connected to motor 46 to drive crank arm assembly 54 in the direction that returns compressor piston 42 to the BDC position. In other embodiments, controller 305c may apply PWM signals to a plurality of FETs connected to motor 46 to drive crank arm assembly 54 in the direction that returns compressor piston 42 to BDC position after fastener drive cycle is completed.

[0083] Although the subject matter has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope of one or more independent aspects of the subject matter described.

Claims

1. A method for controlling a motor of a power tool, the method comprising: A load test is performed on the battery pack of the power tool via the first controller; The first controller determines the control scheme for the first mechanism based on the load test. The first controller receives an input instructing the power tool to begin its operating cycle. Isolate the first controller from the second controller; While the first controller is isolated from the second controller, the motor of the power tool is controlled by the first controller based on the first mechanism control scheme; A dataset indicating the results of the operation cycle of the power tool based on the first mechanism control scheme, sensed via one or more sensors; The dataset is received via the second controller; When the operation cycle is completed, the first controller is connected to the second controller; When the operation cycle is completed, the dataset is transmitted from the second controller to the first controller; as well as The first controller determines the control scheme for the second mechanism based on the dataset.

2. The method of claim 1, further comprising: The first controller receives a second user input instructing the start of a second operating cycle of the power tool. While the first controller is isolated from the second controller, the motor of the power tool is controlled by the first controller based on the second mechanism control scheme.

3. The method as described in claim 1, wherein, The first mechanism control scheme includes applying a pulse width modulation (PWM) signal to control the motor.

4. The method of claim 1, wherein, The first mechanism control scheme includes applying a braking signal to control the motor.

5. The method of claim 1, wherein, The one or more sensors are Hall effect sensors.

6. The method of claim 5, wherein, The method further includes: The position of the first piston of the power tool is sensed via one or more sensors.

7. The method of claim 1, wherein, Isolating the first controller from the second controller prevents data communication while the motor is powered by an external circuit.

8. The method of claim 1, wherein, The second mechanism control scheme is implemented for the second operating cycle of the power tool.

9. A method for controlling a motor of a power tool, the method comprising: The motor is electrically braked based on a first mechanism control scheme via commands from the first controller; The first controller detects the completion of the motor's operating cycle; When the operation cycle is completed, a dataset indicating the position of the first piston of the power tool is transmitted to the first controller via the second controller; as well as The first controller determines the control scheme for the second mechanism based on the dataset. During this operation cycle, the first controller is isolated from the second controller.

10. The method of claim 9, wherein, The electrically braked motor includes dynamic braking using multiple motor control field-effect transistors (FETs).

11. The method of claim 9, wherein, The second mechanism control scheme is implemented for the second operating cycle of the power tool.

12. The method of claim 9, wherein, The first mechanism control scheme is based on load testing of the power tool's battery pack.

13. The method of claim 9, wherein, This operation cycle includes: Drive the motor during the first drive time interval; The motor is dynamically braked during the first braking time interval; The motor is driven during the second drive time interval. The second driving time interval is different from the first driving time interval; The motor is dynamically braked during the second braking time interval. The second braking time interval is different from the first braking time interval.

14. A power-driven fastener driver, comprising: First cylinder; A first piston, which is positioned within the first cylinder, is movable between the top dead center (TDC) position and the bottom dead center (BDC) position; The second cylinder is in fluid communication with the first cylinder; The second piston is positioned within the second cylinder and is capable of moving between the TDC position and the BDC position to initiate the fastener drive cycle. as well as The control system includes a first controller configured to: Based on the first mechanism control scheme, the electric braking motor is used. The motor is driven based on the first mechanism control scheme; Detect the completion of the motor's operating cycle; When the operation cycle is completed, a dataset indicating the position of the first piston of the power tool is received from the second controller; as well as Based on this dataset, a second agency control scheme is determined. During this operation cycle, the first controller is isolated from the second controller.

15. The power fastener driver as claimed in claim 14, wherein, The control system is further configured as follows: Receive a second user input instructing the power tool to begin a second operating cycle; and While the first controller is isolated from the second controller, the motor of the power tool is controlled based on the second mechanism control scheme.

16. The power fastener driver as claimed in claim 14, wherein, Braking the motor involves dynamic braking using multiple motor control field-effect transistors (FETs).

17. The power fastener driver as claimed in claim 14, wherein, The second mechanism control scheme is implemented for the second operating cycle of the power tool.

18. The power fastener driver as claimed in claim 14, wherein, The first mechanism control scheme is based on load testing of the power tool's battery pack.

19. The power fastener driver as claimed in claim 14, wherein, The powered fastener driver further includes one or more sensors configured to sense signals to generate the dataset.

20. The power fastener driver as claimed in claim 19, wherein, The one or more sensors are Hall effect sensors.

21. A non-transitory computer-readable medium storing a program for controlling an electric motor of a power tool, the program including instructions that, when executed by a processor, cause a first controller connected to the processor to implement the method of claim 1.

22. A non-transitory computer-readable medium storing a program for controlling an electric motor of a power tool, the program including instructions that, when executed by a processor, cause a first controller connected to the processor to implement the method of claim 9.

23. A method for controlling a motor of a power tool, the method comprising: The battery pack of the power tool is subjected to a load test via the controller; The controller determines the control scheme for the first mechanism based on the load test. The controller receives input instructing the start of the power tool's operating cycle. The controller isolates sensor inputs from one or more sensors from the determination of the subsequent mechanism control scheme. The controller controls the motor of the power tool based on the first mechanism control scheme, while the sensor inputs of one or more sensors are isolated from the determination of the subsequent mechanism control scheme. A dataset indicating the results of the operation cycle of the power tool based on the first mechanism control scheme, sensed via one or more sensors; The controller receives sensor inputs, including the dataset, via its memory. When the operation cycle is completed, these sensor inputs are connected via the controller, and the subsequent mechanism control scheme is determined. When the operation cycle is completed, the dataset is transferred to the controller via the memory; as well as The controller determines the control scheme for the second mechanism based on the dataset.

24. The method of claim 23, further comprising: The controller receives a second user input instructing the start of a second operating cycle for the power tool. The controller controls the motor of the power tool based on the second mechanism control scheme, while the sensor inputs from one or more sensors are isolated from the determination of the subsequent mechanism control scheme.

25. The method of claim 23, wherein, The first mechanism control scheme includes applying a pulse width modulation (PWM) signal to control the motor.

26. The method of claim 23, wherein, The first mechanism control scheme includes applying a braking signal to control the motor.

27. The method of claim 23, wherein, The one or more sensors are Hall effect sensors.

28. The method of claim 27, wherein, The method further includes: The position of the first piston of the power tool is sensed via one or more sensors.

29. The method of claim 23, wherein, The controller isolates sensor inputs from one or more sensors from the determination of the subsequent mechanism control scheme, preventing the data set from being processed by the controller while the motor is powered by an external circuit.

30. The method of claim 23, wherein, The second mechanism control scheme is implemented for the second operating cycle of the power tool.

31. A power-driven fastener driver, comprising: First cylinder; A first piston, which is positioned within the first cylinder, is movable between the top dead center (TDC) position and the bottom dead center (BDC) position; The second cylinder is in fluid communication with the first cylinder; The second piston is positioned within the second cylinder and is capable of moving between the TDC position and the BDC position to initiate the fastener drive cycle. as well as The control system includes a controller configured to: Based on the first mechanism control scheme, the electric braking motor is used. The motor is driven based on the first mechanism control scheme; Detect the completion of the motor's operating cycle; When the operation cycle is completed, sensor inputs are received from the controller’s memory, including a dataset indicating the position of the first piston of the power tool; as well as Based on this dataset, a second agency control scheme is determined. During this operating cycle, sensor inputs from one or more sensors are isolated from the determination of the subsequent mechanism control scheme by the controller.

32. The power fastener driver as claimed in claim 31, wherein, The control system is further configured as follows: Receive a second user input instructing the power tool to begin a second operating cycle; and The second mechanism control scheme controls the motor of the power tool, while the sensor inputs from one or more sensors are isolated from the determination of the subsequent mechanism control scheme.

33. The power fastener driver as claimed in claim 31, wherein, Braking the motor involves dynamic braking using multiple motor control field-effect transistors (FETs).

34. The power fastener driver as claimed in claim 31, wherein, The second mechanism control scheme is implemented for the second operating cycle of the power tool.

35. The power fastener driver as claimed in claim 31, wherein, The first mechanism control scheme is based on load testing of the power tool's battery pack.

36. The power fastener driver as claimed in claim 31, wherein, The one or more sensors are Hall effect sensors.

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