System and method for detecting clutch disengagement

Abstract

A clutch disengagement detection system (200) for a fastening tool (100) can include a clutch (150) that can operably couple a drive assembly (140) to an output spindle (160) based on an output torque and a predetermined torque threshold, a flange (210) that can be displaced along a rotational axis (165) of the output spindle (160) and the drive assembly (140), an arm (220) that can be displaced along an arm axis (225) in response to the flange (210) being displaced along the rotational axis (165), a magnet (230) that can be disposed at the arm (220), a Hall effect sensor (240), and a processing circuit (180) that can be operably coupled to the Hall effect sensor (240) and can be configured to convert an analog signal from the Hall effect sensor (240) into a digital form clutch disengagement signal. The processing circuit (180) can use the clutch disengagement signal to determine when the clutch (150) is engaging and disengaging the drive assembly (140) and the output spindle (160).

Description

Technical Field

[0001] The exemplary embodiments generally relate to power tools, and more specifically to improvements for handheld fastening tools. Background Technology

[0002] Fastening tools are commonly used in commercial and private settings to tighten various types of fasteners for a variety of purposes. Often referred to as nut wrenches and screwdrivers, fastening tools are frequently used in assembly or disassembly setups. In an exemplary setup, multiple different operators may simultaneously operate individual fastening tools to tighten various fasteners. In some cases, multiple different operators may work at the same step on an assembly line of an object, but in other cases, multiple different operators may work on a variety of different tasks. In this regard, the various different tasks may require fasteners to be tightened to different torque levels depending on the specific task. Thus, fastening tools can be operated differently depending on the required usage.

[0003] The nature of fastening fasteners with fastening tools requires the tool to apply torque to the fastener to induce rotational movement. Due to the high levels of torque applied by fastening tools, and depending on the application, over-tightening or under-tightening of fasteners is not only possible but common. In some cases, over-tightening and under-tightening of fasteners may be due to errors in detecting the clutch disengagement signal, which indicates when the tool's clutch disengages the output spindle from the drive assembly in response to reaching the desired torque rating. In many cases, the current state of clutch disengagement signal detection results in mechanical wear on the corresponding components, which can significantly reduce their usable life. Therefore, a fastening tool may fail to detect clutch disengagement due to component failure. Therefore, developing fastening tools capable of detecting clutch disengagement signals without causing significant mechanical wear on these components can reduce the likelihood of errors in clutch disengagement signal detection and improve the service life of the tool and its components. Summary of the Invention

[0004] Some exemplary embodiments provide a clutch disengagement detection system for fastening tools. The system may include: a clutch operably coupling a drive assembly to an output spindle, the clutch being configured to alternately engage and disengage the output spindle and drive assembly based on an output torque and a predetermined torque threshold; a flange operably coupled to the clutch, the flange being displaceable along the rotational axis of the output spindle and drive assembly; an arm operably coupled to the flange, the arm being displaceable along an arm axis in response to displacement of the flange along the rotational axis; a magnet disposed at a fixed position on the arm; a Hall effect sensor disposed near the arm such that the magnet is movable relative to the Hall effect sensor as the arm displaces; and processing circuitry operably coupled to the Hall effect sensor and configured to convert an analog signal from the Hall effect sensor into a digital clutch disengagement signal. The processing circuitry can use the clutch disengagement signal to determine when the clutch engages and disengages the drive assembly and output spindle.

[0005] Some exemplary embodiments may provide a fastening tool for applying torque to a fastener. The fastening tool may include a housing, a motor disposed within the housing and configured to generate output torque, a power source configured to supply power to the motor, a trigger configured to control the rotational speed of the motor, an output spindle configured to be operatively coupled to a fastener located at a first end of an output spindle, a drive assembly operatively coupled to the motor and to a second end of the output spindle to transmit output torque to the output spindle, and a clutch disengagement detection system. A clutch disengagement detection system may include: a clutch operably coupled to an output spindle, the clutch being configured to alternately engage and disengage the output spindle and the drive assembly based on an output torque and a predetermined torque threshold; a flange operably coupled to the clutch, the flange being displaceable along the rotational axes of the output spindle and the drive assembly; an arm operably coupled to the flange, the arm being displaceable along an arm axis in response to the flange's displacement along the rotational axis; a magnet disposed at a fixed position on the arm; a Hall effect sensor disposed near the arm such that the magnet can move relative to the Hall effect sensor as the arm displaces; and processing circuitry operably coupled to the Hall effect sensor and configured to convert analog signals from the Hall effect sensor into a digital clutch disengagement signal. The processing circuitry can use the clutch disengagement signal to determine when the clutch engages and disengages the drive assembly and the output spindle.

[0006] Some exemplary embodiments provide a method for detecting clutch disengagement in a fastening tool. The tool may include: a clutch operably coupling a drive assembly to an output spindle, the clutch being configured to alternately engage and disengage the output spindle and drive assembly based on an output torque and a predetermined torque threshold; a flange operably coupled to the clutch, the flange being displaceable along the rotational axis of the output spindle and drive assembly; an arm operably coupled to the flange, the arm being displaceable along an arm axis in response to displacement of the flange along the rotational axis; a magnet disposed at a fixed position on the arm; a Hall effect sensor disposed near the arm such that the magnet is movable relative to the Hall effect sensor as the arm displaces; and processing circuitry operably coupled to the Hall effect sensor and configured to convert an analog signal from the Hall effect sensor into a digital clutch disengagement signal. The method may include recording the analog signal from the magnet using the Hall effect sensor, converting the analog signal into a digital clutch disengagement signal via logic circuitry, and using the clutch disengagement signal and the logic circuitry to determine when the clutch disengages from the drive assembly and output spindle. Attached Figure Description

[0007] Some exemplary embodiments have already been described in general terms. Reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and in which: Figure 1 A schematic overall view of a fastening tool for driving fasteners according to an exemplary embodiment is shown; Figure 2 A close-up schematic diagram of a clutch disengagement detection system according to an exemplary embodiment is shown, wherein the clutch is engaged; Figure 3 A close-up schematic diagram of a clutch disengagement detection system according to an exemplary embodiment is shown, wherein the clutch is disengaged; Figure 4 A partial cross-sectional view of a fastening tool according to an exemplary embodiment is shown; Figure 5 A graph of an analog signal from a Hall effect sensor over time is shown according to an exemplary embodiment; Figure 6 A schematic diagram of a logic circuit according to an exemplary embodiment is depicted; and Figure 7 A block diagram of a method for detecting clutch disengagement in a fastening tool according to an exemplary embodiment is shown. Detailed Implementation

[0008] Some exemplary embodiments will now be described more fully below with reference to the accompanying drawings, which illustrate some, but not all, exemplary embodiments. In fact, the examples described and depicted herein should not be construed as limiting the scope, applicability, or configuration of this disclosure. Rather, these exemplary embodiments are provided to enable this disclosure to meet applicable legal requirements. Throughout the document, the same reference numerals refer to the same elements. Furthermore, as used herein, the term “or” will be interpreted as a logical operator that results in a true value whenever one or more of its operands are true. As used herein, an operable connection should be understood to refer to a direct or indirect connection, in either case, that enables the functional interconnection of components operably connected to each other.

[0009] Figure 1 A schematic general view of a fastening tool 100 for driving a fastener 110 according to an exemplary embodiment is shown. The fastening tool 100 may include a power source 120, a motor 130, a drive assembly 140, a clutch 150, an output spindle 160, an end effector 170, and processing circuitry 180, all of which may be housed within or operatively coupled to a housing 190. In this respect, the fastening tool 100 may be embodied as a nut wrench, a cordless screwdriver, a drill, etc., to which the fastener 110 may be operatively coupled for being driven by the fastening tool 100. The motor 130 may be housed within the housing 190 and operatively coupled to other components, such as the power source 120 and the drive assembly 140. The motor 130 may draw power from the power source 120 (possibly via the processing circuitry 180) to generate an output torque capable of driving the fastener 110. The drive shaft of motor 130 can be operatively coupled to drive assembly 140, which may include multiple gears. In some cases, the gears of drive assembly 140 can reduce the rotational speed of the drive shaft and increase the output torque. In this respect, fastening tool 100 can therefore be configured to direct power from power source 120 to motor 130 in response to operator actuation of trigger 135. In this respect, the operator can actuate trigger 135, which can send an actuation signal to processing circuitry 180 indicating the degree to which trigger 135 can be actuated. Processing circuitry 180 can then use the actuation signal to determine how much power from power source 120 can be directed to motor 130, which can thereby indicate the rotational speed of motor 130.

[0010] Processing circuitry 180 may be configured to provide electronic control inputs to one or more functional units of fastening tool 100 and to process data received at or generated therefrom at one or more functional units of fastening tool 100, such as motor 130 and clutch 150. Therefore, according to exemplary embodiments, processing circuitry 180 may be configured to perform data processing, control function execution, and / or other processing and management services. In some embodiments, processing circuitry 180 may be embodied as a chip or chipset. In other words, processing circuitry 180 may include one or more physical packages (e.g., chips) comprising materials, components, and / or wires on structural components (e.g., a substrate such as a printed circuit board (PCB)). Structural components may provide physical strength, dimensional retention, and / or electrical interaction constraints for component circuitry included thereon. Therefore, in some cases, processing circuitry 180 may be configured to implement embodiments of the invention on a single chip or as a single “system-on-a-chip.” Therefore, in some cases, a chip or chipset may constitute means for performing one or more operations to provide the functions described herein.

[0011] In an exemplary embodiment, processing circuitry 180 may include one or more instances of processor 182 and memory 184, which may communicate with or otherwise control other components or modules that interface with processing circuitry 180. Thus, processing circuitry 180 may be embodied as a circuit chip (e.g., an integrated circuit chip) configured (e.g., utilizing hardware, software, or a combination of hardware and software) to perform the operations described herein. In some embodiments, processing circuitry 180 may be embodied as part of an onboard computer housed in housing 190 to control the operation of fastening tool 100.

[0012] In some cases, in response to actuation of trigger 135, motor 130 can generate a relatively high rotational speed at its drive shaft. In this case, drive assembly 140 can reduce the rotational speed from motor 130 to a more suitable rotational speed at output spindle 160, which can correspond to increased output torque. In this regard, drive assembly 140 may include a reducer, which may include an input gear and an output gear. The output gear may have more teeth than the input gear, and the output gear may also have a larger diameter than the input gear. Therefore, the input gear may complete more than one full rotation in each full rotation of the output gear, or in other words, the output gear may rotate slower than the input gear. The result of the reducer will obviously include a lower rotational speed after the reducer (i.e., at the output spindle), but additionally, the output torque can be increased by the gear ratio of drive assembly 140, thereby providing higher output torque to effectively drive fastener 110.

[0013] Output torque can be transmitted from drive assembly 140 to output spindle 160 and end effector 170 via clutch 150. Therefore, fastening tool 100 can be used to tighten fastener 110 in response to operably engaging end effector 170 to fastener 110 and actuating trigger 135 to generate output torque via motor 130. In an exemplary embodiment, power source 120 can be a power source, such as an AC-to-DC converter connected to a mains power supply or a battery supplying DC current to motor 130. In some other cases, power source 120 can be a compressed air source, and motor 130 and therefore fastening tool 100 can be pneumatic.

[0014] In some cases, the clutch 150 may define a predetermined torque threshold, and the fastening tool 100 may tighten the fastener 110 to this predetermined torque threshold so that the fastener 110 is considered properly tightened. (See below for reference.) Figure 2 and 3 The clutch 150 can be configured to disengage in response to reaching a predetermined torque threshold. Therefore, the disengagement of the clutch 150 can indicate the complete and successful tightening of the fastener 110. In this respect, the clutch 150 can rotatably and operably connect the drive assembly 140 to the output spindle 160 at a 1:1 ratio until the predetermined torque threshold is reached. Once the predetermined torque threshold is reached, the clutch 150 disengages and a clutch disengagement signal is generated. In some cases, the clutch disengagement signal can trigger the motor 130 to shut down. In other cases, the clutch disengagement signal can simply notify the processing circuitry 180 of the moment the clutch 150 disengages.

[0015] Now for reference Figure 2-5 , Figure 2 and 3 Close-up schematic diagrams of the clutch disengagement detection system 200 during clutch engagement and disengagement according to an exemplary embodiment are shown. Figure 4 A partial cross-sectional view of a fastening tool 100 according to an exemplary embodiment is shown. A clutch disengagement detection system 200 of some exemplary embodiments may include a clutch 150, a flange 210, an arm 220, a magnet 230, a Hall effect sensor 240, and processing circuitry 180. Figure 2 and 3 The diagram also shows a motor 130, a drive assembly 140, and an output spindle 160 to illustrate how the clutch disengagement detection system 200 is operatively coupled to other components of the fastening tool 100.

[0016] In some embodiments, the clutch 150 may be a ball and pawl type torque limiter. In this respect, the clutch 150 may rely on balls or rollers that can be disposed in pawls formed between two clutch plates, the two clutch plates being able to pass through a spring 250 (see...). Figure 4 The spring forces are biased together. To transmit torque from the drive assembly 140 to the output spindle 160, balls or rollers can be held in their respective pawls and rolled into place to transmit torque from a first clutch plate 152 operably coupled to the drive assembly 140 to a second clutch plate 154 operably coupled to the output spindle 160. The output spindle 160 can remain rotated as long as the second clutch plate 154 can rotate with the amount of torque transmitted by the first clutch plate 152. Figure 2 The state shown is as depicted. However, in some embodiments, the clutch 150 can be configured such that the balls or rollers can roll out of their respective pawls, and the first and second clutch plates 152, 154 can disengage from each other at a predetermined torque threshold, which may be... Figure 3 The state depicted is as follows. In other words, clutch plates 152 and 154 can rely on spring force to hold the balls in their respective pawls and continue to transmit torque from drive assembly 140 to output spindle 160. Once clutch plates 152 and 154 require an amount of torque from drive assembly 140 equal to a predetermined torque threshold to maintain rotation of output spindle 160, the spring force holding the two clutch plates 152 and 154 engaged via the balls can be overcome by torque from motor 130, and thus the balls can roll out of their pawls and disengage clutch 150. Once clutch plates 152 and 154 are disengaged, they may no longer transmit torque from drive assembly 140 to output spindle 160, but can rotate independently of each other. In this respect, clutch 150 is configured to transmit all torque up to a predetermined torque threshold from drive assembly 140 to output spindle 160, but once the output torque reaches the predetermined torque threshold and clutch 150 is disengaged, clutch 150 can stop transmitting torque from drive assembly 140 to output spindle 160. Therefore, the spring force between clutch 150 and the corresponding clutch plates 152, 154 can define a predetermined torque threshold for the fastening tool 100. In some embodiments, the spring force can be adjustable, and the operator can set their desired predetermined torque threshold before operating the fastening tool 100. In some embodiments, clutch 150 can be a slipper clutch or any other suitable type of clutch mechanism.

[0017] When the first clutch plate 152 and the second clutch plate 154 are in contact with each other, the clutch disengagement detection system 200 can determine that the clutch 150 can engage and can generate a clutch disengagement signal accordingly. The clutch disengagement detection system 200 can determine this based on the position of its components. In this regard, the flange 210 can be operatively coupled to the clutch 150 and the arm 220. The flange 210 can be displaced along the axis of rotation 165 of the output spindle 160 and the drive assembly 140. Therefore, the flange 210 can be specifically operatively coupled to the second clutch plate 154. Thus, when the clutch 150 disengages, the second clutch plate 154 displaces away from the first clutch plate 152 along the axis of rotation 165, and then the flange 210 can follow the movement of the second clutch plate 154. In doing so, the flange 210 can carry the arm 220, such that the flange 210 and the arm 220 can move in unison. Therefore, arm 220 can be operably coupled to flange 210 and can be displaced along arm axis 225 in response to displacement of flange 210 along rotation axis 165. Thus, the movement of flange 210 and arm 220 can occur in a 1:1 ratio: for every millimeter of movement of flange 210, arm 220 may also need to move. In some cases, arm axis 225 and rotation axis 165 can be parallel to each other and spaced apart. Thus, flange 210 and arm 220 can move simultaneously relative to each other along their respective axes without altering the operable coupling / spacedness of flange 210 and arm 220. The movement of flange 210 and arm 220 is achieved through… Figure 2 and 3 The difference in position between the central flange 210 and the arm 220 is highlighted.

[0018] In an exemplary embodiment, arm 220 may include a magnet 230 disposed at a fixed position on arm 220. In this respect, magnet 230 may be disposed on the side of arm axis 225 opposite to flange 210. In some cases, magnet 230 may be disposed at the axial end of arm 220, but in other cases, magnet 230 may be disposed at other suitable positions along arm 220. Since magnet 230 may be disposed at a fixed position on arm 220, magnet 230 may also move at a 1:1 ratio with arm 220 and flange 210. The movement of magnet 230 may be restricted to back-and-forth movement in plane 235, which may be configured to be parallel to and spaced apart from arm axis 225. Plane 235 may also be parallel to and spaced apart from PCB including processing circuitry 180. Thus, rotation axis 165, arm axis 225, plane 235, and PCB including processing circuitry 180 may all be spaced apart in a direction perpendicular to the respective axes and the extension direction of the PCB. In this respect, the magnet 230 may not need to contact the PCB including the processing circuitry 180. The Hall effect sensor 240 may be positioned near the arm 220 such that the magnet 230 can move relative to the Hall effect sensor 240 when the arm 220 can be displaced. In some cases, the Hall effect sensor 240 may be positioned on the side of the processing circuitry 180 opposite to the magnet 230, such that the PCB can be positioned between the Hall effect sensor 240 and the magnet 230. In an exemplary embodiment, the Hall effect sensor 240 may be positioned at the axial end of the PCB including the processing circuitry 180. Therefore, when the magnet 230 moves back and forth on the processing circuitry 180, the magnet 230 may also need to move back and forth on the Hall effect sensor 240. This can cause the Hall effect sensor to generate an analog signal indicating the input voltage 260 sensed by the magnet 230.

[0019] In other words, when the clutch disengagement detection system 200 is in Figure 2 In the position shown, where the clutch 150 can engage, the magnet 230 can be left out of the vicinity of the Hall effect sensor 240, and therefore the Hall effect sensor 240 may not generate an analog signal. However, in response to the clutch 150 disengaging at a predetermined torque threshold, the second clutch disc 154 can move the flange 210, which in turn moves the arm 220, which in turn moves the magnet 230 relative to the Hall effect sensor 240. At the point in time when the magnet 230 can be positioned closest to the Hall effect sensor 240, the analog signal can reach its peak, or in other words, the input voltage 260 can reach its peak input voltage 270. The analog signal can be represented by the interaction between the magnet 230 and the Hall effect sensor 240. Figure 5The curve shown generates an input voltage 260. A peak input voltage 270 can occur when the magnet 230 is at its closest point to the Hall effect sensor 240 during its path of motion in its plane 235. Processing circuitry 180 can be operatively coupled to the Hall effect sensor 240 and can be configured to convert the analog signal from the Hall effect sensor 240 into a digital clutch disengagement signal. Processing circuitry 180 can therefore use the clutch disengagement signal to determine when the clutch 150 disengages the drive assembly 140 from the output spindle 160.

[0020] The above and Figure 2-4 The clutch disengagement detection system 200 shown can be improved upon existing examples of currently available clutch disengagement detection systems. For example, some current clutch disengagement detection systems may include the use of a microswitch. In this regard, the microswitch may be operatively coupled to arm 220, and in response to clutch 150 disengagement, arm 220 may trigger the microswitch, causing the microswitch to send a signal to processing circuitry 180 that clutch 150 has disengaged. In this regard, in the above exemplary embodiment of clutch disengagement detection system 200, the microswitch may need to contact arm 220 to trigger the switch. Therefore, the operative coupling of arm 220 to the microswitch may introduce increased mechanical wear on these specific components. This mechanical wear may not only significantly shorten the service life of the microswitch and arm 220, but may also significantly shorten the service life of clutch disengagement detection system 200 as a whole. In this regard, after an extended period of time in which the microswitch and arm 220 may have worn, clutch disengagement detection system 200 may be uniformly or, in some cases, completely stopped to detect when clutch 150 disengaged. Therefore, including a magnet 230 and a Hall effect sensor 240 in the clutch disengagement detection system 200 can minimize the number of parts of the clutch disengagement detection system 200 that may be subject to increased mechanical wear, thereby improving the lifespan and accuracy of the system 200.

[0021] As mentioned above, Figure 5 A graph depicting the input voltage 260 from the Hall effect sensor 240 over time, according to an exemplary embodiment, is shown. Figure 5 In this diagram, arm 220, magnet 230, processing circuitry 180, and Hall effect sensor 240 are overlaid to better illustrate the correlation between the position of magnet 230 relative to Hall effect sensor 240 and the resulting input voltage 260 value. In this respect, in Figure 5At time zero, arm 220 and magnet 230 are positioned in a first position 280, as depicted by the dashed outline of arm 220 and magnet 230. The first position 280 may correspond to clutch 150 being engaged. Arm 220 and magnet 230 can thus move from the first position 280 to a second position 290, where magnet 230 is closest to Hall effect sensor 240, as shown by the solid line depiction of arm 220 and magnet 230. Therefore, in the graph showing input voltage 260, it is clear that input voltage 260 increases as magnet 230 approaches Hall effect sensor 240. Input voltage 260 can increase to a peak input voltage 270, which may occur at the second position 290, where magnet 230 is closest to Hall effect sensor 240. As time continues, clutch 150 can re-engage, which can be seen as arm 220 and magnet 230 moving back to the first position 280, corresponding to the subsequent drop in input voltage 260 after peak input voltage 270. This process can be repeated over time, with arm 220 and magnet 230 oscillating between the first and second positions 280, 290. Therefore, if Figure 5 If the curve in the curve is extended to future times, then the curve can show the repetitive peak indicating the repetitive peak input voltage 270.

[0022] Figure 6A schematic diagram of a logic circuit according to an exemplary embodiment is depicted. In this respect, the processing circuit 180 may include logic circuit 300, which may include amplifier 310 and differential capacitor 320. Logic circuit 300 may be how processing circuit 180 determines whether clutch 150 is disengaged based on input voltage 260. In this respect, amplifier 310 may scale up the input voltage 260 from Hall effect sensor 240 in logic circuit 300. Amplifier 310 may be included in some exemplary embodiments because the amplitude of input voltage 260 generated by Hall effect sensor 240 may be small due to the nature of Hall effect sensor 240 and how it generates input voltage 260 due to the magnetic field of magnet 230. Therefore, in order to bring input voltage 260 to a scale usable by logic circuit 300, amplifier 310 may appropriately scale up input voltage 260. Logic circuit 300 may determine when clutch 150 has disengaged by substantially comparing input voltage 260 after it can be amplified by amplifier 310 with a threshold voltage difference defined by differential capacitor 320. Once the input voltage 260 increases to a point exceeding the threshold voltage difference of the differential capacitor 320, the logic circuit 300 can determine that the clutch 150 has disengaged and the output torque has reached a predetermined torque threshold. The logic circuit 300 can then accordingly generate a digital clutch disengagement signal for the processing circuit 180, thereby converting the analog signal into a digital clutch disengagement signal. In some cases, the threshold voltage difference may correspond to the peak input voltage 270 that can be generated when the magnet 230 and the Hall effect sensor 240 can be arranged in the closest possible range. Figure 6 In the logic circuit 300 shown, all the resistors, capacitors or other values ​​shown on the logic circuit 300 represent non-limiting examples of these values.

[0023] Figure 7 A block diagram of a method for detecting clutch 150 disengagement in a fastening tool 100 is shown. The method may include recording an analog signal from a magnet 230 using a Hall effect sensor 240 in operation 700, and converting the analog signal into a digital clutch disengagement signal by a processing circuit 180 including logic circuitry 300 in operation 710. Finally, the method may also include using the clutch disengagement signal and logic circuitry 300 at operation 720 to determine when the clutch 150 can disengage the drive assembly 140 and the output spindle 160.

[0024] Some exemplary embodiments provide a clutch disengagement detection system for fastening tools. The system may include: a clutch operably coupling a drive assembly to an output spindle, the clutch being configured to alternately engage and disengage the output spindle and drive assembly based on an output torque and a predetermined torque threshold; a flange operably coupled to the clutch, the flange being displaceable along the rotational axis of the output spindle and drive assembly; an arm operably coupled to the flange, the arm being displaceable along an arm axis in response to displacement of the flange along the rotational axis; a magnet disposed at a fixed position on the arm; a Hall effect sensor disposed near the arm such that the magnet is movable relative to the Hall effect sensor as the arm displaces; and processing circuitry operably coupled to the Hall effect sensor and configured to convert an analog signal from the Hall effect sensor into a digital clutch disengagement signal. The processing circuitry can use the clutch disengagement signal to determine when the clutch engages and disengages the drive assembly and output spindle.

[0025] Some embodiments of the clutch disengagement detection system may include additional features, modifications, enhancements, and / or the like to achieve further objectives or enhance system performance. Additional features, modifications, enhancements, etc., can be added in any combination of each other. Below is a list of various additional features, modifications, and enhancements that can be added to each other individually or in any combination. For example, the arm axis and the rotation axis may be parallel and spaced apart from each other. In an exemplary embodiment, a magnet may be disposed on the side of the arm axis opposite to the flange. In some cases, the flange may carry the arm such that the flange and the arm can move in unison. In an exemplary embodiment, a Hall effect sensor may be operatively coupled to the side of a printed circuit board of processing circuitry opposite to the arm, such that the printed circuit board may be disposed between the Hall effect sensor and the magnet. In some cases, the processing circuitry may include logic circuitry including an amplifier and a differential capacitor. In an exemplary embodiment, the analog signal from the Hall effect sensor may be an input voltage. In some cases, the amplifier may scale up the input voltage from the Hall effect sensor in the logic circuitry. In an exemplary embodiment, the differential capacitor may include a threshold voltage difference, which may correspond to the peak input voltage generated when the magnet and the Hall effect sensor can be arranged to be closest to each other. In some cases, in response to the input voltage exceeding the threshold voltage difference, the logic circuitry may determine that the clutch may have disengaged the output spindle from the drive assembly, and that the output torque may have reached a predetermined torque threshold.

[0026] Some exemplary embodiments may provide a fastening tool for applying torque to a fastener. The fastening tool may include a housing, a motor disposed within the housing and configured to generate output torque, a power source configured to supply power to the motor, a trigger configured to control the rotational speed of the motor, an output spindle configured to be operatively coupled to a fastener located at a first end of an output spindle, a drive assembly operatively coupled to the motor and to a second end of the output spindle to transmit output torque to the output spindle, and a clutch disengagement detection system. A clutch disengagement detection system may include: a clutch operably coupled to an output spindle, the clutch being configured to alternately engage and disengage the output spindle and the drive assembly based on an output torque and a predetermined torque threshold; a flange operably coupled to the clutch, the flange being displaceable along the rotational axes of the output spindle and the drive assembly; an arm operably coupled to the flange, the arm being displaceable along an arm axis in response to the flange's displacement along the rotational axis; a magnet disposed at a fixed position on the arm; a Hall effect sensor disposed near the arm such that the magnet can move relative to the Hall effect sensor as the arm displaces; and processing circuitry operably coupled to the Hall effect sensor and configured to convert analog signals from the Hall effect sensor into a digital clutch disengagement signal. The processing circuitry can use the clutch disengagement signal to determine when the clutch engages and disengages the drive assembly and the output spindle.

[0027] Some exemplary embodiments provide a method for detecting clutch disengagement in a fastening tool. The tool may include: a clutch operably coupling a drive assembly to an output spindle, the clutch being configured to alternately engage and disengage the output spindle and drive assembly based on an output torque and a predetermined torque threshold; a flange operably coupled to the clutch, the flange being displaceable along the rotational axis of the output spindle and drive assembly; an arm operably coupled to the flange, the arm being displaceable along an arm axis in response to displacement of the flange along the rotational axis; a magnet disposed at a fixed position on the arm; a Hall effect sensor disposed near the arm such that the magnet is movable relative to the Hall effect sensor as the arm displaces; and processing circuitry operably coupled to the Hall effect sensor and configured to convert an analog signal from the Hall effect sensor into a digital clutch disengagement signal. The method may include recording the analog signal from the magnet using the Hall effect sensor, converting the analog signal into a digital clutch disengagement signal via logic circuitry, and using the clutch disengagement signal and the logic circuitry to determine when the clutch disengages from the drive assembly and output spindle.

[0028] Benefiting from the teachings presented in the foregoing description and associated drawings, those skilled in the art will conceive of many modifications and other embodiments of the invention set forth herein. Therefore, it should be understood that the invention is not limited to the specific embodiments disclosed, and that modifications and other embodiments are intended to be included within the scope of the appended claims. Furthermore, although exemplary embodiments have been described in the foregoing description and associated drawings in the context of certain exemplary combinations of elements and / or functions, it should be understood that different combinations of elements and / or functions may be provided by alternative embodiments without departing from the scope of the appended claims. In this regard, for example, combinations of elements and / or functions different from those explicitly described above are also considered to be set forth in some of the appended claims. Where advantages, benefits, or solutions to problems are described herein, it should be understood that such advantages, benefits, and / or solutions may be applicable to some exemplary embodiments but not necessarily to all exemplary embodiments. Therefore, any advantages, benefits, or solutions described herein should not be considered critical, necessary, or indispensable to all embodiments or the embodiments claimed herein. Although specific terms are used herein, they are used only in a general and descriptive sense and not for limiting purposes.

Claims

1. A clutch disengagement detection system for fastening tools, the system comprising: A clutch that operatively connects a drive assembly to an output spindle, the clutch being configured to alternately engage and disengage the output spindle and the drive assembly based on an output torque and a predetermined torque threshold. A flange operably coupled to the clutch, the flange being displaceable along the rotational axes of the output spindle and the drive assembly; An arm operably coupled to the flange, the arm being displaced along the arm axis in response to displacement of the flange along the axis of rotation; A magnet, which is positioned at a fixed location on the arm; A Hall effect sensor is positioned close to the arm such that when the arm is displaced, the magnet moves relative to the Hall effect sensor. and A processing circuit, operably coupled to the Hall effect sensor and configured to convert the analog signal from the Hall effect sensor into a digital clutch disengagement signal, The processing circuit uses the clutch disengagement signal to determine when the clutch disengages from the drive assembly and the output spindle.

2. The system according to claim 1, wherein, The arm axis and the rotation axis are parallel to each other and spaced apart.

3. The system of claim 1, wherein the magnet is disposed on the side of the arm axis opposite to the flange.

4. The system of claim 1, wherein the flange carries the arm such that the flange and the arm move in unison.

5. The system according to claim 1, wherein, The Hall effect sensor is operatively coupled to the side of the printed circuit board of the processing circuit opposite to the arm, such that the printed circuit board is disposed between the Hall effect sensor and the magnet.

6. The system of claim 1, wherein the processing circuitry includes logic circuitry, the logic circuitry including an amplifier and a differential capacitor.

7. The system of claim 6, wherein the analog signal from the Hall effect sensor is an input voltage, and The amplifier therein amplifies the input voltage from the Hall effect sensor in the logic circuit proportionally.

8. The system according to claim 7, wherein, The differential capacitor includes a threshold voltage difference corresponding to the peak input voltage generated when the magnet and the Hall effect sensor are arranged to be closest to each other.

9. The system according to claim 8, wherein, In response to the input voltage exceeding the threshold voltage difference, the logic circuit determines that the clutch has disengaged the output spindle from the drive assembly and that the output torque has reached the predetermined torque threshold.

10. A fastening tool for applying torque to a fastener, the fastening tool comprising: case; A motor, which is disposed within the housing and configured to generate output torque; A power source configured to supply power to the motor; A trigger configured to control the rotational speed of the motor; An output spindle is configured to be operably coupled to a fastener located at a first end of the output spindle; A drive assembly operatively coupled to the motor and a second end of the output spindle to transmit the output torque to the output spindle; and Clutch disengagement detection system, the clutch disengagement detection system comprising: A clutch that operatively connects the drive assembly to the output spindle, the clutch being configured to alternately engage and disengage the output spindle and the drive assembly based on output torque and a predetermined torque threshold; A flange operably coupled to the clutch, the flange being displaceable along the rotational axes of the output spindle and the drive assembly; An arm operably coupled to the flange, the arm being able to move along the arm axis in response to displacement of the flange along the axis of rotation; A magnet, which is positioned at a fixed location on the arm; A Hall effect sensor is positioned close to the arm such that when the arm is displaced, the magnet moves relative to the Hall effect sensor; and A processing circuit, operably coupled to the Hall effect sensor and configured to convert the analog signal from the Hall effect sensor into a digital clutch disengagement signal, The processing circuit uses the clutch disengagement signal to determine when the clutch disengages from the drive assembly and the output spindle.

11. The tool according to claim 10, wherein, The arm axis and the rotation axis are parallel to each other and spaced apart.

12. The tool of claim 10, wherein the magnet is disposed on the side of the arm axis opposite to the flange.

13. The tool of claim 10, wherein the flange carries the arm such that the flange and the arm move in unison.

14. The tool according to claim 10, wherein, The Hall effect sensor is operatively coupled to the side of the printed circuit board of the processing circuit opposite to the arm, such that the printed circuit board is disposed between the Hall effect sensor and the magnet.

15. The tool of claim 10, wherein the processing circuitry includes logic circuitry, the logic circuitry including an amplifier and a differential capacitor.

16. The tool of claim 15, wherein the analog signal from the Hall effect sensor is an input voltage, and The amplifier therein amplifies the input voltage from the Hall effect sensor in the logic circuit proportionally.

17. The tool according to claim 16, wherein, The differential capacitor includes a threshold voltage difference corresponding to the peak input voltage generated when the magnet and the Hall effect sensor are arranged to be closest to each other.

18. The tool of claim 17, wherein in response to the input voltage exceeding the threshold voltage difference, the logic circuit determines that the clutch has disengaged the output spindle from the drive assembly and that the output torque has reached the predetermined torque threshold.

19. A method for detecting clutch disengagement in a fastening tool, the tool comprising: A clutch that operably connects a drive assembly to an output spindle, the clutch being configured to disengage the output spindle from the drive assembly when the output torque reaches a predetermined torque threshold. A flange operably coupled to the clutch, the flange being displaceable along the rotational axes of the output spindle and the drive assembly; An arm operably coupled to the flange, the arm being able to move along the arm axis in response to displacement of the flange along the axis of rotation; A magnet, which is positioned at a fixed location on the arm; A Hall effect sensor is positioned close to the arm such that when the arm is displaced, the magnet moves relative to the Hall effect sensor. and A processing circuit, operably coupled to the Hall effect sensor and configured to convert an analog signal from the Hall effect sensor into a digital clutch disengagement signal, the method comprising: The Hall effect sensor is used to record analog signals from the magnet; The analog signal is converted into a digital clutch disengagement signal using logic circuitry; and The timing of clutch disengagement from the drive assembly and the output spindle is determined based on the clutch disengagement signal and the logic circuit.

20. The method of claim 19, wherein the logic circuitry comprises an amplifier and a differential capacitor. The analog signal from the Hall effect sensor is the input voltage. The amplifier therein amplifies the input voltage from the Hall effect sensor in the logic circuit proportionally. in, The differential capacitor includes a threshold voltage difference corresponding to the peak input voltage generated when the magnet and the Hall effect sensor are positioned in closest proximity to each other. In response to the input voltage exceeding the threshold voltage difference, the logic circuit determines that the clutch has disengaged the output spindle from the drive assembly and that the output torque has reached the predetermined torque threshold.

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