Powered fastener driver

Abstract

A powered fastener driver includes: a housing; a front end piece extending from the housing; a driver blade movable within the front end piece between a ready position and a driven position; a piston coupled to the driver blade to move therewith; a driver cylinder in which a piston can move; a cartridge coupled to the front end piece, the arranged fasteners being receivable in the cartridge; a fastener delivery mechanism coupled to the front end piece for individually transferring the arranged fasteners in the cartridge to a fastener drive channel in the front end piece, the fastener delivery mechanism being movable between a fastener acquisition position and a fastener delivery position; and a sensor for determining a position of the fastener delivery mechanism.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 593,695 filed on October 27, 2023 and U.S. Provisional Patent Application No. 63 / 505,584 filed on June 1, 2023, the entire contents of both provisional patent applications are incorporated herein by reference. Technical Field

[0003] The utility model relates to a dynamic fastener driver. Background Art

[0004] Powered fastener drivers are used to drive fasteners (e.g., nails, tacks, staples, etc.) into a workpiece. Such fastener drivers typically include a magazine in which the fasteners are stored and a pusher mechanism for individually transferring the fasteners from the magazine to a fastener driving channel, wherein the fasteners are struck by a driver blade during a fastener driving operation. Utility Model Content

[0005] In one aspect, the present invention provides a powered fastener driver comprising: a housing; a front end piece extending from the housing; a driver blade movable between a ready position and a driven position within the front end piece; a piston coupled to the driver blade for movement therewith; a driver cylinder within which the piston is movable; a magazine coupled to the front end piece in which arranged fasteners may be received; a fastener delivery mechanism coupled to the front end piece for individually delivering arranged fasteners in the magazine to a fastener drive channel in the front end piece, the fastener delivery mechanism being movable between a fastener acquisition position and a fastener delivery position; and a sensor for determining the position of the fastener delivery mechanism.

[0006] On the other hand, the present invention provides a method for operating a powered fastener driver, and the method includes: monitoring the position of a fastener delivery mechanism; determining whether the fastener delivery mechanism has moved from a fastener acquisition position to a fastener delivery position; and allowing the fastener driver to fire when a trigger is actuated and when the fastener delivery position is detected.

[0007] On the other hand, the utility model provides a powered fastener driver, which has: a housing; a front end member extending from the housing; a workpiece contact support slidably disposed on the front end member, the workpiece contact support including at least one workpiece contact support target; a driver blade movable between a ready position and a driven position in the front end member; a piston connected to the driver blade to move therewith; a driver cylinder in which the piston is movable; a magazine connected to the front end member, in which arranged fasteners can be received; a fastener delivery mechanism connected to the front end member for individually delivering the arranged fasteners in the magazine to a fastener drive channel in the front end member, the fastener delivery mechanism including at least one actuator target; a first sensor for detecting movement of at least one workpiece contact support target and the workpiece contact support; and a second sensor for detecting movement of at least one actuator target and movement of the fastener delivery mechanism.

[0008] On the other hand, the utility model provides a powered fastener driver, which includes: a housing; a front end member extending from the housing; a driver blade movable between a ready position and a driven position within the front end member; a piston connected to the driver blade to move therewith; a driver cylinder within which the piston is movable; a magazine connected to the front end member, in which arranged fasteners can be received; a fastener delivery mechanism connected to the front end member for individually delivering the arranged fasteners in the magazine to a fastener drive channel in the front end member; a fastener delivery mechanism movable between a fastener acquisition position and a fastener delivery position; and a sensor for detecting whether a fastener is in the fastener drive channel.

[0009] Other features and aspects of the present invention will become apparent by considering the following detailed description and accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 is a perspective view of a gas spring powered fastener driver.

[0011] Figure 2 yes Figure 1 Left side view of the gas spring powered fastener driver.

[0012] Figure 3 yes Figure 1 Right side view of the fastener driver.

[0013] Figure 4 yes Figure 1 Front view of a fastener driver.

[0014] Figure 5 yes Figure 1 Rear view of the fastener driver.

[0015] Figure 6 yes Figure 1 Right side view of a fastener driver with a portion of the housing removed and with a partial cross section through the reservoir cylinder.

[0016] Figure 7 yes Figure 1 A top view of a fastener driver with the housing and other parts removed.

[0017] Figure 8 yes Figure 1 Left side view of a fastener driver with the housing and other parts removed.

[0018] Fig. 9 yes Figure 1 Right side view of the fastener driver with the housing and other parts removed.

[0019] Fig.10 is used for Figure 1 Top view of the sensor bracket of the fastener driver.

[0020] Fig.11 yes Fig.10 Right side view of the sensor bracket.

[0021] Fig.12 yes Fig.10 Left side view of the sensor bracket.

[0022] Fig.13 is a flow chart illustrating a method of operating a gas spring powered fastener driver.

[0023] Fig.14 is a right side view of another fastener driver with a portion of the housing removed and with a partial cross section through the reservoir cylinder.

[0024] Fig.15 yes Fig.14 A top view of a fastener driver with the housing and other parts removed.

[0025] Fig.16 yes Fig.14 Left side view of a fastener driver with the housing and other parts removed.

[0026] Fig.17 yes Fig.14 Right side view of the fastener driver with the housing and other parts removed.

[0027] Fig.18 is used for Fig.14 Top view of the sensor bracket of the fastener driver.

[0028] Fig.19 yes Fig.18 Right side view of the sensor bracket.

[0029] Fig. 20 yes Fig.18 Left side view of the sensor bracket;

[0030] Fig.21 is a block diagram of a gas spring powered fastener actuator.

[0031] Fig. 22 is a flow chart illustrating another method of operating a gas spring powered fastener driver.

[0032] Fig.23 is a flow chart illustrating yet another method of operating a gas spring powered fastener driver.

[0033] Fig.24 is a flow chart illustrating yet another method of operating a gas spring powered fastener driver.

[0034] Before explaining any embodiments of the present disclosure in detail, it should be understood that the present disclosure 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 present disclosure can have other embodiments and can be practiced or performed in various ways. In addition, it should be understood that the words and terms used herein are for descriptive purposes and should not be considered restrictive. DETAILED DESCRIPTION

[0035] Reference Figures 1 to 6 , an embodiment of a gas spring powered fastener driver 100 is shown. The fastener driver 100 is operable to drive a fastener, such as a nail from a coil or ring, into a workpiece. The fastener driver 100 includes a housing 102 having a first housing shell 104 coupled to a second housing shell 106. The housing 102 includes a head portion 108 having a handle portion 110 extending therefrom and a drive unit housing portion 112. The housing 102 also includes a battery receptacle portion 114 extending from the handle portion 110 and sized and shaped to receive a removable battery pack 116 therein. Further, the housing 102 includes a fastener delivery portion 120 extending along the drive unit housing portion 112 from a front end piece 121 to a cassette receptacle portion 124 adjacent to the battery receptacle portion 114. A workpiece contact bracket 122 is slidably disposed on the front end piece 121.

[0036] As shown, the cassette receptacle portion 124 is generally cylindrical and is sized and shaped to receive the coiled fasteners therein. A cassette cover 126 is rotatably disposed on the housing 102 and provides access to a cassette 128 that is removably disposed within the cassette receptacle portion 124. The cassette 128 is a canister cassette containing a coiled arrangement of strips of nails. During operation of the fastener driver 100, each fastener is sequentially loaded into the front end 121 from the cassette 128 by the fastener delivery portion 120.

[0037] like Figure 2 As shown, the fastener driver 100 defines a drive axis 130 along which a fastener is driven from the fastener driver 100 into a workpiece. Further, as depicted, the fastener driver 100 includes a first left wear pad 132 disposed on the head portion 108 of the first housing shell 104, near the front end piece 121. The first left wear pad 132 extends in a direction parallel to the drive axis 130. The fastener driver 100 further includes a second left wear pad 134 disposed on the head portion 108 of the first housing shell 104, near the end of the head portion 108 opposite to the front end piece 121. The second left wear pad 134 extends in a direction perpendicular to the drive axis 130. As shown in FIG. Figure 2 As further shown, fastener driver 100 includes a third left wear pad 136 disposed on cassette receptacle portion 124 at an angle relative to drive axis 130 .

[0038] Figure 3 It is indicated that the fastener driver 100 includes a first right wear pad 142, which is disposed on the head portion 108 of the second housing shell 106, near the front end 121. The first right wear pad 142 extends in a direction parallel to the drive axis 130. The fastener driver 100 further includes a second right wear pad 144, which is disposed on the head portion 108 of the second housing shell 106, near the end of the head portion 108 opposite to the front end 121. The second right wear pad 144 extends in a direction perpendicular to the drive axis 130. Figure 3 As further shown, fastener driver 100 includes a third right side wear pad 146 disposed on cassette receptacle portion 124 at an angle relative to the drive axis.

[0039] like Figure 4As shown, the fastener driver 100 further includes a first wear plate 148 adjacent to the third left wear pad 136 and a second wear plate 149 adjacent to the third right wear pad 146. The wear plates 148, 149 are molded into the magazine receptacle portion 124 so that they face in a forward direction, i.e., the same direction as the front end 121 and the same direction as the direction in which the fastener is driven from the fastener driver 100. The wear plates 148, 149 are constructed of a material having a relatively high hardness and thus a relatively high wear resistance. For example, the wear plates 148, 149 are made of a metal (such as a high carbon alloy steel).

[0040] Figures 6 to 9 The internal components of the fastener driver 100 are shown. As shown, the fastener driver 100 includes a storage chamber cylinder 150 disposed in the head portion 108 of the housing 102. The storage chamber cylinder 150 includes a valve port 152 in which a filling valve is disposed. The filling valve is in fluid communication with the interior of the storage chamber cylinder 150. For example, the filling valve can be configured as a Schrader valve, a Presta valve, a Dunlop valve, or some other similar valve. When connected to a compressed gas source, the filling valve enables the storage chamber cylinder 150 to be filled with compressed gas or refilled with compressed gas in the event of any leak.

[0041] The storage chamber cylinder 150 includes a driver cylinder 160 disposed therein. Further, a movable piston 162 is slidably disposed in the driver cylinder 160. A driver blade 164 is connected to the movable piston 162. As shown, the driver blade 164 includes a proximal end 166 and a distal end 168. The proximal end 166 of the driver blade 164 is connected to the movable piston 162 by a pin 170. When the piston 162 moves to the top dead center (TDC) (i.e., retracted or ready) position in the driver cylinder 160 and the fastener driver 100 is ready to be fired, the distal end 168 of the driver blade 164 is adjacent to the front end 121. When firing, the distal end 168 of the driver blade 164 is moved into the front end 121 to drive the fastener from the front end 121 and allow the fastener to enter the workpiece until the piston 162 reaches the bottom dead center (BDC) (i.e., extending or driven) position in the driver cylinder 160.

[0042] Figures 6 to 9It is further indicated that the fastener driver 100 includes a circuit board 172 that controls the operation of the fastener driver 100. A user interface 174 is disposed on the circuit board 172 and extends through the housing 102 to an area near the handle portion 110. The user interface 174 provides user controls for the fastener driver 100 and includes, for example, an on / off switch, a mode selector button, a remaining power indicator, a charging indicator, and other additional buttons and indicators as necessary. The circuit board 172 is electrically connected to the battery receptacle portion 114 and the battery pack 116 when engaged with the battery receptacle portion and the battery pack, and provides DC power to a motor 176 (e.g., a brushless direct current (BLDC) motor) that is operably coupled to a lift mechanism 180. The lift mechanism 180 selectively engages the driver blade 164, and the lift mechanism 180 is driven by the motor 176 to move the driver blade 164 from a driven or BDC position to a ready position (between the BDC position and the TDC position) prior to a subsequent fastener driving operation. In response to initiating a subsequent fastener driving operation, the motor 176 is restarted to cause the lift mechanism 180 to move the driver blade 164 from the ready position to the TDC position, after which the lift mechanism 180 disengages the driver blade 164, which is then urged toward the driven position or BDC position by the force of the compressed gas acting on the piston 162. Figure 7 and Fig. 9 As best shown, the latch actuator assembly 190 cooperates with the lift mechanism 180 to selectively engage and retain the driver blade 164 in a ready position before the latch actuator assembly 190 is actuated by the lift mechanism 180 to release the driver blade 164 into the nose piece 121 to drive a fastener from the fastener driver 100 into a workpiece.

[0043] like Figures 6 to 9As further depicted, the fastener driver 100 further includes a sensor bracket 200 disposed at least partially above the lifting mechanism 180. The sensor bracket 200 includes a first sensor 202 configured to sense the angular (or rotational) position of the lifting mechanism 180, a second sensor 204 sensing the linear position of a workpiece contact bracket 122 slidably disposed on the front end 121, and a third sensor 206 sensing the position of a fastener delivery mechanism 230 described below. For example, the sensors 202, 204, 206 are Hall effect sensors configured to sense the presence of a magnet or magnetic field. The workpiece contact bracket 122 includes a magnet 212 that is sensed by the second sensor 204 when the workpiece contact bracket 122 engages with the workpiece and slides on the front end 121. When the magnet 212 is sensed, the fastener driver 100 is allowed to fire. If the magnet 212 on the workpiece contact bracket 122 is not sensed, the fastener driver is not allowed to fire. The fastener delivery mechanism 230 also includes a magnet 214. If the magnet 214 on the fastener delivery mechanism 230 is not sensed, it indicates that the fastener delivery mechanism 230 is not properly positioned - possibly due to a stuck fastener - and does not allow the fastener driver 100 to fire.

[0044] As shown, the fastener driver 100 includes a depth adjuster 220 having a threaded shaft 222 threadably engaged with the workpiece contact bracket 122. The depth adjuster 220 is rotatable to change the linear position of the workpiece contact bracket 122 relative to the nose piece 121. This changes the depth to which a fastener ejected from the fastener driver 100 is driven into the workpiece.

[0045] As shown, the fastener driver 100 also includes a fastener delivery mechanism 230. Figures 8 to 9 As best shown, the fastener delivery mechanism 230 includes a spring-loaded actuator portion 300 slidably disposed within a bracket 302 on the front end piece 121. The actuator portion 300 includes a proximal end 304 and a distal end 306. A spring 308 is mounted in compression adjacent the proximal end 304 of the actuator portion 300 to bias the actuator portion 300 toward a drive channel 310 of the front end piece 121. An advancer portion 312 is mounted on the distal end 306 of the actuator portion 300 via a hinge pin 314. In another aspect, the advancer portion 312 and the actuator portion 300 are integrally formed as a single unitary part, and the advancer portion 312 is formed on the actuator portion 300 (e.g., the distal end 306 of the actuator portion 300). A torsion spring 316 is disposed on the hinge pin 314 to bias the advancer portion 312 about the hinge pin 314 toward the front end piece 121.

[0046] The fastener delivery mechanism 230 also includes a first rocker arm 318 rotatably mounted on the front end 121 via a first post 320 (e.g., a threaded fastener). The first rocker arm 318 includes a forked end 322 that fits around a transverse post 324 on the distal end 306 of the actuator portion 300. As shown, the fastener delivery mechanism 230 also includes a second rocker arm 326 rotatably mounted on the front end 121 via a second post 328 and mounted to the first rocker arm 318 via a third post 330. A spring-loaded actuator 332 is mounted on the free end of the second rocker arm 326. The spring-loaded actuator 332 can rotate in only a single direction toward the delivery end of the fastener driver 100 to overcome the force of the spring that returns it to a vertical position. When driver blade 164 returns to the TDC position, the teeth on driver blade 164 engage spring loaded actuator 332 to actuate fastener delivery mechanism 230 and move the fastener into drive channel 310 of nose piece 121 to be fired when the trigger is pulled.

[0047] Figure 8 The first rocker arm 318 is indicated to include a recess 340 in which the magnet 214 is disposed. When the first rocker arm 318 rotates clockwise, the first rocker arm 318 moves the pusher portion 312 in a first direction (e.g., in a downward direction away from the front piece 121) along the aligned fastener strip, and the fastener delivery mechanism 230 moves to the fastener acquisition position. In the fastener acquisition position, the magnet 214 moves away from the third sensor 206 and is no longer detected by the third sensor 206. When the first rocker arm 318 rotates clockwise and the pusher portion 312 moves in a second direction (e.g., in an upward direction toward the front piece 121), when the actuator portion 300 is fully extended, the pusher portion 312 moves the acquired fastener into the drive channel 310 of the front piece 121, and the fastener delivery mechanism 230 moves to the fastener delivery position. In the fastener delivery position, the magnet 214 is detected by the third sensor 206 and the fastener driver 100 is allowed to fire. Specifically, when the presence of the magnet 214 is detected, the circuit board 172 (i.e., the electronic control unit) of the fastener driver 100 receives input from the third sensor 206, which indicates that the fastener is properly loaded into the fastener drive channel 310. Thereafter, the circuit board 172 activates the motor 176 in response to the workpiece contact bracket 122 being retracted or depressed onto the workpiece and the trigger being pulled.

[0048] If the third sensor 206 does not detect the magnet 214, the fastener in the pusher portion 312 is not fully delivered, and if the fastener driver 100 is allowed to fire, a jam may occur. Thus, if the magnet 214 on the first rocker arm 318 is not detected, the fastener driver 100 is not allowed to fire. Specifically, when the presence of the magnet 214 is not detected, the circuit board 172 (i.e., the electronic control unit) of the fastener driver 100 receives input from the third sensor 206, which indicates that the fastener is not properly loaded into the fastener drive channel 310. Thus, if the workpiece contact bracket 122 is retracted and the trigger is pulled, the circuit board 172 will not activate the motor 176.

[0049] Reference Figures 10 to 12 , showing the details of the sensor bracket 200. As previously described, the sensor bracket 200 is configured to hold the first sensor 202, the second sensor 204 and the third sensor 206. Figure 7 As shown. Figures 10 to 12 As shown, the sensor bracket 200 includes an elongated body 402 having a first end 404 and a second end 406. The elongated body 402 of the sensor bracket 200 defines a longitudinal axis 408. A first mounting tab 410 extends from the elongated body 402 near the first end 404. A second mounting tab 412 extends from the elongated body 402 near a midpoint of the elongated body 402 between the midpoint and the second end 406. As shown, the first mounting tab 410 defines a longitudinal axis 414 that is parallel to the longitudinal axis 408 of the elongated body 402 of the sensor bracket 200. The second mounting tab 412 defines a longitudinal axis 416 that is perpendicular to the longitudinal axis 408 of the elongated body 402. As shown, the mounting tabs 410, 412 are formed with apertures 418, 420 to allow a fastener to extend therethrough, thereby mounting the sensor bracket 200 within the housing 102 of the fastener driver 100.

[0050] Figures 10 to 12The sensor bracket 200 is further shown to include a first sensor pocket 422 formed near a midpoint of the elongated body 402 between the midpoint and the first end 404. The first sensor pocket 422 is configured to receive the first sensor 202 therein. Further, the first sensor pocket 422 is oriented such that a longitudinal axis 424 of the first sensor pocket 422 is at an acute angle A relative to a longitudinal axis 408 of the elongated body 402. Moreover, the first sensor pocket 422 and the first sensor 202 disposed therein are parallel to the first mounting tab 410. In particular aspects, the acute angle A is greater than or equal to 5.0°, such as greater than or equal to 6.0°, greater than or equal to 7.0°, greater than or equal to 8.0°, greater than or equal to 9.0°, greater than or equal to 10.0°, greater than or equal to 11.0°, or greater than or equal to 12.0°. Further, angle A is less than or equal to 20.0°, such as less than or equal to 19.0°, less than or equal to 18.0°, less than or equal to 17.0°, less than or equal to 16.0°, less than or equal to 15.0°, less than or equal to 14.0°, or less than or equal to 13.0. It should be understood that angle A can be within a range between and including any of the maximum and minimum values ​​of A disclosed herein.

[0051] The sensor bracket 200 also includes a second sensor pocket 426 located near the midpoint of the elongated body 402, between the midpoint and the second end 406, and near the second mounting tab 412. As shown, the second sensor pocket 426 is configured to receive the second sensor 204 therein. Further, the second sensor pocket 426 is oriented such that a longitudinal axis 428 of the second sensor pocket 426 is perpendicular to the longitudinal axis 408 of the elongated body 402. Additionally, the second sensor pocket 426 and the second sensor 204 disposed therein are parallel to the longitudinal axis 416 of the second mounting tab 412.

[0052] The sensor bracket 200 further includes a third sensor pocket 430 near the second end 406 of the elongated body 402. The third sensor pocket 430 is configured to receive the third sensor 206 therein. In addition, the third sensor pocket 430 is oriented such that a longitudinal axis 432 of the third sensor pocket 430 is perpendicular to the longitudinal axis 408 of the elongated body 402. In addition, the third sensor pocket 430 and the third sensor 206 disposed therein are oriented parallel to the longitudinal axis 416 of the second mounting tab 412.

[0053] The sensor bracket 200 also includes a curved extension 440 extending from the first end 404 of the elongated body 402. The curved extension 440 is disposed relative to Fig.11 and Fig.12The curved extension 440 extends in a downward direction and is generally perpendicular to the longitudinal axis 408 of the elongated body 402. The curved extension 440 includes an inner surface 442 and an outer surface 444. The inner surface 442 is shaped to fit around a gusset on one end of the reservoir cylinder 150. The outer surface 444 is curved to match the curvature of the outer surface of the reservoir cylinder 150 adjacent to the sensor bracket 200.

[0054] Now refer to Fig.13 , a method of operating a gas spring powered fastener driver is shown, and the method is generally designated as 500. As shown, the method 500 begins at frame 502 and includes monitoring the position of a fastener delivery mechanism by monitoring the position of a magnet within a first rocker arm of the fastener delivery mechanism. The method 500 proceeds to frame 504 and includes determining whether the fastener delivery mechanism has moved from a fastener acquisition position to a fastener delivery position by sensing a magnet within the first rocker arm at a third sensor located on a sensor bracket. Thereafter, at step 506, the method 500 includes determining whether a fastener delivery position is detected. If a fastener delivery position is detected, the method 500 proceeds to frame 508 and includes allowing the fastener driver to fire when the trigger is actuated. The method 500 then proceeds to step 510 and includes determining whether the power supply is turned off. If the power supply is turned off, the method 500 ends. Otherwise, if the power supply remains on, the method 500 returns to frame 502 and continues as described herein.

[0055] Returning to step 506, if the fastener delivery position is not detected, the method 500 moves to box 514 and includes indicating that a jam condition may occur. This can be achieved by providing a visual indication, an audible indication, or a combination of both. Thereafter, at box 516, the method 500 includes preventing the fastener driver from firing. The method 500 then proceeds to step 510 and includes determining whether the power supply is off. If the power supply is off, the method 500 ends. Otherwise, if the power supply remains on, the method 500 returns to box 502 and continues as described herein.

[0056] Figures 14 to 17 The internal components of another fastener driver 1000 are shown. These internal components can be used with the fastener driver 100 to replace Figures 6 to 9 Internal components shown (and described in conjunction therewith). As shown, fastener driver 1000 includes a nose piece 1020, wherein a workpiece contact support 1022 is slidably disposed on nose piece 1020. Nose piece 1020 extends from or is attached to a reservoir cylinder 1050. Brief Reference Figures 1 to 5, if used in conjunction with the external components of the fastener driver 100 described above, the storage chamber cylinder 1050 will be disposed within the head portion 108 of the housing 102. The storage chamber cylinder 1050 includes a valve port 1052 in which a filling valve is disposed. The filling valve is in fluid communication with the interior of the storage chamber cylinder 1050. For example, the filling valve can be configured as a Schrader valve, a Presta valve, a Dunlop valve, or some other similar valve. When connected to a compressed gas source, the filling valve enables the storage chamber cylinder 1050 to be filled with compressed gas or refilled with compressed gas in the event of any leak.

[0057] The storage chamber cylinder 1050 includes a driver cylinder 1060 disposed therein. Further, a movable piston 1062 is slidably disposed within the driver cylinder 1060. A driver blade 1064 is connected to the movable piston 1062. As shown, the driver blade 1064 includes a proximal end 1066 and a distal end 1068. The proximal end 1066 of the driver blade 1064 is connected to the movable piston 1062 by a pin 1070. When the piston 1062 moves to the top dead center (TDC) (i.e., retracted or ready) position within the driver cylinder 1060 and the fastener driver 100 is ready to be fired, the distal end 1068 of the driver blade 1064 is adjacent to the front end 1020. When fired, the distal end 1068 of the driver blade 1064 is moved into the front end 1020 to drive the fastener from the front end 1020 and into the workpiece until the piston 1062 reaches the bottom dead center (BDC) (i.e., extended or driven) position within the driver cylinder 1060.

[0058] Although Figures 14 to 17 1064, but fastener driver 1000 may include a circuit board (similar to circuit board 172) that controls the operation of fastener driver 1000. The circuit board is electrically connected to the battery receptacle portion and the battery pack when engaged therewith, and provides DC power to a motor 1076 (e.g., a brushless direct current (BLDC) motor) that is operably coupled to a lift mechanism 1080. Lift mechanism 1080 selectively engages driver blade 1064, and lift mechanism 1080 is driven by motor 1076 to move driver blade 1064 from the BDC position to the TDC position, and in the process moves piston 1062 from the BDC position to the TDC position. The latch actuator assembly 1090 cooperates with the lift mechanism 1080 to selectively engage and hold the driver blade 1064 in a ready position before the latch actuator assembly 1090 is actuated by the lift mechanism 1080 to release the driver blade 1064 into the front end 1020 to drive the fastener from the fastener driver 100 into the workpiece.

[0059] like Figures 14 to 17 As further depicted, the fastener driver 1000 further includes a sensor bracket 1100 disposed at least partially above the lifting mechanism 1080. The sensor bracket 1100 includes a first sensor 1102 configured to sense an angular (or rotational) position of the lifting mechanism 1080, a second sensor 1104 sensing a linear position of a workpiece contact bracket 1022 slidably disposed on the front end 1020, and a third sensor 1106 sensing a position of a fastener delivery mechanism 1130 described below or one or more links within the fastener delivery mechanism 1130. For example, the first sensor 1102 is a Hall effect sensor configured to sense the presence of a nearby magnet or a nearby magnetic field. The second sensor 1104 and the third sensor 1106 are inductive sensors configured to output signals based on movement of one or more metal targets mounted on the fastener driver 1000 moving near the sensors 1104, 1106.

[0060] As shown, the lifting mechanism 1080 includes a magnet 1110 that is sensed by the first sensor 1102 to determine the angle (or rotation) of the lifting mechanism 1080 when the lifting mechanism 1080 or a portion thereof rotates to move the driver blade 1064 from the BDC position to the TDC position. The workpiece contact bracket 1022 includes a workpiece contact bracket (WCB) target 1112, which is a metal target, such as a ferrous target. Further, the WCB target 1112 is a steel target, such as a carbon steel target. The WCB target 1112 is sensed by the second sensor 1104 to determine the position of the workpiece contact bracket 1022 when it slides on the front end 1020 between an extended position and a retracted or depressed position, in which the fastener driver 100 is prevented from firing, and in which the fastener driver 100 is engaged with the workpiece and the fastener driver 100 is permitted to fire and drive the fastener into the workpiece.

[0061] Figures 14 to 17 It is further indicated that the fastener driver 100 includes a depth adjuster 1120 having a threaded shaft 1122 threadably engaged with the workpiece contact bracket 1022. The depth adjuster 1120 is rotatable to change the linear position of the workpiece contact bracket 1022 relative to the nosepiece 1020. This changes the depth to which a fastener discharged from the fastener driver 100 is driven into the workpiece.

[0062] like Fig.16 and Fig.17As best shown, the fastener driver 100 also includes a fastener delivery mechanism 1130. The fastener delivery mechanism 1130 includes a spring-loaded actuator portion 1200 slidably disposed within a bracket 1202 on the nose piece 1020. The actuator portion 1200 includes a proximal end 1204 and a distal end 1206. A spring 1208 is mounted in compression adjacent the proximal end 1204 of the actuator portion 1200 to bias the actuator portion 1200 toward a drive channel 1210 of the nose piece 1020. An advancer 1212 is mounted on the distal end 1206 of the actuator portion 1200 via a hinge pin 1214. A torsion spring 1216 is disposed on the hinge pin 1214 to bias the advancer 1212 about the hinge pin 1214 toward the nose piece 1020.

[0063] The fastener delivery mechanism 1130 also includes a first rocker arm 1218 rotatably mounted on the front end 1020 via a first post 1220 (e.g., a threaded fastener). The first rocker arm 1218 includes a forked end 1222 that fits around a transverse post 1224 on the distal end 1206 of the actuator portion 1200. As shown, the fastener delivery mechanism 1130 also includes a second rocker arm 1226 rotatably mounted on the front end 1020 via a second post 1228 and mounted to the first rocker arm 1218 via a third post 1230. A spring-loaded actuator 1232 is mounted on the free end of the second rocker arm 1226. The spring-loaded actuator 1232 can rotate in only a single direction toward the delivery end of the fastener driver 1000 against the force of a spring that returns it to a vertical position. When the driver blade 1064 returns to the TDC position, the teeth on the driver blade 1064 engage the spring loaded actuator 1232 to actuate the fastener delivery mechanism 1130 and move the fastener into the drive channel 1210 of the nose piece 1020 to be fired when the trigger is pulled.

[0064] Fig.16The fastener delivery mechanism 1130 of the fastener driver 1000 is indicated to include a first actuator target 1240 on the forked end 1222 of the first rocker arm 1218, above the transverse post 1224 on the distal end 1206 of the actuator portion 1200. In addition, the fastener delivery mechanism 1130 of the fastener driver 1000 includes a second actuator target 1242 on the forked end 1222 of the first rocker arm 1218, below the transverse post 1224 on the distal end 1206 of the actuator portion 1200, opposite the first actuator target 1240. In certain aspects, the actuator targets 1240, 1242 are metal targets, such as ferrous targets. Further, the actuator targets 1240, 1242 are steel targets, such as carbon steel targets. In one embodiment, the actuator targets 1240, 1242 are the same size and shape. In another embodiment, the actuator targets 1240, 1242 are different in size and shape. For example, the first actuator target 1240 can be larger than the second actuator target 1242. Further, the first actuator target 1240 can be smaller than the second actuator target 1242. In another embodiment, the actuator targets 1240, 1242 can have the same mass. In yet another embodiment, the actuator targets 1240, 1242 can have different masses. For example, the mass of the first actuator target 1240 can be larger than the mass of the actuator target 1242. Alternatively, the mass of the first actuator target 1240 can be smaller than

[0065] The actuator targets 1240, 1242 are sensed by the second sensor 1104 to determine the position of the first swing arm 1218 and the position of the fastener delivery mechanism 1130 as it delivers fasteners one at a time to the drive channel 1210 of the front piece 1020. For example, when the first swing arm 1218 rotates clockwise and moves the pusher 1212 in a first direction (e.g., in a downward direction away from the front piece 1020) along the aligned fastener strip, the fastener delivery mechanism 1130 moves to the fastener acquisition position. In the fastener acquisition position, the magnet 1114 moves away from the third sensor 1106 and is no longer detected by the third sensor 1106. When the first rocker arm 1218 rotates clockwise and the pusher 1212 moves in a second direction (e.g., in an upward direction toward the front piece 1020), when the actuator portion 1200 is fully extended, the pusher 1212 moves the captured fastener into the drive channel 1210 of the front piece 1020, and the fastener delivery mechanism 1130 moves to the fastener delivery position. In the fastener delivery position, the magnet 1114 is detected by the third sensor 1106 and the fastener driver 100 is allowed to fire. Specifically, when the presence of the magnet 1114 is detected, the circuit board (i.e., the electronic control unit) of the fastener driver 100 receives an input from the third sensor 1106, which indicates that the fastener is correctly loaded into the fastener drive channel 1210. Thereafter, the circuit board activates the motor 1076 in response to the workpiece contact bracket 1022 being retracted or pressed onto the workpiece and the trigger being pulled.

[0066] If the third sensor 1106 does not detect the magnet 1114, the fastener in the pusher 1212 is not fully delivered, and if the fastener driver 100 is allowed to fire, a jam may occur. Thus, if the magnet 1114 on the first rocker arm 1218 is not detected, the fastener driver 100 is not allowed to fire. Specifically, when the presence of the magnet 1114 is not detected, the circuit board (i.e., the electronic control unit) of the fastener driver 100 receives input from the third sensor 1106, which indicates that the fastener is not properly loaded into the fastener drive channel 1210. Thus, if the workpiece contact bracket 1022 is retracted and the trigger is pulled, the circuit board will not activate the motor 1076.

[0067] Reference Figures 18 to 20 , showing the details of the sensor bracket 1100. As previously described, the sensor bracket 1100 is configured to hold the first sensor 1102, the second sensor 1104 and the third sensor 1106. Fig.15 As shown. Figures 18 to 20As shown, the sensor bracket 1100 includes an elongated body 1302 having a first end 1304 and a second end 1306. The elongated body 1302 of the sensor bracket 1100 defines a longitudinal axis 1308. A first mounting tab 1310 extends from the elongated body 1302 near the first end 1304. A second mounting tab 1312 extends from the elongated body 1302 near the midpoint of the elongated body 1302, between the midpoint and the second end 1306. As shown, the first mounting tab 1310 defines a longitudinal axis 1314 that is parallel to the longitudinal axis 1308 of the elongated body 1302 of the sensor bracket 1100. The second mounting tab 1312 defines a longitudinal axis 1316 that is perpendicular to the longitudinal axis 1308 of the elongated body 1302. As shown, mounting tabs 1310 , 1312 are formed with apertures 1318 , 1320 to allow fasteners to extend therethrough to thereby mount sensor bracket 1100 within housing 102 of fastener driver 100 .

[0068] Figures 18 to 20 The sensor bracket 1100 is further shown to include a first sensor pocket 1322 formed near a midpoint of the elongated body 1302 between the midpoint and the first end 1304. The first sensor pocket 1322 is configured to receive the first sensor 1102 therein. Further, the first sensor pocket 1322 is oriented such that a longitudinal axis 1324 of the first sensor pocket 1322 is at an acute angle AA relative to a longitudinal axis 1308 of the elongated body 1302. Moreover, the first sensor pocket 1322 and the first sensor 1102 disposed therein are parallel to the first mounting tab 1310. In particular aspects, the acute angle AA is greater than or equal to 5.0°, such as greater than or equal to 6.0°, greater than or equal to 7.0°, greater than or equal to 8.0°, greater than or equal to 9.0°, greater than or equal to 10.0°, greater than or equal to 11.0°, or greater than or equal to 12.0°. Further, angle AA is less than or equal to 110.0°, such as less than or equal to 109.0°, less than or equal to 108.0°, less than or equal to 107.0°, less than or equal to 106.0°, less than or equal to 105.0°, less than or equal to 14.0°, or less than or equal to 13.0. It should be understood that angle AA can be within a range between and including any of the maximum and minimum values ​​of AA disclosed herein.

[0069] The sensor bracket 1100 also includes a second sensor pocket 1326 located near the midpoint of the elongated body 1302, between the midpoint and the second end 1306, and near the second mounting tab 1312. As shown, the second sensor pocket 1326 is configured to receive the second sensor 1104 therein. Further, the second sensor pocket 1326 is oriented such that a longitudinal axis 1328 of the second sensor pocket 1326 is parallel to the longitudinal axis 1308 of the elongated body 1302. Additionally, the second sensor pocket 1326 and the second sensor 1104 disposed therein are perpendicular to the longitudinal axis 1316 of the second mounting tab 1312.

[0070] like Fig.18 As shown, the second sensor pocket 1326 has a pocket length PL extending at least partially along the total length L of the sensor bracket 1100. In one aspect, the pocket length PL is less than or equal to forty percent (40%) of the total length L, such as less than or equal to thirty-five percent (35%) of the total length L, less than or equal to forty percent (30%) of the total length L, or less than or equal to twenty-five percent (25%) of the total length L. Further, the pocket length PL is greater than or equal to five percent (5%) of the total length L, such as greater than or equal to ten percent (10%) of the total length, greater than or equal to fifteen percent (15%) of the total length, or greater than or equal to twenty percent (20%) of the total length. In another aspect, the pocket length PL is within a range between and including any of the maximum and minimum values ​​of the pocket lengths PL disclosed herein.

[0071] The sensor bracket 1100 further includes a third sensor pocket 1330 proximate the second end 1306 of the elongated body 1302. The third sensor pocket 1330 is configured to receive the third sensor 1106 therein. In addition, the third sensor pocket 1330 is oriented such that a longitudinal axis 1332 of the third sensor pocket 1330 is perpendicular to the longitudinal axis 1308 of the elongated body 1302 and the longitudinal axis 1328 of the second sensor pocket 1326. In addition, the third sensor pocket 1330 and the third sensor 1106 disposed therein are oriented parallel to the longitudinal axis 1316 of the second mounting tab 1312.

[0072] like Fig.19As shown, the third sensor pocket 1330 has a pocket height PH extending at least partially along the overall height H of the sensor bracket 1100. In one aspect, the pocket height PH is less than or equal to seventy percent (70%) of the overall height H, such as less than or equal to sixty-five percent (65%) of the overall height H, less than or equal to sixty percent (60%) of the overall height H, or less than or equal to fifty-five percent (55%) of the overall height H. Further, the pocket height PH is greater than or equal to thirty-five percent (35%) of the overall height H, such as greater than or equal to forty percent (40%) of the overall height, greater than or equal to forty-five percent (45%) of the overall height, or greater than or equal to fifty percent (50%) of the overall height. In another aspect, the pocket height PH is within a range between and including any of the maximum and minimum values ​​of the pocket height PH disclosed herein.

[0073] The sensor bracket 1100 also includes a curved extension 1340 extending from the first end 1304 of the elongated body 1302. The curved extension 1340 is Fig.11 and Fig.12 The curved extension 1340 extends in a downward direction and is generally perpendicular to the longitudinal axis 1308 of the elongated body 1302. The curved extension 1340 includes an inner surface 1342 and an outer surface 1344. The inner surface 1342 is shaped to fit around a gusset on one end of the reservoir cylinder 1050. The outer surface 1344 is curved to match the curvature of the outer surface of the reservoir cylinder 1050 adjacent to the sensor bracket 1100.

[0074] Fig.21 1 is a block diagram showing a gas spring powered fastener driver 1400. As shown, the gas spring powered fastener driver 1400 includes a controller 1402, i.e., an electronic control unit. A motor 1404 and a battery 1406 are operably coupled to the controller 1402. Further, a trigger 1408 is operably coupled to the controller 1402 and the motor 1404. A first sensor 1410, a second sensor 1412, a third sensor 1414, and a fourth sensor 1416 are operably coupled to the controller 1402. The controller 1402 uses signals from the sensors 1410, 1412, 1414, 1416 to control the operation of the motor 1404 and the gas spring fastener driver 1400. The sensors 1410, 1412, 1414, 1416 include Hall sensors, inductive sensors, micro switches, optical sensors, acoustic sensors, or any combination thereof.

[0075] As shown, a first sensor 1410 is positioned within the gas spring powered fastener driver 1400 to sense a fastener 1420, such as a nail, within a fastener drive channel 1422 of a front end 1424 of the gas spring powered fastener driver 1400. For example, the first sensor 1410 may be placed adjacent to the fastener drive channel 1422. Alternatively, the first sensor 1410 may be partially or completely disposed within the fastener drive channel 1422, such as in a side wall thereof. If the first sensor 1410 senses a fastener 1420 within the fastener drive channel 1422, the controller 1402 sends a signal to the trigger 1408 to allow the motor 1404 to be actuated. If no fastener 1420 is sensed within the fastener drive channel 1422, the controller 1402 prevents the motor 1404 from being actuated when the trigger 1408 is depressed or otherwise switched.

[0076] The second sensor 1412 is positioned to sense a workpiece contact bracket (WCB) target 1430, such as a ferrous target, on a workpiece contact bracket 1432 slidably disposed on the front end 1424. When the WCB target 1430 is sensed, indicating that the workpiece contact bracket 1432 is engaged with the workpiece, the controller 1402 sends a signal to the trigger 1408 to allow the motor 1404 to be actuated to drive the fastener into the workpiece. If the WCB target 1430 is not detected, the controller 1402 prevents the motor 1404 from being actuated when the trigger 1408 is depressed or otherwise switched.

[0077] Fig.21 It is further shown that the third sensor 1414 and the fourth sensor 1416 are positioned to detect the first actuator target 1440 and the second actuator target 1442 on the actuator 1444 within the fastener delivery mechanism 1446 to determine the position of the actuator 1444 and the fastener delivery mechanism 1446 when the fastener delivery mechanism 1446 is moving or attempting to move the fastener 1420 into the fastener driving channel 1422 of the front end 1424. The position of the fastener delivery mechanism 1446 can indicate whether the fastener 1420 is properly delivered or whether a jam has occurred. If the position of the fastener delivery mechanism 1446 indicates that the fastener 1420 is properly delivered, the controller 1402 sends a signal to the trigger 1408 to allow the motor 1404 to be actuated to drive the fastener into the workpiece. If the position of the fastener delivery mechanism 1446 indicates that a jam has occurred, the controller 1402 prevents the motor 1404 from being actuated when the trigger 1408 is depressed or otherwise switched. It should be understood that other portions of the fastener delivery mechanism 1446 may include targets that can be detected by the third sensor 1414 and the fourth sensor 1416 to determine the position of the fastener delivery mechanism 1446.

[0078] Now refer to Fig. 22 , a method of operating a gas spring powered fastener driver is shown and is generally designated as 1500. As shown, the method 1500 begins at box 1502 and includes monitoring the position of a fastener delivery mechanism by monitoring the position of a first metal target and a second metal target disposed on or molded into a first rocker arm of the fastener delivery mechanism. The method 1500 proceeds to box 1504 and includes determining whether the fastener delivery mechanism has moved from a fastener acquisition position to a fastener delivery position by sensing the first metal target and the second metal target within the first rocker arm at a third sensor located on a sensor bracket. Thereafter, at step 1506, the method 1500 includes determining whether a fastener delivery position is detected. If a fastener delivery position is detected, the method 1500 proceeds to box 1508 and includes allowing the fastener driver to fire when the trigger is actuated. The method 1500 then proceeds to step 1510 and includes determining whether the power supply is off. If the power supply is off, the method 1500 ends. Otherwise, if the power supply remains on, the method 1500 returns to box 1502 and continues as described herein.

[0079] Returning to step 1506, if a fastener delivery position is not detected, the method 1500 moves to box 1514 and includes indicating that a jam condition may occur or has occurred. This can be achieved by providing a visual indication, an audible indication, tactile feedback, or a combination thereof. Thereafter, at box 1516, the method 1500 includes preventing the fastener driver from firing. The method 1500 then proceeds to step 1510 and includes determining whether the power supply is off. If the power supply is off, the method 1500 ends. Otherwise, if the power supply remains on, the method 1500 returns to box 1502 and continues as described herein.

[0080] Fig.23Another method of operating a gas spring powered fastener driver is depicted. The method is generally designated as 1600. As shown, method 1600 starts at frame 1602 and includes monitoring the position of a fastener delivery mechanism by monitoring the position of a first metal target and a second metal target disposed on or molded into a first rocker arm of the fastener delivery mechanism. Method 1600 proceeds to frame 1604 and includes determining the position of the fastener delivery mechanism by sensing the first metal target and the second metal target in the first rocker arm at a third sensor located on a sensor bracket. Thereafter, at step 1606, method 1600 includes determining whether an error position is detected. For example, an error position may include a position in which the fastener delivery mechanism is not properly returned to the position of the fastener drive channel of the front end of the powered fastener driver where the nail is (or should be) loaded. If an error position is not detected, method 1600 proceeds to frame 1608 and includes allowing the fastener driver to fire when the trigger is actuated. Then method 1600 proceeds to step 1610 and includes determining whether the power supply is turned off. If the power is off, then the method 1600 ends. Otherwise, if the power remains on, then the method 1600 returns to block 1602 and continues as described herein.

[0081] Returning to step 1606, if an incorrect position is detected, the method 1600 moves to box 1614 and includes indicating that a jam condition may occur or has occurred. This can be achieved by providing a visual indication, an audible indication, tactile feedback, or a combination thereof. Thereafter, at box 1616, the method 1600 includes preventing the fastener driver from firing. The method 1600 then proceeds to step 1610 and includes determining whether the power supply is off. If the power supply is off, the method 1600 ends. Otherwise, if the power supply remains on, the method 1600 returns to box 1602 and continues as described herein.

[0082] Fig.24Another method of operating a gas spring powered fastener driver is shown. The method is generally designated as 1700. As shown, method 1700 starts at frame 1702 and includes monitoring the position of a fastener in a powered fastener driver, for example, by monitoring a fastener drive channel. Method 1700 proceeds to frame 1704 and includes determining the position of the fastener by sensing / not sensing the fastener using a sensor placed adjacent to the fastener drive channel. Thereafter, at step 1706, method 1700 includes determining whether a fastener is detected in the fastener drive channel. If a fastener is detected in the fastener drive channel, method 1700 proceeds to frame 1708 and includes allowing the fastener driver to fire when the trigger is actuated. Then method 1700 proceeds to step 1710 and includes determining whether the power supply is turned off. If the power supply is turned off, method 1700 ends. Otherwise, if the power supply remains on, method 1700 returns to frame 1702 and continues as described herein.

[0083] Returning to step 1706, if no fastener is detected in the fastener drive channel, the method 1700 moves to box 1714 and includes indicating that a jam condition may occur or has occurred. This can be achieved by providing a visual indication, an audible indication, tactile feedback, or a combination thereof. Thereafter, at box 1716, the method 1700 includes preventing the fastener driver from firing. The method 1700 then proceeds to step 1710 and includes determining whether the power is off. If the power is off, the method 1700 ends. Otherwise, if the power remains on, the method 1700 returns to box 1702 and continues as described herein.

[0084] Although the disclosure has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects of the disclosure described.

[0085] Various features of the invention are set forth in the appended claims.

Claims

1. A powered fastener driver, characterized in that: The powered fastener driver includes: case; a front end member extending from the housing; a driver blade movable within the front end member; a piston coupled to the driver blade for movement with the driver blade; a driver cylinder in which the piston is movable from a top dead center position and a bottom dead center position; a cassette coupled to the front end member, wherein the array of fasteners can be received in the cassette; a fastener delivery mechanism coupled to the front end piece for individually delivering the aligned fasteners in the magazine to the fastener drive channels in the front end piece, the fastener delivery mechanism being movable between a fastener acquisition position and a fastener delivery position; and A sensor is used to determine the position of the fastener delivery mechanism.

2. The powered fastener driver of claim 1, wherein: When the fastener delivery mechanism is in the fastener delivery position, the powered fastener driver is permitted to fire and drive a fastener into a workpiece.

3. The powered fastener driver of claim 1, wherein: When the fastener delivery mechanism is in an incorrect position, the powered fastener driver is prevented from firing.

4. The powered fastener driver of claim 1, wherein: When the fastener delivery mechanism is not in the fastener delivery position, the powered fastener driver is not permitted to fire and drive fasteners into a workpiece.

5. The powered fastener driver of claim 1, wherein: The fastener delivery mechanism includes an actuator portion coupled to the pusher, and wherein the actuator portion moves the pusher in a first direction to retrieve the fastener when the fastener delivery mechanism is in the fastener retrieval position.

6. The powered fastener driver of claim 5, wherein: When the fastener delivery mechanism is in the fastener delivery position, the actuator portion moves the advancer in a second direction to move a fastener into the fastener drive channel.

7. The powered fastener driver of claim 1, wherein: The fastener delivery mechanism includes at least one magnet, and the at least one magnet is sensed by the sensor to determine when the fastener delivery mechanism is in the fastener delivery position.

8. The powered fastener driver of claim 7, wherein: The sensor is a Hall Effect sensor.

9. The powered fastener driver of claim 1, wherein: The fastener delivery mechanism includes at least one metal target, and the at least one metal target is sensed by the sensor to determine when the fastener delivery mechanism is in the fastener delivery position.

10. The powered fastener driver of claim 9, wherein: The sensor is an inductive sensor.

11. The powered fastener driver of claim 1, wherein: The powered fastener driver further comprises: A workpiece contact support disposed on the front end member, the workpiece contact support including a workpiece contact support target; and The second sensor is used to detect the position where the workpiece contacts the support target.

12. A powered fastener driver, characterized in that: The powered fastener driver includes: case; a front end member extending from the housing; a workpiece contact support slidably disposed on the front end member, the workpiece contact support including at least one workpiece contact support target; a driver blade movable within the front end member; a piston coupled to the driver blade for movement therewith; a driver cylinder in which the piston is movable between a top dead center position and a bottom dead center position; a cassette coupled to the front end member, wherein the array of fasteners can be received in the cassette; a fastener delivery mechanism coupled to the front end piece for individually delivering the aligned fasteners in the magazine to the fastener drive channels in the front end piece, the fastener delivery mechanism comprising at least one actuator target; a first sensor for detecting movement of the at least one workpiece contact support target and the workpiece contact support; and A second sensor is provided for detecting movement of the at least one actuator target and movement of the fastener delivery mechanism.

13. The powered fastener driver of claim 12, wherein: The at least one workpiece contact holder target and the at least one actuator target include metal targets.

14. The powered fastener driver of claim 13, wherein: These metal targets are ferrous targets.

15. The powered fastener driver of claim 14, wherein: These ferrous targets are steel targets.

16. The powered fastener driver of claim 12, wherein: The first sensor and the second sensor include inductive sensors.

17. The powered fastener driver of claim 12, wherein: When the workpiece contact support slides on the front end between the extended position and the retracted position, the at least one workpiece contact support target is sensed by the second sensor to determine the position of the workpiece contact support.

18. The powered fastener driver of claim 17, wherein: In the extended position, the powered fastener driver is prevented from firing.

19. The powered fastener driver of claim 18, wherein: In the retracted position, the powered fastener driver is engaged with a workpiece and the powered fastener driver is authorized to fire.

20. The powered fastener driver of claim 12, wherein: The fastener delivery mechanism includes a first rocker arm coupled to an advancer, and at least one actuator target is sensed by the second sensor to determine a position of the fastener delivery mechanism as the fastener delivery mechanism delivers fasteners one at a time to the fastener drive channel of the front piece.

21. The powered fastener driver of claim 20, wherein: The fastener delivery mechanism moves to the fastener acquisition position when the first rocker arm rotates clockwise and moves the pusher in a downward direction away from the nose piece.

22. The powered fastener driver of claim 21, wherein: When the first rocker arm rotates clockwise, the pusher moves in an upward direction toward the nose piece and moves the captured fastener into the fastener drive channel of the nose piece, and the fastener delivery mechanism moves to the fastener delivery position.

23. The powered fastener driver of claim 22, wherein: In the fastener delivery position, the powered fastener driver is permitted to fire.

24. A powered fastener driver, characterized in that: The powered fastener driver includes: case; a front end member extending from the housing; a driver blade movable within the front end member; a piston coupled to the driver blade for movement therewith; a driver cylinder in which the piston is movable between a top dead center position and a bottom dead center position; a cassette coupled to the front end member, wherein the array of fasteners can be received in the cassette; a fastener delivery mechanism coupled to the front end piece for individually delivering the aligned fasteners in the magazine to the fastener drive channels in the front end piece, the fastener delivery mechanism being movable between a fastener acquisition position and a fastener delivery position; and A sensor is used to detect whether a fastener is in the fastener drive channel.

25. The powered fastener driver of claim 24, wherein: The powered fastener driver is enabled to fire when a fastener is detected within the fastener drive channel.

26. The powered fastener driver of claim 24, wherein: The powered fastener driver is inhibited from firing when no fastener is detected within the fastener drive channel.

27. The powered fastener driver of claim 24, wherein: The sensor is an inductive sensor adjacent to the fastener drive channel.

28. The powered fastener driver of claim 24, wherein: The sensor is a micro switch within the fastener drive channel.

29. The powered fastener driver of claim 24, wherein: The sensor is an optical sensor adjacent to the fastener drive channel.

30. The powered fastener driver of claim 24, wherein: The sensor is an acoustic sensor adjacent to the fastener drive channel.

31. The powered fastener driver of claim 24, wherein: The fastener delivery mechanism includes an actuator, and wherein the actuator includes an actuator target that is sensed to determine when the fastener delivery mechanism is in the fastener acquisition position and the fastener delivery position.

32. The powered fastener driver of claim 31, wherein: The powered fastener driver further includes a motor and a lifter mechanism operable to return the driver blade within the driver cylinder toward the top dead center position, wherein the motor is activatable to drive a fastener into a workpiece when the fastener delivery mechanism is in the fastener delivery position.

33. The powered fastener driver of claim 32, wherein: When the fastener delivery mechanism is not in the fastener delivery position, the motor cannot be activated.

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