Rotary hammer

Abstract

A rotary hammer includes a housing and a mode selection dial supported in the housing. The mode selection dial includes a cam. The housing supports a motor that provides a rotational output. The housing supports a link that is movable between a first position and a second position in response to engagement of the cam. The runaway detection system measures acceleration of the housing and disables the motor when the acceleration exceeds an acceleration threshold. The housing supports an operation mode detection system including a magnet and a Hall effect sensor. A magnet is coupled to the link and is movable with the link between a third position corresponding to the first position of the link and a fourth position corresponding to the second position of the link. The Hall effect sensor provides an output signal indicative of the magnet position. The out-of-control detection system is selectively disabled based on the output signal.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 582,991 filed on September 15, 2023 and U.S. Provisional Patent Application No. 63 / 505,023 filed on May 30, 2023, the entire contents of each of which are incorporated herein by reference. Technical Field

[0003] The present disclosure relates to rotary hammers and, more particularly, to a rotary hammer operating mode detection system. Background Art

[0004] A rotary hammer is generally configured to generate simultaneous rotational and axial motion of a tool bit. The rotary hammer includes a housing and a motor supported in the housing, the motor providing a rotational output transmitted to the tool bit. During use, the protection of the rotary hammer is a technical problem that needs to be urgently addressed. Utility Model Content

[0005] The present disclosure provides a rotary hammer configured to produce simultaneous rotational and axial motion of a tool bit, the rotary hammer having a runaway detection system and an operating mode detection system. The runaway detection system is deactivated based on the operating mode of the tool as detected by the operating mode detection system.

[0006] On the other hand, the present disclosure provides a rotary hammer that can be operated in a first mode and a second mode, in which only a hammering operation that reciprocates a tool bit along a drive axis is performed, and in which the tool bit is driven rotationally around the drive axis. The rotary hammer includes a housing, a mode selection dial, a motor, a connecting rod, a loss of control detection system, and an operation mode detection system. The mode selection dial is supported in the housing and can move between a plurality of positions indicating a first mode and a second mode. The mode selection dial includes a cam. The motor is supported in the housing and provides a rotational output. The connecting rod is supported in the housing and can move between a first position and a second position in response to engagement of the cam. The loss of control detection system is configured to measure the acceleration of the housing and disable the motor when the acceleration exceeds an acceleration threshold. The operation mode detection system is supported in the housing and includes a magnet and a Hall effect sensor. The magnet is coupled to the connecting rod and can move with the connecting rod between a third position corresponding to the first position of the connecting rod and a fourth position corresponding to the second position of the connecting rod. The Hall effect sensor is coupled to the housing and provides an output signal indicating the position of the magnet. A runaway detection system is selectively disabled based on the output signal.

[0007] In some embodiments, the operating mode detection system further includes a magnet holder coupled to the connecting rod, the magnet holder securing the magnet to the connecting rod.

[0008] In some embodiments, the magnet holder is coupled to the connecting rod via a snap fit.

[0009] In some embodiments, the rotary hammer further includes a controller configured to operate the runaway detection system, wherein the controller is coupled to the Hall effect sensor via a first wire, and wherein the housing defines a channel, the first wire being at least partially disposed in the channel.

[0010] In some embodiments, the rotary hammer further includes a lighting ring disposed on a front side of the housing and electrically connected to the controller via a second wire, wherein the second wire is at least partially disposed within the channel together with the first wire.

[0011] In some embodiments, the mode selection dial is supported on a side of the housing.

[0012] In some embodiments, the mode selection dial is supported on a top portion of the housing.

[0013] In some embodiments, the connecting rod is capable of moving in a direction parallel to the drive axis.

[0014] In some embodiments, the rotary hammer further includes: an intermediate shaft defining a rotational axis, the intermediate shaft being supported in the housing so that the rotational axis is perpendicular to the motor rotational output and parallel to the drive axis, the intermediate shaft receiving the rotational output from the motor; a pinion gear coupled to the intermediate shaft and rotatable therewith; a rotational output gear supported on the intermediate shaft and rotatable relative to the intermediate shaft, the rotational output gear being configured to provide a rotational output to the tool bit, the connecting rod being engageable with the rotational output gear in the second position; and a coupling sleeve slidably disposed on the pinion gear and selectively engageable with the rotational output gear to transmit rotation from the pinion gear to the rotational output gear, wherein the mode selection dial engages the coupling sleeve to slide the coupling sleeve along the pinion gear out of engagement with the rotational output gear while the connecting rod moves to the second position, thereby engaging the rotational output gear and disabling the rotational output to the tool bit.

[0015] In some embodiments, the loss of control detection system is disabled when the output signal is within a range of sensor thresholds.

[0016] In some embodiments, the fourth position is closer to the Hall effect sensor than the third position, and wherein the runaway detection system is enabled when the magnet is closer to the third position.

[0017] In another aspect, the present disclosure provides a rotary hammer comprising a housing, a sensor coupled to the housing, a mode selection dial, a motor, a transmission mechanism, a connecting rod supported in the housing, a controller, and an operating mode detection system. The sensor is configured to provide a parameter signal indicating a measured parameter of the housing about a drive axis. The mode selection dial includes a cam and is supported in the housing and is movable between a plurality of positions indicating a first operating mode and a second operating mode. The motor is supported in the housing and provides a rotational output. The transmission mechanism is supported in the housing and is configured to receive the rotational output from the motor and selectively provide a rotational transmission output to a tool bit. The connecting rod is movable between a first position and a second position in response to engagement of the cam. The controller includes a runaway detection system configured to receive a parameter signal and compare the parameter signal with a parameter threshold. The controller is operable to disable the motor when the parameter signal exceeds the parameter threshold. The operating mode detection system includes: a magnet coupled to the connecting rod and movable with the connecting rod; and a Hall effect sensor coupled to the housing and providing an output signal indicating the position of the magnet. The runaway detection system is disabled when the rotational transmission output to the tool bit is disabled.

[0018] In some embodiments, the transmission mechanism includes: an intermediate shaft defining a rotational axis, the intermediate shaft supported in the housing so that the rotational axis is perpendicular to the motor rotational output and parallel to the drive axis, the intermediate shaft receiving the rotational output from the motor; a pinion gear coupled to the intermediate shaft and rotatable therewith; a rotational output gear supported on the intermediate shaft and rotatable relative to the intermediate shaft, the rotational output gear being configured to provide a rotational output to the tool bit; and a coupling sleeve slidably disposed on the pinion gear and selectively engageable with the rotational output gear to transmit rotation from the pinion gear to the rotational output gear, wherein the connecting rod is slidable in a direction parallel to the rotational axis and engageable with the rotational output gear in the second position, and wherein the mode selection dial engages the coupling sleeve to slide the coupling sleeve along the pinion gear out of engagement with the rotational output gear while the connecting rod moves to the second position, thereby engaging the rotational output gear and disabling the rotational output to the tool bit.

[0019] In some embodiments, the connecting rod is capable of moving in a direction perpendicular to the drive axis.

[0020] In some embodiments, the loss of control detection system is disabled when the output signal is within a range of sensor thresholds.

[0021] In some embodiments, the housing includes a lighting ring disposed on a front side of the housing, the lighting ring defining a channel therein extending away from the tool bit, the Hall effect sensor being coupled to the housing proximate the channel.

[0022] In some embodiments, the operating mode detection system further includes a magnet holder coupled to the connecting rod, the magnet holder maintaining the magnet in a coupled relationship with the connecting rod.

[0023] In another aspect, the present disclosure provides a rotary hammer comprising a housing, a mode selection dial supported in the housing, a motor, an impact mechanism, a connecting rod supported in the housing, a controller, and an operation mode detection system including a magnet and a Hall effect sensor. The mode selection dial can be rotated between a plurality of positions indicating the operation modes, the operation modes including a first hammering operation, and a second mode in which only a drilling operation is performed. The mode selection dial includes a cam. The motor is supported in the housing and provides a rotational output received by the impact mechanism, which converts the rotational output into a successive reciprocating motion, thereby performing the first mode. The impact mechanism can be selectively activated by the mode selection dial. The connecting rod can move between a first position and a second position based on the engagement of the cam. The controller includes a runaway detection system configured to disable the motor when the acceleration of the housing exceeds an acceleration threshold. The magnet is coupled to the connecting rod and can move with the connecting rod. The Hall effect sensor is coupled to the housing and provides an output signal indicating the position of the magnet to the controller. When the connecting rod is in the second position, the Hall effect sensor is closer to the magnet than when the connecting rod is in the first position.

[0024] In some embodiments, the controller can use the output signal to control the direction of rotation of the motor.

[0025] In some embodiments, the controller can use the output signal to control the speed of the motor.

[0026] Other features and aspects of the subject matter will become apparent by consideration of the following detailed description and accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 is a first embodiment of a rotary hammer according to the present disclosure.

[0028] Figure 2 yes Figure 1 A cross-sectional view of a portion of a rotary hammer.

[0029] Figure 3 yes Figure 1A cross-sectional view of a portion of a rotary hammer including a transmission mechanism.

[0030] Figure 4 yes Figure 1 A cross-sectional view of a portion of a rotary hammer including a transmission mechanism.

[0031] Figure 5 yes Figure 1 A cross-sectional view of a portion of a rotary hammer including a transmission mechanism.

[0032] Figure 6 yes Figure 1 A cross-sectional view of a portion of a rotary hammer including a transmission mechanism.

[0033] Figure 7 yes Figure 1 A cross-sectional view of a portion of a rotary hammer including an operating mode detection system.

[0034] Figure 8 yes Figure 1 A cross-sectional view of a portion of a rotary hammer including an operating mode detection system.

[0035] Fig. 9 yes Figure 1 A perspective view of the operating mode detection system of the rotary hammer.

[0036] Fig.10 is a perspective view of a section of another embodiment of a rotary hammer.

[0037] Fig.11 yes Fig.10 An overhead view of the mode selector dial for the rotating hammer.

[0038] Fig.12 yes Fig.10 Cross-sectional view of a rotary hammer.

[0039] Fig.13 yes Fig.10 A perspective view of a rotary hammer including an operating mode detection system and a mode selection dial.

[0040] Fig.14 yes Fig.10 A perspective view of a rotary hammer including an operating mode detection system and a mode selection dial.

[0041] Fig.15 yes Fig.10 A cross-sectional view of a rotary hammer including an operating mode detection system.

[0042] Fig.16 yes Fig.10 A cross-sectional view of a rotary hammer including an operating mode detection system.

[0043] Fig.17 yes Fig.10 A cross-sectional view of a rotary hammer including an operating mode detection system.

[0044] Before explaining any embodiments of the subject matter in detail, it should be understood that the subject matter is not limited in its application to the construction details and component arrangements set forth in the following description or shown in the following figures. The subject matter can have other embodiments and can be practiced or implemented in a variety of different ways. In addition, it should be understood that the words and terms used herein are for descriptive purposes and should not be considered limiting. DETAILED DESCRIPTION

[0045] refer to Figure 1 and Figure 2 , a first embodiment of a tool (e.g., a rotary hammer 10) is shown that is operable to convert the rotary motion of a motor 14 into simultaneous rotary motion and axial motion of a tool bit 18 along a drive axis A1. The illustrated rotary hammer 10 is operable in four modes: (1) a hammer-only mode, in which the rotary hammer 10 performs only a hammering operation, i.e., the tool bit 18 only reciprocates along the drive axis A1; (2) a drill-only mode, in which the rotary hammer 10 performs only a drilling operation, i.e., rotation of the tool bit 18 about the drive axis A1; (3) a hammer-drill mode, in which the rotary hammer 10 performs both a hammering operation and a drilling operation; and (4) a chisel adjustment mode or chisel rotation mode, in which a user rotates the tool bit 18 about the drive axis A1, but the rotary output of the motor 14 is not transmitted to the tool bit 18, and only a hammering operation is performed. The tool bit 18 is shown as a drill bit, however, other types of bits (e.g., a chisel bit) may be substituted for the drill bit depending on the application in which the user is operating the rotary hammer 10.

[0046] The rotary hammer 10 has a housing 22 having sides (a left side 26 is shown, a right side is not shown but is similar to the left side), a top 34 connecting the sides 26, and a front 38 from which the tool bit 18 extends. A rear portion 42 of the housing 22 includes a handle 46 from which extends a trigger 50 that activates the rotary hammer 10. A power source 54 (e.g., a battery pack, such as a rechargeable battery pack having a voltage capacity of 12V, 18V, or other voltage capacity) is coupled to the housing 22, adjacent to a bottom 58 of the housing 22.

[0047] The housing 22 includes an illumination ring 62 (eg, Figure 7 and Figure 82 ), the lighting ring is disposed on the front portion 38 of the housing 22. The lighting ring 62 includes a plurality of light emitting diodes 66 (LEDs, for example three LEDs), each supported on a printed circuit board (LED PCB 70). The lighting ring 62 defines a channel 74 extending along an extension 78 of the lighting ring 62 extending from an annular portion 82 where the LEDs 66 are located. Power wires 84 for the LEDs 66 are routed within the channel 74 and interconnect the LED PCB 70 with a controller 90. The LEDs 66 are directed toward the tool bit 18 to illuminate the tool bit 18 and the work space surrounding the tool bit 18.

[0048] refer to Figure 2 , the controller 90 is in the rearward direction of the motor 14 (i.e., toward the handle 46, toward Figure 2 14 ) is supported in the housing 22. The controller 90 is configured to control the operation of the rotary hammer 10. The controller 90 includes a loss of control detection system 94 (schematically shown as LOCDS) having a sensor 98 that measures a parameter of the housing 22 (e.g., acceleration, angular acceleration, angular velocity, position, etc. of the housing 22) and outputs a parameter signal. When the measured parameter exceeds a parameter threshold for a set amount of time, the controller 90 performs a protective operation (e.g., disabling operation of the motor 14, reducing power supplied to the motor 14, etc.). The amount of time may vary depending on many factors (e.g., the type of tool connected, the selected operating mode, etc.).

[0049] In this regard, when the rotary hammer 10 is in operation, the motor 14 (e.g., a brushless DC motor) provides a rotational output that is transmitted to the tool bit 18, and the controller 90 samples the parameter signal of the sensor 98 (e.g., the angular acceleration on each of the three orthogonal main axes) to determine the measured parameter of the housing 22 (e.g., the angular acceleration about the drive axis A1 measured in radians per square second). In other embodiments, the controller 90 can integrate the output or perform other operations to determine the measured parameter (e.g., the angular velocity of the tool 1 measured in radians per second; the position of the rotary hammer 10 relative to the initial position), and perform a protective operation when the measured parameter (e.g., the angular velocity or the position of the rotary hammer 10) has exceeded a tool threshold (e.g., a threshold speed, or a position change that has exceeded a threshold). In some embodiments, the controller 90 samples the rotational speed of the housing 22 every ten milliseconds, but in other embodiments, this sampling frequency can be higher or lower. For example, in some embodiments, the controller 90 samples the rotational speed of the housing 22 every millisecond.

[0050] In some embodiments, the controller 90 increments or decrements a counter when comparing the measured parameter with the tool threshold and determining that the measured parameter has exceeded the tool threshold, and then compares the counter with the counter threshold, and if the counter has exceeded the counter threshold, determines that a loss of control event has occurred, and when the counter has exceeded the counter threshold, performs a protection operation on the rotary hammer 10. In other embodiments, the controller 90 may instead reduce the power supplied to the motor 14 to slow the rotation of the motor 14.

[0051] The housing 22 supports the motor 14, which includes a rotor 102 coupled to a motor output shaft 106, which is supported within a stator 110 (e.g., via bearings 114) and rotatable about a motor rotation axis A2. A fan 118 is coupled to the motor output shaft 106 at a first end 122, and a motor pinion 126 is coupled to the motor output shaft 106 at a second end 130. The motor pinion 126 engages a transmission input gear 134 (e.g., a bevel gear) to transfer the rotation of the motor output shaft 106 to a transmission 138.

[0052] The transmission 138 includes an intermediate shaft 142 on which a transmission input gear 134, a transmission pinion 146, a rotary output gear 150, and a first coupling sleeve 154 and a second coupling sleeve 158 are supported. The transmission pinion 146 is coupled to the intermediate shaft 142 to rotate with the intermediate shaft 142 about the transmission rotation axis A3, and the rotary output gear 150 is supported on the intermediate shaft 142 (e.g., by a bearing) so that the rotary output gear 150 can rotate relative to the intermediate shaft 142, that is, independently of the intermediate shaft. The first coupling sleeve 154 is supported on the transmission pinion 146 and is slidable so as to engage the rotary output gear 150, thereby coupling the rotary output gear 150 to rotate with the intermediate shaft 142 and the transmission pinion 146. The second coupling sleeve 158 is also supported on the transmission pinion 146 and is slidable relative to the transmission pinion 146 so as to engage the impact mechanism 162 supported on the intermediate shaft 142.

[0053] The rotational output gear 150 engages the gear portion 166 of the spindle 170 to transfer rotation of the intermediate shaft 142 to the spindle 170, and thereby to the tool bit 18, which is coupled to the spindle 170 (e.g., via a chuck, quick-change collet, or other fastening structure configured to receive the tool bit 18 and couple it to the rotary hammer 10). When the first coupling sleeve 154 is engaged with the rotational output gear 150, the rotational output of the motor 14 is transferred from the motor output shaft 106 to the intermediate shaft 142 via the transmission input gear 134, from the intermediate shaft 142 to the rotational output gear 150 through the coupling engagement of the first coupling sleeve 154 with the transmission pinion 146 and the rotational output gear 150, and from the rotational output gear 150 to the spindle 170 and the tool bit 18. Disengagement of the first coupling sleeve 154 from the rotational output gear 150 disables the transfer of the rotational output from the motor 14 to the tool bit 18.

[0054] The impact mechanism 162 (e.g., a swing drive system including a swing support 174) is supported on the intermediate shaft 142 between the transmission input gear 134 and the transmission pinion 146, and the rotary output gear 150 is rotatably supported on the intermediate shaft 142 at a position farthest from the transmission input gear 134. The impact mechanism 162 is also supported on the intermediate shaft 142 (e.g., with a bearing) so that it can rotate independently of the intermediate shaft 142. The second coupling sleeve 158 slides on the transmission pinion 146 to engage the swing support 174. The impact mechanism 162 also includes a cylinder 178, which is supported on the main shaft 170 and coupled to the swing support 174. The cylinder 178 reciprocates through the swing support 174, and the striker 182 supported in the cylinder 178 reciprocates through an air cushion within the cylinder 178 and between the cylinder 178 and the striker 182. The striker 182 impacts an anvil 186 supported on the spindle 170 and applies axial impacts thereto, which are transmitted to the tool bit 18 as hammer impacts.

[0055] The mode selector dial 86 is supported on the side 26 of the housing 22 and is rotatable between a plurality of positions (P1 to P4) that indicate the mode in which the rotary hammer 10 is operating. Figures 3 to 6 , the mode selection dial 86 includes a first arm 190 and a second arm 194 extending from the mode selection dial 86 and a cam 198 at least partially defined by surfaces of the mode selection dial 86 and the arms 190, 194. The arms 190, 194 engage the first coupling sleeve 154 and the second coupling sleeve 158 to translate the first coupling sleeve 154 and the second coupling sleeve 158 along the transmission pinion 146.

[0056] The connecting rod 202 is supported in the housing 22 and is slidable between a first position P5 and a second position P6 parallel to the drive axis A1. A biasing member 206 (eg, a compression spring) biases the connecting rod 202 to the second position P6 ( Figure 3 The cam 198 selectively engages the link 202 (eg, by rotation of the mode selector dial 86) to overcome the bias of the biasing member 206 and translate the link 202 to the first position P5 ( Figure 4 ). refer to Fig. 9 , the connecting rod 202 includes an engagement portion 210 having teeth 214 corresponding to the pitch of the rotary output gear 150. Return Figure 3 When the connecting rod 202 is in the second position P6, the connecting rod 202 engages the rotation output gear 150, thereby preventing the rotation output gear 150 from rotating, thereby preventing the main shaft 170 from rotating.

[0057] refer to Figure 3 When the mode selection dial 86 is in the position P1 corresponding to the first hammer-only mode in which the rotary hammer 10 performs only the hammering operation, the first arm 190 engages the first coupling sleeve 154 so as to slide the first coupling sleeve 154 along the transmission pinion 146 against the bias of the spring 218 engaging the first coupling sleeve 154 so as to slide the first coupling sleeve 154 out of engagement with the rotary output gear 150. By disengaging the transmission pinion 146 from the rotary output gear 150, rotation is not transmitted from the motor 14 to the spindle 170, thereby disabling rotation of the tool bit 18. The spring 218 biases the second coupling sleeve 158 along the transmission pinion 146 into engagement with the swing support 174, thereby allowing the rotation output of the motor 14 to be transmitted from the intermediate shaft 142 and the transmission pinion 146 to the swing support 174, thereby enabling an axial impact to be applied to the tool bit 18. In position P1 corresponding to the hammer-only mode, the cam 198 does not engage the connecting rod 202, and the connecting rod 202 is biased from the first position P5 to the second position P6 by the biasing member 206. The engaging portion 210 of the connecting rod 202 contacts and prevents the rotating output gear 150 from rotating, and thus the spindle 170 from rotating.

[0058] refer to Figure 4, when the mode selection dial 86 is in the position P2 of the second drilling-only mode corresponding to the rotary hammer 10 performing only the drilling operation or the rotation of the tool bit 18 about the drive axis A1. The spring 218 biases the first coupling sleeve 154 along the transmission mechanism pinion 146 into engagement with the rotation output gear 150 to enable the rotation output to be transmitted from the motor 14 to the rotation output gear 150 via the transmission mechanism pinion 146, and thus, to the spindle 170 and the tool bit 18. The cam 198 of the mode selection dial 86 engages the connecting rod 202 to overcome the force of the biasing member 206 and push the connecting rod 202 out of engagement with the rotation output gear 150, thereby allowing the rotation output gear 150 to rotate.

[0059] refer to Figure 5 When the mode selection dial 86 is in the position P3 corresponding to the third hammer-drilling mode in which the hammering operation and the drilling operation are performed simultaneously, the arms 190, 194 of the mode selection dial 86 do not engage the first sleeve 154 and the coupling sleeve 158. The first coupling sleeve 154 engages the transmission mechanism pinion 146 and the rotation output gear 150 to transmit the rotation of the motor 14 to the rotation output gear 150, the spindle 170, and the tool bit 18. The second coupling sleeve 158 engages the swing support 174 and the transmission mechanism pinion 146 to transmit the rotation output of the motor 14 to the swing support 174, which applies an axial impact to the tool bit 18 through the impact mechanism 162. The cam 198 biases the connecting rod 202 out of engagement with the rotation output gear 150.

[0060] refer to Figure 6 , when the mode select dial 86 is in position P4 corresponding to the fourth chisel adjustment mode or chisel rotation mode, the first arm 190 of the mode select dial 86 biases the first coupling sleeve 154 out of engagement with the rotation output gear 150, thereby disabling the transmission of rotation output from the motor 14 to the rotation output gear 150, the spindle 170, and the tool bit 18. The cam 198 engages the connecting rod 202 to bias the connecting rod 202 out of engagement with the rotation output gear 150, thereby allowing the rotation output gear 150 to rotate relative to the intermediate shaft 142 without subsequently transmitting the rotation to the transmission mechanism pinion 146. The user is able to rotate the spindle 170 and thus the tool bit 18 to position the tool bit 18 to perform an operation.

[0061] refer to Figures 7 to 9, an operating mode detection system 222 is supported in the housing 22. The operating mode detection system 222 includes a magnet 226 and a Hall effect sensor 230 located on a Hall effect PCB 232, which senses the magnetic field of the magnet 226 and outputs an output signal indicating the position of the magnet 226 relative to the Hall effect sensor 230. In the present embodiment, the sensor is a pulse width modulated sensor that outputs a digital signal (i.e., a high value or a low value) having a duty cycle (i.e., a pulse width) that depends on the strength of the magnetic field. In other embodiments, the sensor may be an analog sensor that outputs a signal that depends linearly on the strength of the measured magnetic field. In yet other embodiments, the sensor may alternatively be a digital sensor that outputs a high value or a low value depending on whether the strength of the magnetic field is above a sensor threshold, below a sensor threshold, or within a sensor threshold range.

[0062] The magnet 226 is coupled to the connecting rod 202 and can be in the first position P5 ( Figure 7 ) and the third position P7 corresponding to the second position P6 ( Figure 8 ) and slide between the fourth position P8 corresponding to the magnet holder 234 ( Fig. 9 ) is coupled to the connecting rod 202 (e.g., with a snap fit) to maintain the position of the magnet 226 in a coupled relationship with the connecting rod 202. In other embodiments, the magnet 226 may be coupled to the magnet holder 234 or the connecting rod 202 in another manner. When the connecting rod 202 is in the first position P5 and the magnet 226 is in the third position P7, the magnet 226 is farther from the Hall effect sensor 230 than when the connecting rod 202 is in the second position P6 and the magnet 226 is in the fourth position P8. When the connecting rod 202 is in the second position P6 and the magnet 226 is in the fourth position P8, the strength of the magnetic field, and therefore the output signal, is stronger than when the connecting rod 202 is in the first position P5 and the magnet 226 is in the third position P7.

[0063] The Hall effect PCB 232 is disposed in a receptacle 233 in the front portion 38 of the housing 22 and is electrically coupled to and provides output signals to the controller 90 via wires 238 disposed in the channel 74 of the lighting ring 62, alongside the power wires 84 of the LEDs 66. In another embodiment, the receptacle 233 is defined in the extension 78 of the lighting ring 62.

[0064] The controller 90 disables the LOCDS 94 based on the output signal from the Hall effect sensor 230. In the present embodiment, the LOCDS 94 operates as a default condition. That is, unless the controller 90 has disabled the LOCDS 94, the LOCDS 94 is enabled. The controller 90 disables the LOCDS 94 when the output signal from the Hall effect sensor 230 is within the range of the sensor threshold (i.e., within the range of values ​​corresponding to the sensing threshold). In other embodiments, the controller 90 disables the LOCDS 94 when the output signal from the Hall effect sensor 230 is below the sensor threshold. In other embodiments, the controller 90 disables the LOCDS 94 when the output signal from the Hall effect sensor 230 is above the sensor threshold. When the connecting rod 202 translates from the first position P5 to the second position P6 in a direction parallel to the drive axis A1, and the magnet 226 translates from the third position P7 to the fourth position P8, the strength of the magnetic field increases, and the output signal of the Hall effect sensor 230 reflects the increase in the magnetic field. The controller 90 disables the LOCDS 94 when the output signal is within the sensor threshold range. When the connecting rod 202 translates from the second position P6 to the first position P5, and the magnet 226 translates from the fourth position P8 to the third position P7, the magnetic field measured by the Hall effect sensor 230 becomes weaker, or decreases to a zero magnetic field, the output signal of the Hall effect sensor 230 reflects the decrease, and the LOCDS 94 defaults to an enabled state. In other words, the controller 90 disables the LOCDS 94 when the rotary hammer 10 is operated in the hammer-only mode and the chisel adjustment mode, that is, when the rotation transmission output to the tool bit 18 is disabled. When rotation is not transmitted to the spindle 170, the risk of the operator losing control of the rotary hammer 10 is reduced. It will be appreciated that by disabling the LOCDS 94, a nuisance cutoff (e.g., a protective operation in which the motor is disabled when the user maintains (i.e., has not lost) control of the rotary hammer) can be eliminated.

[0065] refer to Figures 10 to 17 , shows a second embodiment of a rotary hammer 10' (e.g., a rotary hammer) that is operable to convert the rotary motion of a motor 14' into simultaneous rotary motion and axial motion of a tool bit 18' along a drive axis A1, similar to the above rotary hammer 10. Numbers of features that differ from the above features will include a prime (') reference number, wherein like features are indicated by like reference numerals.

[0066] refer to Figures 10 to 12, the rotary hammer 10' shown can be operated in three modes: (1) a hammer-only mode, in which the rotary hammer 10' only performs a hammering operation, that is, the tool bit 18' only reciprocates along the drive axis A1; (2') a hammer-drill mode, in which the rotary hammer 10' simultaneously performs a hammering operation and a drilling operation; and (3') a chisel adjustment mode or a chisel rotation mode, in which the user rotates the tool bit 18' about the drive axis A1, but the rotational output of the motor 14' is not transmitted to the tool bit 18', and only a hammering operation is performed.

[0067] Instead of the mode select dial 86' being rotatably supported on the side 26' of the housing 22', the mode select dial 86' is supported on the top 34' of the housing 22'. The mode select dial 86' is rotatable between four positions (P1' to P4') indicating the three modes of operation.

[0068] The controller 90' is located below the motor 14' in a direction away from the mode selection dial 86' (ie, toward the Fig.10 The controller 90' is configured to control the operation of the rotary hammer 10' in substantially the same manner as the first embodiment. In this regard, the controller 90' includes a LOCDS 94 (shown schematically) and performs protective operations, such as disabling the motor 14', reducing power to the motor 14', etc. when a measured parameter of the sensor 98 exceeds a parameter threshold.

[0069] The motor 14' includes a rotor 102' coupled to a motor output shaft 106', which is rotatably supported within a stator 110' (e.g., via bearings 114). A fan 118' is coupled to the motor output shaft 106' at a second end 130, and a motor pinion 126' is also coupled to the motor output shaft 106' at a second end 130. The motor pinion 126' engages with a transmission input gear 134' to transfer rotation of the motor output shaft 106' to the transmission 138' and the impact input gear 242 to transfer rotation to the impact mechanism 162'.

[0070] The transmission 138' includes an intermediate shaft 142' on which the transmission input gear 134' is supported. The intermediate shaft 142' is rotatably supported in the housing 22' (e.g., by bearings 144') and includes a rotary output gear portion 150' that engages with the gear portion 166' of the spindle 170' to transmit the rotary output of the motor 14' to the spindle 170' and the tool bit 18' coupled thereto. The intermediate shaft 142' defines a transmission rotation axis A3 that is substantially parallel to the rotation axis A2 of the motor 14' and perpendicular to the drive axis A1.

[0071] The impact mechanism 162' includes an impact input gear 242 coupled to the crankshaft 246 at a first end 250 of the crankshaft 246. The crankshaft 246 includes an eccentric pin 254 at a second end 258 coupled to a connecting rod 262. The connecting rod 262 is coupled to a piston 266, which is slidably supported on the main shaft 170'. The rotational output of the motor 14' is transmitted to the impact mechanism 162' via the impact input gear 242, which in turn rotates the crankshaft 246 about the crankshaft axis A4. The rotation of the crankshaft 246 about the crankshaft axis A4 is transmitted to the connecting rod 262 through the eccentric pin 254, which converts the rotation of the motor 14' and the crankshaft 246 into axial movement of the connecting rod 262 and, therefore, the piston 266 along the drive axis A1. The piston 266 transmits the axial movement to the striker 270 supported on the spindle 170' via the air cushion between the piston 266 and the striker 270, which reciprocates along the drive axis A1 with the piston 266. The striker 270 contacts the anvil 186' to produce continuous impacts on the anvil 186' and thus the tool bit 18'.

[0072] refer to Figure 13 to Figure 14 , the mode selection dial 86' includes an eccentrically oriented cam 198'. A link 202' having a central opening 274 is slidably supported in the housing 22', and the cam 198' is positioned in the central opening 274. The eccentric positioning of the cam 198' in the central opening 274 drives the link 202' to slide in the left-right direction along a link movement axis A5 perpendicular to the drive axis A1 between a first position P5' illustrated as the rightmost position in the figure and a second position P6' illustrated as the leftmost position in the figure.

[0073] refer to Fig.13 and Fig.15 , when the mode selection dial 86' is in the position P1 corresponding to the first hammer-only mode in which the rotary hammer 10' performs only the hammering operation, the connecting rod 202' is positioned at the first right position P5' by the cam 198' positioned in the central opening 274. In the hammer-only mode, the rotational output to the tool bit 18' is disabled, and only the axial impact is applied to the tool bit 18'.

[0074] refer to Fig.14 and 16 , when the mode selection dial 86' is in the position P2' corresponding to the second hammer drill mode for performing hammering operation and rotary drilling operation simultaneously, the connecting rod 202' is in the second farthest left position P6' based on the position of the cam 198' in the central opening 274. In the hammer drill mode, the rotary output to the tool bit 18' is enabled, as well as the axial impact applied to the tool bit 18'.

[0075] refer to Fig.11 and Fig.17 When the mode selection dial 86' is in the position P3', P4' corresponding to the third chisel adjustment mode, the connecting rod 202' is positioned between the first position P5' and the second position P6' based on the position of the cam 198' in the central opening 274. In the chisel adjustment mode, the rotational output from the motor 14' to the tool bit 18' is disabled, but the tool bit 18' can be rotatably positioned.

[0076] refer to Figures 13 to 17 , an operating mode detection system 222' is supported in the housing 22'. The operating mode detection system 222' includes a magnet 226' and a Hall effect sensor 230' coupled to a Hall effect PCB 232', which operate in substantially the same manner as described in the previous embodiment.

[0077] The magnet 226' is coupled to the connecting rod 202' and can be in the first position P5' ( Fig.13 , Fig.15 ) and the third position P7' corresponding to the second position P6' ( Fig.14 , Fig.16 ) between the fourth position P8' corresponding to the first position P10'. The magnet holder 234' is coupled to the connecting rod 202' (eg, by snap fit) to maintain the position of the magnet 226' in a coupled relationship with the connecting rod 202'.

[0078] The Hall effect sensor 230' is coupled to the housing 22', adjacent to the connecting rod 202'. The Hall effect sensor 230' provides an output signal to the controller 90'. When the connecting rod 202' is in the first position P5' and the magnet 226' is in the third position P7', the magnet 226' is farther from the Hall effect sensor 230' than when the connecting rod 202' is in the second position P6' and the magnet 226' is in the fourth position P8'. When the connecting rod 202' is in the second position P6' and the magnet 226' is in the fourth position P8', the strength of the magnetic field, and therefore the output signal, is stronger than when the connecting rod 202' is in the first position P5' and the magnet 226' is in the third position P7'.

[0079] The controller 90' enables the LOCDS 94' based on the output signal from the Hall effect sensor 230'. In the present embodiment, the LOCDS 94' is disabled as a default condition. That is, unless the controller 90' has enabled the LOCDS 94', the LOCDS 94' is disabled. In other words, the controller 90 enables the LOCDS 94 when the rotary hammer 10 is operating in the rotary hammer mode, that is, when the rotational drive output to the tool bit 18 is enabled; and the LOCDS 94 is disabled when the drive rotational output to the tool bit 18 is disabled. The controller 90' enables the LOCDS 94' when the output signal from the Hall effect sensor 230' is within the range of the sensor threshold. When the connecting rod 202' translates from the first position P5' to the second position P6' along the connecting rod movement axis A5 perpendicular to the drive axis A1, and the magnet 226' translates from the third position P7' to the fourth position P8', the strength of the magnetic field increases, and the output signal of the Hall effect sensor 230' reflects the increase in the magnetic field. The controller 90' enables LOCDS 94' when the output signal is within the range of sensor thresholds. When the connecting rod 202' translates from the second position P6' to the first position P5', and the magnet 226' translates from the fourth position P8' to the third position P7', the magnetic field measured by the Hall effect sensor 230' becomes weaker, or decreases to a zero magnetic field, the output signal of the Hall effect sensor 230' reflects the decrease, and LOCDS 94' returns to the default disabled state.

[0080] The controller 90, 90' of any of the foregoing embodiments may control other tool parameters based on the output signal from the Hall effect sensor 230, 230'. In one embodiment, the controller 90, 90' may control the direction of rotation of the motor 14, 14' based on the output signal received from the Hall effect sensor 230, 230'. That is, when the Hall effect sensor 230, 230' generates a signal indicating that the rotary hammer 10, 10' is operating in the hammer-only mode, the controller 90, 90' enables the motor to rotate in only one direction. In another embodiment, the trigger 50 is a variable speed trigger, whereby the rotation speed of the motor 14, 14' increases as the trigger 50 is depressed a greater distance, and the controller 90, 90' modifies the trigger map based on the output signal of the Hall effect sensor 230, 230'. For example, when the controller 90, 90' determines that the rotary hammer 10, 10' is operating in the hammer-only mode based on the output signal from the Hall effect sensor 230, 230', the controller 90, 90' operates the motor 14, 14' at the maximum speed when the trigger 50 has been depressed by a smaller amount than when the rotary hammer 10, 10' is operating in another mode (e.g., drill-only mode, rotary hammer mode). In other words, in one operating mode, operating the motor 14, 14' at the maximum speed requires a greater trigger shift than in a different operating mode. As an example, when the rotary hammer 10, 10' is operating in the hammer-only mode, the motor 14, 14' may be operated at the maximum speed when the trigger 50 has been depressed by 50% of the maximum trigger shift, and when the rotary hammer 10, 10' is operating in the other mode, the motor 14, 14' may be operated at the maximum speed when the trigger 50 has been depressed by seventy-five percent of the maximum trigger shift. In other embodiments, different trigger mappings may be used, such as different trigger shift percentages, different operating modes, etc. In other embodiments, the controller 90, 90' may operate other parameters of the rotary hammer 10, 10' in different ways based on the output signals from the Hall Effect sensors 230, 230'.

[0081] Although the subject matter 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 described subject matter.

[0082] Various features of the subject matter are set forth in the appended claims.

Claims

1. A rotary hammer, characterized in that: The rotary hammer is operable in a first mode in which only a hammering operation of reciprocating a tool bit along a drive axis is performed and in a second mode in which the tool bit is rotationally driven about the drive axis, the rotary hammer comprising: case; a mode select dial supported in the housing and movable between a plurality of positions indicating the first mode and the second mode, the mode select dial including a cam; a motor supported in the housing, the motor providing a rotational output; a connecting rod supported in the housing and movable between a first position and a second position in response to engagement of the cam; a runaway detection system configured to measure acceleration of the housing and disable the motor when the acceleration exceeds an acceleration threshold; and an operating mode detection system supported in the housing, the operating mode detection system comprising: a magnet coupled to the link and movable with the link between a third position corresponding to the first position of the link and a fourth position corresponding to the second position of the link, and a Hall effect sensor coupled to the housing, the Hall effect sensor providing an output signal indicative of a position of the magnet, Wherein the loss of control detection system is selectively disabled based on the output signal.

2. The rotary hammer according to claim 1, wherein: The operating mode detection system further includes a magnet holder coupled to the connecting rod, the magnet holder securing the magnet to the connecting rod.

3. The rotary hammer according to claim 2, wherein: The magnet holder is coupled to the connecting rod via a snap fit.

4. The rotary hammer of claim 1, further comprising a controller configured to operate the runaway detection system, wherein: The controller is coupled to the Hall effect sensor via a first wire, and wherein the housing defines a channel, the first wire being at least partially disposed in the channel.

5. The rotary hammer of claim 4, further comprising a lighting ring disposed on a front side of the housing and electrically connected to the controller through a second wire, wherein The second conductor is at least partially disposed within the channel together with the first conductor.

6. The rotary hammer according to claim 1, wherein: The mode selection dial is supported on one side of the housing.

7. The rotary hammer according to claim 1, wherein: The mode selection dial is supported on the top of the housing.

8. The rotary hammer according to claim 1, wherein: The connecting rod is movable in a direction parallel to the drive axis.

9. The rotary hammer of claim 1, further comprising: an intermediate shaft defining an axis of rotation, the intermediate shaft being supported in the housing such that the axis of rotation is perpendicular to the motor rotational output and parallel to the drive axis, the intermediate shaft receiving the rotational output from the motor; a pinion gear coupled to the intermediate shaft and rotatable with the intermediate shaft; a rotational output gear supported on the intermediate shaft and rotatable relative to the intermediate shaft, the rotational output gear being configured to provide a rotational output to the tool bit, the connecting rod being engageable with the rotational output gear in the second position; as well as a coupling sleeve slidably disposed on the pinion gear and selectively engageable with the rotary output gear to transmit rotation from the pinion gear to the rotary output gear, wherein the mode select dial engages the coupling sleeve to slide the coupling sleeve along the pinion gear out of engagement with the rotational output gear while the connecting rod moves to the second position, thereby engaging the rotational output gear and disabling rotational output to the tool bit.

10. The rotary hammer according to claim 1, wherein: When the output signal is within a range of sensor thresholds, the runaway detection system is disabled.

11. The rotary hammer according to claim 1, wherein: The fourth position is closer to the Hall effect sensor than the third position, and wherein the runaway detection system is enabled when the magnet is closer to the third position.

12. A rotary hammer, characterized in that: The rotary hammer is operable in a first mode in which only a hammering operation of reciprocating a tool bit along a drive axis is performed and in a second mode in which the tool bit is rotationally driven about the drive axis, the rotary hammer comprising: case; a sensor coupled to the housing and configured to provide a parameter signal indicative of a measured parameter of the housing about the drive axis; a mode select dial supported in the housing and movable between a plurality of positions indicating the first mode and the second mode, the mode select dial including a cam; a motor supported in the housing, the motor providing a rotational output; a transmission mechanism supported in the housing and configured to receive a rotational output from the motor, the transmission mechanism being configured to selectively provide a rotational transmission output to the tool bit; a connecting rod supported in the housing and movable between a first position and a second position in response to engagement of the cam; a controller including a runaway detection system configured to receive the parameter signal and compare the parameter signal to a parameter threshold, the controller being operable to disable the motor when the parameter signal exceeds the parameter threshold; and An operation mode detection system, the operation mode detection system comprising: a magnet coupled to the connecting rod and movable with the connecting rod; and a Hall effect sensor coupled to the housing, the Hall effect sensor providing an output signal indicative of a position of the magnet, Wherein, the loss of control detection system is disabled when the rotational transmission output to the tool bit is disabled.

13. The rotary hammer according to claim 12, wherein: The transmission mechanism comprises: an intermediate shaft defining an axis of rotation, the intermediate shaft being supported in the housing such that the axis of rotation is perpendicular to the motor rotational output and parallel to the drive axis, the intermediate shaft receiving the rotational output from the motor; a pinion gear coupled to the intermediate shaft and rotatable with the intermediate shaft; a rotary output gear supported on and rotatable relative to the intermediate shaft, the rotary output gear being configured to provide a rotary output to the tool bit; and a coupling sleeve slidably disposed on the pinion gear and selectively engageable with the rotary output gear to transmit rotation from the pinion gear to the rotary output gear, wherein the connecting rod is slidable in a direction parallel to the rotation axis and is engageable with the rotation output gear in the second position, and wherein the mode select dial engages the coupling sleeve to slide the coupling sleeve along the pinion gear out of engagement with the rotational output gear while the connecting rod moves to the second position, thereby engaging the rotational output gear and disabling rotational output to the tool bit.

14. The rotary hammer according to claim 13, wherein: The connecting rod is movable in a direction perpendicular to the drive axis.

15. The rotary hammer according to claim 12, wherein: When the output signal is within a range of sensor thresholds, the runaway detection system is disabled.

16. The rotary hammer according to claim 12, wherein: The housing includes a lighting ring disposed on a front side of the housing, the lighting ring defining a passage therein extending away from the tool bit, the Hall effect sensor being coupled to the housing proximate the passage.

17. The rotary hammer according to claim 12, wherein: The operating mode detection system further includes a magnet holder coupled to the connecting rod, the magnet holder maintaining the magnet in coupled relationship with the connecting rod.

18. A rotary hammer, characterized in that: The rotary hammer includes: case; a mode selection dial supported in the housing and rotatable between a plurality of positions indicating a plurality of modes, the plurality of modes including a first mode in which only a hammering operation of reciprocating the tool bit along the drive axis is performed and a second mode in which only a drilling operation of rotating the tool bit about the drive axis is performed, the mode selection dial including a cam; a motor supported in the housing and providing a rotational output; an impact mechanism supported in the housing and configured to receive a rotational output from the motor and convert the rotational output into a sequential reciprocating motion to thereby execute the first mode, the impact mechanism being selectively activatable by the mode select dial; a connecting rod supported in the housing and movable between a first position and a second position based on engagement of the cam; a controller including a runaway detection system configured to disable the motor when an acceleration of the housing exceeds an acceleration threshold; and An operation mode detection system, the operation mode detection system comprising: a magnet coupled to the connecting rod and movable with the connecting rod; and a Hall effect sensor coupled to the housing, the Hall effect sensor providing an output signal to the controller indicative of the position of the magnet, Wherein, when the connecting rod is in the second position, the Hall effect sensor is closer to the magnet than when the connecting rod is in the first position.

19. The rotary hammer according to claim 18, wherein: The controller can use the output signal to control the direction of rotation of the motor.

20. The rotary hammer according to claim 19, wherein: The controller can use the output signal to control the speed of the motor.

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