Power tool

Abstract

A power tool includes a housing, a motor, a first user input device, a second user input device, a controller, and a circuit board. The motor is at least partially disposed within the housing. The first input device is partially disposed within the housing and is configured to move along a first axis. A second input device is also partially disposed within the housing and is configured to move along a second axis orthogonal to the first axis. The controller is configured to control an operating characteristic of the motor. The circuit board is connected to the controller. The circuit board includes a first sensor and a second sensor on a first side of the circuit board. The first sensor is configured to sense a plurality of different positions of the first user input device. The second sensor is configured to sense a displacement along the second axis.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 594,485, filed October 31, 2023; U.S. Provisional Patent Application No. 63 / 633,325, filed April 12, 2024; and U.S. Provisional Patent Application No. 63 / 667,324, filed July 3, 2024, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This utility model relates to a power tool. Background Technology

[0004] Conventional power tools do not have the function of adjusting their operating characteristics or performance. The power tool of this application is equipped with multiple user input devices. After these user input devices are sensed by sensors on the circuit board, the sensors send the information to the controller, which then controls the operation of the motor, thereby realizing the adjustment of the operating characteristics or performance of the power tool. Utility Model Content

[0005] An embodiment of this utility model provides a power tool including a housing, a motor, a first user input device, a second user input device, a controller, and a circuit board. The motor is at least partially disposed within the housing. The first input device is also partially disposed within the housing and configured to move along a first axis to multiple different positions. The second input device is also partially disposed within the housing and configured to move along a second axis orthogonal to the first axis. The controller is configured to control the operating characteristics of the motor. The circuit board is connected to the controller. The circuit board includes a first sensor and a second sensor, both located on a first side of the circuit board. The first sensor is configured to sense multiple different positions of the first user input device. The second sensor is configured to sense displacement along the second axis of the second user input device.

[0006] In some respects, the first user input device is a multi-position switch, and the first user input device includes a switch body, a first magnetic element, and a first elastic element.

[0007] In some aspects, the switch body includes a recess configured to receive the first magnetic element, and the recess faces the first side of the circuit board.

[0008] In some respects, each of the multiple different locations sensed by the first sensor corresponds to the operating mode of the motor.

[0009] In some respects, the second user input device is a trigger for a power tool, and the second user input device includes a second magnetic element and a second elastic element.

[0010] In some respects, the displacement sensed by the second sensor determines the motor's output characteristics.

[0011] In some respects, the second user input device is orthogonal to the second axis along which it moves and the first user input device is orthogonal to the first axis along which it moves.

[0012] In some respects, the third sensor is located on the first side of the circuit board, adjacent to the first sensor, and the third sensor is configured to sense multiple different locations of the first user input device.

[0013] In some respects, the third sensor is located on the first side of the circuit board, adjacent to the second sensor, and is configured to sense displacement along the second axis of the second user input device.

[0014] In some respects, the third sensor generates a binary output based on the displacement of the second user input device along the second axis.

[0015] An embodiment of this utility model provides a power tool including a housing, a motor, a first user input device, a second user input device, a controller, a first circuit board, and a second circuit board. The first input device is also partially disposed within the housing and configured to move along a first axis to multiple different positions. The second input device is also partially disposed within the housing and configured to move along a second axis orthogonal to the first axis. The controller is configured to control the operating characteristics of the motor. The controller is mounted on the first circuit board. The second circuit board is electrically connected to the first circuit board and includes a first sensor and a second sensor. The first sensor is configured to sense multiple different positions of the first user input device. The second sensor is configured to sense displacement along the second axis of the second user input device.

[0016] In some respects, a third sensor is located on the second circuit board adjacent to the second sensor, and the third sensor is configured to sense displacement along the second axis of the second user input device.

[0017] In some respects, the third sensor generates a binary output based on the displacement of the second user input device along the second axis.

[0018] An embodiment of this utility model provides a power tool, which includes a housing, a motor, a controller, an input device housing, a first user input device, a second user input device, and a second circuit board. The motor is partially disposed within the housing. The controller is configured to control the operating characteristics of the motor and is mounted on the first circuit board. The first user input device is partially located within the input device housing and is displaceable along a first axis. The first user input device includes a first slider and a trigger magnet. The second input device is partially located within the input device housing and is rotatable about a second axis. The second user input device includes a second slider. The second circuit board is located within the input device housing and includes a first non-contact sensor, a plurality of contact rails, a plurality of contact pads, and a second non-contact sensor. The first non-contact sensor is configured to measure whether the first input device is displaced. The plurality of contact rails are configured to engage the first slider of the first user input device. The plurality of contact pads are configured to engage the second slider of the second input device. The second non-contact sensor is configured to measure the displacement of the first user input device along the first axis.

[0019] In some aspects, the input device housing includes a positioning groove with multiple notches.

[0020] In some aspects, the second user input device also includes multiple positioning balls and ball springs, with the multiple positioning balls located in positioning slots within the input device housing.

[0021] In some aspects, the first slide of the second user input device is circular and includes a plurality of protrusions configured to engage a plurality of contact pads on the second circuit board.

[0022] In some respects, the non-contact sensor is a digital Hall effect sensor configured to measure the magnetic flux of a trigger magnet as a first user input device moves along a first axis.

[0023] In some respects, the non-contact sensor is an inductive sensor configured to measure the change in inductance as a metallic target of the first user input device moves along a first axis.

[0024] In some respects, the sensor includes one or more contact rails configured to engage a second sliding plate of a first user input device.

[0025] Before explaining any embodiment in detail, it should be understood that the application of this embodiment is not limited to the component configuration and setup details described below or shown in the accompanying drawings. This embodiment can be implemented or performed in various ways. Furthermore, it should be understood that the wording and terminology used in this invention are for descriptive purposes only and should not be considered limiting. The use of "comprising," "containing," or "having..." and variations thereof means including the items listed below and their equivalents, as well as other items. Unless otherwise stated or limited, the terms "installation," "connection," "support," and "coupling," and variations thereof, are used broadly to include direct and indirect installation, connection, support, and coupling.

[0026] Unless otherwise explicitly stated in the context, the articles “a” and “this” should not be interpreted as “one” or “only one”. Instead, these articles should be interpreted as “at least one” or “one or more”. Similarly, when the terms “the” or “the” are used to refer to a noun previously introduced by the indefinite article “a”, “the” and “the” mean “at least one” or “one or more”, unless otherwise explicitly stated.

[0027] Furthermore, it should be understood that embodiments of this utility model may include hardware, software, and electronic components or modules, and for ease of discussion, these components may be described and illustrated primarily through hardware implementation. However, those skilled in the art will recognize, upon reading this detailed description, that in at least one embodiment, the electronic aspects may be implemented by software executed by one or more processing units (such as microprocessors and / or application-specific integrated circuits (“ASICs”) – for example, stored on a non-transitory computer-readable medium). Therefore, it should be noted that this embodiment may be implemented using multiple hardware and software-based devices and multiple different structural components. For example, “server,” “computing device,” “controller,” “processor,” etc., as described in the specification may include one or more processing units, one or more computer-readable medium modules, one or more input / output interfaces, and various connections (such as system buses) connecting the components.

[0028] Relative terms, such as “approximately,” “about,” “substantially,” and “truly,” used with respect to quantity or condition, are understood by one of ordinary skill in the art to include the stated value and have a meaning defined by the context (e.g., the term includes at least the degree of error associated with measurement accuracy, tolerances associated with a particular value [e.g., manufacturing, assembly, use, etc.]). These terms should also be considered to disclose a range defined by the absolute values ​​of the two endpoints. For example, the expression “from about 2 to about 4” also discloses a range “from 2 to 4.” Relative terms may refer to a percentage (e.g., 1%, 5%, 10%, or more) around an indicated value.

[0029] It should be understood that although some of the accompanying drawings illustrate the hardware and software in a particular device, these descriptions are for illustrative purposes only. The functions performed by one component as described in this invention can be performed by multiple components in a distributed manner. Similarly, functions performed by multiple components can also be combined into one component. In some embodiments, the illustrated components may be combined or divided into separate software, firmware, and / or hardware. For example, logic and processing may be distributed across multiple electronic processors, rather than residing in and being performed by a single electronic processor. Regardless of the combination or division, hardware and software components may reside on the same computing device or be distributed among different computing devices connected via one or more networks or other suitable transmission links. Similarly, components described as performing specific functions may also perform other functions not described in this invention. For example, a device or structure "configured" in a certain way is at least configured in this manner, but may also be configured in other ways not explicitly listed.

[0030] Therefore, in a claim, if an apparatus, method, or system is defined to include, for example, a controller, control unit, electronic processor, computing device, logic element, module, storage module, communication channel or network, or other elements configured in a certain way to define, for example, performing multiple functions, then the claim or the elements in the claim should be interpreted as referring to one or more such elements, wherein any one or more of the elements is configured as claimed, for example, to implement any one or more of the said multiple functions, such that the one or more elements together perform the multiple functions.

[0031] Other aspects of this embodiment will become apparent from the following detailed description and accompanying drawings. Attached Figure Description

[0032] Figure 1 This is a perspective view of a power tool including a first input device and a second input device according to some embodiments.

[0033] Figure 2A The illustration includes, according to some embodiments Figure 1 A cross-sectional side view of the first input device and the second input device.

[0034] Figure 2B According to some embodiments, including Figure 1 Cross-sectional view of the first input device and the second input device.

[0035] Figure 3A According to some embodiments, including Figure 1 A cross-sectional view of the second input device and the circuit board.

[0036] Figure 3B According to some embodiments, including Figure 1 A cross-sectional view of an alternative embodiment of the second input device and circuit board.

[0037] Figure 4 According to some embodiments, including Figure 1 Other cross-sectional views of the second input device.

[0038] Figure 5 A cross-sectional perspective view of an embodiment including a second input device according to some embodiments is shown.

[0039] Figure 6A The illustration includes, according to some embodiments Figure 1 The first input device and Figure 5 A cross-sectional view of the second input device.

[0040] Figure 6B According to some embodiments, including Figure 5 A cross-sectional view of the second input device.

[0041] Figure 7 This is a cross-sectional side view of an embodiment including a first input device according to some embodiments.

[0042] Figure 8A This is a cross-sectional side view of an embodiment including a first input device and a circuit board, according to some embodiments.

[0043] Figure 8B yes Figure 8A A schematic diagram of the first input device and the circuit board.

[0044] Figure 9 This is a cross-sectional view of an embodiment including a first input device according to some embodiments.

[0045] Figure 10 The following are illustrations of a method for using according to some embodiments. Figure 1 A block diagram of the controller for a power tool.

[0046] Figure 11The reception and processing of signals from sensors according to some embodiments are illustrated for control. Figure 1 A flowchart of a method for determining the operating characteristics of a motor in a power tool.

[0047] Figure 12 The reception and processing of signals from sensors according to some embodiments are illustrated for control. Figure 1 A flowchart of a method for determining the operating characteristics of a motor in a power tool.

[0048] Figure 13 The reception and processing of signals from sensors according to some embodiments are illustrated for control. Figure 1 A flowchart of a method for determining the motor speed of a power tool.

[0049] Figure 14 This is a cross-sectional view of an input device housing according to some embodiments, including a first input device and a second input device.

[0050] Figure 15 According to some embodiments Figure 14 A cross-sectional perspective view of the bottom of the second input device.

[0051] Figure 16 According to some embodiments Figure 14 A bottom view of the second input device.

[0052] Figure 17 According to some embodiments Figure 14 A cross-sectional view of the second input device.

[0053] Figure 18 According to some embodiments Figure 14 A perspective view of the switch slider of the second input device.

[0054] Figure 19A According to some embodiments Figure 14 A top view of the circuit board inside the input device housing.

[0055] Figure 19B According to some embodiments Figure 19A A bottom view of the circuit board.

[0056] Figure 20A According to some embodiments Figure 19A The circuit board and the first position Figure 14 A bottom view of the first input device.

[0057] Figure 20B According to some embodiments Figure 19A The circuit board and the circuit board in the second position Figure 14 A bottom view of the first input device.

[0058] Figure 21 This is a cross-sectional view of an input device housing according to some embodiments, including a first input device and a second input device.

[0059] Figure 22A According to some embodiments Figure 21 A top view of the circuit board inside the input device housing.

[0060] Figure 22B According to some embodiments Figure 22A A bottom view of the circuit board.

[0061] Figure 23A According to some embodiments, from Figure 22A A diagram showing the signals received by the first and second trigger sensors on the circuit board.

[0062] Figure 23B According to some embodiments, from Figure 22A A diagram illustrating the difference between the signals received by the first and second trigger sensors on the circuit board.

[0063] Figure 24 The following are illustrations of a method for using according to some embodiments. Figure 14 or Figure 21 A block diagram of the controller for a power tool.

[0064] Figure 25 The reception and processing of signals from sensors according to some embodiments are illustrated to determine Figure 14 or Figure 21 The flowchart of the method for the power tool pattern.

[0065] Figure 26 The reception and processing of signals from sensors according to some embodiments are illustrated to determine Figure 14 or Figure 21 The flowchart of the method for the power tool pattern.

[0066] Figure 27 The reception and processing of signals from sensors according to some embodiments are illustrated to determine Figure 21 The flowchart of the method for the power tool pattern. Detailed Implementation

[0067] Figure 1A power tool 10 in the form of a rotary tool (e.g., a handheld power drill) is shown. The power tool 10 shown includes a housing 14 defined by cooperating, clamshell-like halves 18a, 18b. The housing 14 includes a motor housing portion 22, a handle portion 26, and a chuck portion 30. The motor housing portion is configured to enclose the motor (e.g., a brushless DC motor). The handle portion 26 is configured to provide an area for a user to grip when operating the power tool. The handle portion 26 also defines a battery pack socket 34 defined at its bottom end. The battery pack socket 34 is configured to receive a battery pack that supplies power to the motor. In other embodiments, the power tool 10 may include a power cord for electrically connecting the power tool 10 to an AC power source. As another alternative, the power tool 10 may be configured to operate using a different power source (e.g., a pneumatic power source, etc.). The chuck portion 30 is configured to receive and rotate a cutting head (e.g., a drill bit or threading bit) about a rotation axis R1. The power tool 10 also includes multiple user input devices for adjusting the operating characteristics or performance of the power tool 10. In the illustrated embodiment, the input devices include a first input device or trigger 38 and a second input device or multi-position switch 42.

[0068] Figure 2A-2B The interior of the housing 14 of the power tool 10 is shown, focusing on the trigger 38 and the multi-position switch 42. The trigger 38 is configured to start from a starting position (…). Figure 2A-2B The displacement of the actuator 38 controls the speed of the motor. The actuator 38 includes an actuable portion 46 and a receiving portion 50. The actuable portion 46 is partially located within the housing 14 and configured to move along the trigger axis T1 when engaged by a user. The actuable portion 46 includes a post 54 and a convex rail 62. The post 54 includes a first magnet recess 58 configured to receive a first magnet 60. The post 54 is also configured to support an elastic element 64 (e.g., a spring) that always biases the actuable portion 46 away from the housing 14. The receiving portion 50 is located within the housing and receives the actuable portion 46. The receiving portion 50 includes a socket 66 and a recessed rail 70. The socket 66 receives the post 54 of the actuable portion 46 and supports the actuable portion 46 during movement along the trigger axis T1. The socket 66 also includes a through-hole 74 fluidly connecting the socket 66 to the housing 14. The recessed rail 70 is configured to receive the convex rail 62 and supports the actuable portion 46 during movement along the trigger axis T1.

[0069] Figure 3A-4The interior of the housing 14 of the power tool 10 is shown, focusing on a multi-position switch 42. In the illustrated embodiment, the multi-position switch 42 is configured to move along a switch axis S1 between a forward position, a reverse position, and an intermediate position. The switch axis S1 is orthogonal to the trigger axis T1. When the multi-position switch 42 is in the forward position, the motor of the power tool 10 is configured to rotate in a first direction, and when the multi-position switch 42 is in the reverse position, the motor is configured to rotate in a second direction. In the intermediate position, the motor cannot rotate because the multi-position switch 42 prevents displacement of the trigger 38. In other embodiments, the positions of the multi-position switch 42 may include more or fewer than three distinct positions. The multi-position switch 42 includes a switch body 76 having a first end 78, a second end 82, and a trigger locking portion 86 (see [link to documentation]). Figure 3A-2B The multi-position switch 42 includes a second magnet recess 90 and multiple positioning slots 94. The first end 78 and the second end 82 extend beyond the housing 14 and are user-actuable to move the multi-position switch 42 to any of three positions (forward, reverse, or intermediate). A trigger locking portion 86 is configured to selectively contact the actuable portion 46 of the trigger 38 to prevent displacement of the trigger 38 when the multi-position switch 42 is in the intermediate position. By preventing displacement of the trigger 38, the motor of the power tool 10 is prevented from being powered. When the multi-position switch 42 moves between one of the three positions, the second magnet recess 90 is configured to receive and carry the second magnet 98. The second magnet recess 90 is formed on a protrusion extending vertically from the rest of the switch body 76 and facing the circuit board 106.

[0070] like Figure 4 As shown, the leaf spring 102 engages at least one of the positioning slots 94 to hold the multi-position switch 42 in one of three positions. Figure 4 In the middle position, the multi-position switch 42 is held in the intermediate position, wherein the trigger locking part 86 prevents the trigger 38 from being actuated. To... Figure 4 To transition from the intermediate position to the forward or reverse position, the user applies force to either end 78, 82 of the multi-position switch 42. Initially, the leaf spring 102 resists the movement of the multi-position switch 42. However, once the user applies a sufficiently large force to either end 78 or the second end 82 of the multi-position switch 42, the leaf spring 102 deforms, allowing the multi-position switch 42 to move to the new position. In the illustrated embodiment, there are three positioning slots 94 corresponding to the forward, reverse, and intermediate positions of the multi-position switch 42. In other embodiments, the number of positioning slots 94 may be increased to match the number of positions of the multi-position switch 42.

[0071] Figure 2A -B、 Figure 3A and Figure 4A circuit board 106 located within a housing 14 is shown. The circuit board 106 includes a first side 108 facing the trigger 38 and the multi-position switch 42, and a second side 110 opposite the first side 108. The first side 108 of the circuit board 106 includes a first sensor or trigger sensor 116 and a second sensor or multi-position switch sensor 120. In the illustrated embodiment, the two sensors 116, 120 are digital Hall effect sensors. For example, a digital Hall effect sensor may be configured to output a pulse width modulation (“PWM”) signal based on the amount of sensed magnetic flux. In other embodiments, sensors 116, 120 may be analog Hall effect sensors or other types of non-contact sensors. In the illustrated embodiment, the trigger sensor 116 is configured to sense the degree to which the trigger 38 is pressed (e.g., not pressed, fully pressed, 75% pressed, etc.). As the first magnet 60 of the trigger 38 moves toward or away from the trigger sensor 116, the trigger sensor 116 senses the position of the trigger by measuring the change in magnetic flux. Figure 3A In the illustrated embodiment, the multi-position switch sensor 120 senses the magnetic flux of the second magnet 98 along the sensing axis A1 at each of the three positions of the multi-position switch 42. In some embodiments, the sensing axis A1 extends through the multi-position switch sensor 120 and is orthogonal to the switch axis S1. For descriptive and / or practical purposes, the trigger sensor 116 and the circuit board 106 may be part of the trigger 38; however, the circuit board 106 and the trigger sensor 116 may also be separate components. Similarly, for descriptive and / or practical purposes, the multi-position switch sensor 120 and the circuit board 106 may be part of the multi-position switch 42. However, the circuit board 106 and the multi-position switch sensor 120 may alternatively be separate components.

[0072] Figure 3B An alternative embodiment of circuit board 106B is shown, which includes a set of multi-position switch sensors 120B (e.g., a second sensor and a third sensor). In the illustrated embodiment, the multi-position switch sensor 120B is a digital Hall effect sensor and is configured to measure the magnetic flux of a second magnet 98 along a sensing axis A2 when the multi-position switch 42 is moved to any of the three positions. In some embodiments, the sensing axis A2 extends through circuit board 106B and is orthogonal to the switch axis S1. For example, the digital Hall effect sensor may be configured to output a pulse width modulation (“PWM”) signal based on the amount of sensed magnetic flux. In other embodiments, sensor 120B may be an analog Hall effect sensor or other types of non-contact sensors. For descriptive and / or practical purposes, the multi-position switch sensor 120B and circuit board 106B may be part of the multi-position switch 42; however, the circuit board 106B and the multi-position switch sensor 120B may also be separate components.

[0073] Figure 5-6B An embodiment of a multi-position switch 242 is shown, which has components similar to those of a multi-position switch 42. Figure 5-6B The reference numerals with the same designation plus "200" are explained below. The multi-position switch 242 is configured to move relative to the multi-position switch sensor 120 along the switch axis S2 between two or more different positions. In the illustrated embodiment, the multi-position switch 242 includes three different positions (e.g., forward position, reverse position, and intermediate position). The multi-position switch 242 includes a switch body 276 having a first end 278, a second end 282, and a trigger locking portion 286 (see...). Figure 6A -B), the switch body 276 with the second magnet recess 290 and multiple positioning slots 294. For example... Figure 6A As shown in Figure -B, when the multi-position switch 242 moves between one of the three positions, the second magnet recess 290 is configured to receive and carry the second magnet 98. Unlike the second magnet recess 90, the second magnet recess 290 is not formed on a protrusion but is formed directly in the switch body 276. Furthermore, compared to the shape of the second magnet recess 90, the shape of the second magnet recess 290 allows a larger portion of the second magnet 98 to be exposed to the multi-position sensor 120.

[0074] Figure 7 Another embodiment of the trigger 338 and the multi-position switch 342 is shown, which has the same components as the trigger 38 and the multi-position switch 42. Figure 7 The embodiments shown have the same reference numerals plus "300", the differences of which will be explained below. The trigger 338 is movable by a user along the trigger axis T2 and includes a trigger magnet 360 embedded within the trigger 338.

[0075] Figure 7 It also shows parallel to the Figure 2B The created planar positioning circuit board 412 (see Figure 1 In some embodiments, circuit board 412 is an extension of main circuit board 406 and is therefore part of main circuit board 406 (e.g., integrated into and coplanar with main circuit board 406). Main circuit board 406 is separate from motor circuit board 414, which includes, for example, a plurality of Hall effect sensors for detecting rotor position. In some embodiments, circuit board 412 is mechanically separate from both main circuit board 406 and motor circuit board 414, but electrically connected to main circuit board 406.

[0076] In the illustrated embodiment, circuit board 412 includes a first trigger sensor 416A, a second trigger sensor 416B adjacent to the first trigger sensor 416A, and a multi-position switch sensor 420. Sensors 416A, 416B, and 420 are, for example, digital Hall effect sensors and can be configured to output a signal (e.g., a pulse width modulation [“PWM”] signal) based on the amount of sensed magnetic flux. In other embodiments, sensors 416A, 416B, and 420 may be analog Hall effect sensors or other types of non-contact sensors. In the illustrated embodiment, both the first trigger sensor 416A and the second trigger sensor 416B sense the degree to which the trigger 338 is pressed. More specifically, the first trigger sensor 416A determines only whether the trigger 338 is pressed to any degree and outputs a binary output of the trigger state (pressed or not pressed). The second trigger sensor 416B senses the specific degree to which the trigger 338 is pressed (e.g., 25% pressed, 50% pressed, 75% pressed, etc.). When the trigger magnet 360 moves relative to the trigger sensors 416A and 416B, the trigger sensors 416A and 416B output signals based on changes in magnetic flux. The multi-position sensor 420 operates in a manner similar to... Figure 3A The position of the multi-position switch 342 is measured in the manner described in the aforementioned embodiment.

[0077] Figures 8A-8B Another embodiment of the trigger 538 and the multi-position switch 542 is shown, which has components similar to those of the trigger 38 and the multi-position switch 42. Figure 8A -B has the same reference numerals plus "500", the difference of which is explained below. Trigger 538 includes a magnet 560 located, for example, on a cantilever 548 and / or a post 554. Post 554 is housed in a bracket 568, which supports linear movement of trigger 538 along trigger axis T3. Figures 8A-8B The illustrated embodiment also includes a circuit board 612 electrically connected to and mechanically separated from the main circuit board of the power tool 10. Circuit board 612 is also mechanically separated from the Hall effect sensor board of the power tool 10. Circuit board 612 may be oriented substantially perpendicular to the main circuit board and the Hall effect sensor board in the power tool 10. In some embodiments, circuit board 612 is located within a recess 532 formed in a housing 514 and between a trigger 538 and a multi-position switch 542. Circuit board 612 includes a first side 608 facing the trigger 538 and a second side 610 facing the multi-position switch 542. Figure 8B As shown, the first side 608 includes a set of multi-position switch sensors 620, which are capable of sensing the position of the multi-position switch 542 by measuring the change in magnetic flux when the multi-position switch magnet 698 moves, as previously described. Figure 3BThe illustrated embodiment is described. In other embodiments, the first side of the circuit board 612 may include a single multi-position sensor, and may be as previously described. Figure 3A It works as described in the embodiments shown. Figure 8B As shown, the second side 610 includes a first trigger sensor 616A and a second trigger sensor 616B. Similar to... Figure 7 In the illustrated embodiment, the first trigger sensor 616A only determines whether the trigger 538 has been pressed to any degree and outputs a binary output of the state of the trigger 538 (pressed or not pressed). Moreover, similar to... Figure 7 In the embodiment shown, the second trigger sensor 616B determines the specific degree to which the trigger 538 is pressed (e.g., 25%, 50%, 75%, etc.).

[0078] Figure 9 Another embodiment of the trigger 738 is shown, which has components similar to those of the trigger 38. Figure 9 The embodiments shown have similar reference numerals plus "700", the differences of which are explained below. The trigger 738 is pivotable about the trigger axis T4 and includes a trigger magnet 760. Figure 9 The illustrated embodiment also includes a circuit board 812 electrically connected to but separate from the main circuit board 806. Circuit board 812 includes a trigger sensor 816 capable of sensing the degree to which the trigger 738 is pressed by measuring changes in magnetic flux as the trigger magnet 760 moves relative to the trigger sensor 816. In some embodiments, circuit board 812 includes more than one trigger sensor, as shown in… Figure 7-8B As described in the illustrated embodiment. In the illustrated embodiment, circuit board 812 is perpendicular to main circuit board 806. Trigger 738 can be used in place of any other triggers or user input described herein.

[0079] Figure 10 A controller 900 for a power tool 10 is shown. The controller 900 is electrically and / or communicatively connected to various modules or components of the power tool 10. For example, the controller 900 shown is connected to an indicator 945, a current sensor 970, a speed sensor 950, a temperature sensor 972, a secondary sensor 974 (e.g., a voltage sensor, accelerometer, torque sensor, or torque transducer), triggers 38 / 338 / 538 / 738, multi-position switches 42 / 242 / 342 / 542, a power switch network 955, and a power input unit 960.

[0080] The controller 900 includes multiple electrical and electronic components that provide power, operational control, and protection to the components and modules within the controller 900 and / or the power tool 10. For example, the controller 900 particularly includes a processing unit 905 (e.g., a microprocessor, electronic processor, electronic controller, microcontroller, or other suitable programmable device), a memory 925, an input unit 930, and an output unit 935. The processing unit 905 particularly includes a control unit 910, an arithmetic logic unit (“ALU”) 915, and multiple registers 920 (in... Figure 10 The data is shown as a set of registers and is implemented using known computer architectures (e.g., modified Harvard architecture, von Neumann architecture, etc.). The processing unit 905, memory 925, input unit 930, and output unit 935, as well as various modules connected to the controller 900, are connected via one or more control and / or data buses (e.g., common bus 942). For illustrative purposes, in Figure 10 Control and / or data buses are generally illustrated. It is well known to those skilled in the art that interconnection and communication between modules, circuits, and components are achieved using one or more control and / or data buses according to embodiments of the present invention.

[0081] Memory 925 is a non-transitory computer-readable medium and includes, for example, a program storage area and a data storage area. The program storage area and data storage area may include combinations of different types of memory, such as ROM, RAM (e.g., DRAM, SDRAM, etc.), EEPROM, flash memory, hard disk, SD card, or other suitable magnetic storage device, optical storage device, physical storage device, or electronic storage device. Processing unit 905 is connected to memory 925 and executes software instructions that can be stored in RAM of memory 925 (e.g., during execution), ROM of memory 925 (e.g., on a generally permanent basis), or another non-transitory computer-readable medium such as another memory or disk. Software included in the implementation of power tool 10 may be stored in memory 925 of controller 900, and this software includes, for example, firmware, one or more application programs, program data, filters, rules, one or more program modules, and other executable instructions. Among other things, controller 900 is configured to retrieve from memory 925 and execute instructions related to the control processes and methods described herein. In other embodiments, controller 900 includes additional, fewer, or different components.

[0082] Controller 900 drives motor 980 to rotate an output (e.g., a driver) in response to user actuation of triggers 38 / 338 / 538 / 738. The driver causes motor 980 to rotate in a direction corresponding to the current position of multi-position switches 42 / 242 / 342 / 542. The output can be connected to motor 980 via an output shaft. Pressing triggers 38 / 338 / 538 / 738 changes the magnetic flux sensed by trigger sensor 116. When the change in magnetic flux sensed by trigger sensor 116 exceeds a minimum threshold (e.g., a certain amount of pressing), the magnetic flux of multi-position switch sensor 120 is measured. Based on the measured magnetic flux of sensors 116 and 120, a signal is sent to controller 900 to drive motor 980 at a specific speed and in a specific direction. Figure 7-8B In the illustrated embodiment, a first trigger sensor 416A or 616A determines whether the magnetic flux exceeds a minimum threshold (e.g., a certain amount of pressure), and a second trigger sensor 416B or 616B measures a specific magnetic flux to determine a specific speed at which the motor 980 should rotate. In some embodiments, the controller 900 controls a power switching network 955 (e.g., a FET switching bridge) to drive the motor 980. For example, the power switching network 955 may include a plurality of high-side switching elements (e.g., FETs) and a plurality of low-side switching elements (e.g., FETs). The controller 900 may control each of the plurality of high-side and low-side switching elements to drive each phase of the motor 980. For example, the power switching network 955 may be controlled to decelerate the motor 980 more quickly. In some embodiments, the controller 900 monitors the rotation of the motor 980 (e.g., the rotational rate of the motor 980, the speed of the motor 980, the position of the motor 980, the direction of rotation of the motor 980, etc.). The motor 980 may be configured to drive a gearbox (e.g., a mechanism).

[0083] The indicator 945 is also connected to and receives control signals from the controller 900 to turn the power tool 10 on and off or otherwise transmit information according to different states of the power tool 10. The indicator 945 includes, for example, one or more light-emitting diodes (LEDs) or a display screen. The indicator 945 can be configured to display the status of the power tool 10 or information related to the power tool 10; for example, the indicator 945 can display information related to the operating state of the power tool 10, such as mode or speed settings. The indicator 945 can also display information related to malfunctions or other anomalies of the power tool 10. In addition to or instead of a visual indicator, the indicator 945 may also include a speaker or haptic feedback mechanism to convey information to the user through auditory or haptic outputs.

[0084] A battery pack interface 985 is connected to a controller 900 and configured to couple to a battery pack 990. The battery pack interface 985 includes a combination of mechanical (e.g., a battery pack receiver) and electrical components configured and operable to dock (e.g., mechanically, electrically, and communicatively) the power tool 10 to the battery pack 990. The battery pack interface 985 is coupled to a power input unit 960. The battery pack interface 985 transmits power received from the battery pack 990 to the power input unit 960. The power input unit 960 includes active and / or passive components (e.g., a voltage buck controller, voltage converter, rectifier, filter, etc.) to regulate or control the power received through the battery pack interface 985 and transmitted to the controller 900. In some embodiments, the battery pack interface 985 is also coupled to a power switch network 955. The operation of the power switch network 955, controlled by the controller 900, determines how power is supplied to the motor 980.

[0085] Current sensor 970 senses the current supplied by battery pack 990, the current associated with motor 980, or a combination thereof. In some embodiments, current sensor 970 senses at least one phase current of motor 980, and current sensor 970 may be, for example, an inline phase current sensor, a pulse width modulation center sampling inverter bus current sensor, etc. Speed ​​sensor 950 senses the speed of motor 980. Speed ​​sensor 950 may include, for example, one or more Hall effect sensors. In some embodiments, temperature sensor 972 senses the temperature of switching network 955, battery pack 990, motor 980, or a combination thereof.

[0086] Figure 11 This is a flowchart of a method 1000 for receiving sensor signals from the trigger sensor 116 and the multi-position switch sensor 120 on the circuit board 106 and controlling the operating characteristics of the power tool 10 based on the sensor signals.

[0087] In box 1010, the multi-position switch sensor 120 is read. The reading of the multi-position switch sensor 120 determines the position of the multi-position switches 42 / 242 / 342 / 542. Figure 2A -B、 Figure 3A , Figure 4 , Figure 5 and Figure 6AIn the embodiment shown in -B, the multi-position switch sensor 120 reads the magnetic flux of the second magnet 98 on a sensing axis A1 orthogonal to the switch axis S1, which varies as the multi-position switch 42 or 242 moves along the switch axis S1 or S2. For example, in an intermediate position, the magnetic flux is measured as a decreasing value (e.g., a minimum value). When in a forward or reverse position, the magnetic flux is measured as an increasing value (e.g., a maximum value), and, for example, the polarity of the output of the multi-position switch sensor 120 indicates the position. In other embodiments, the magnetic flux value used to determine the intermediate position may be a maximum value, and the magnetic flux value used to determine the forward or reverse position may be a decreasing value.

[0088] At block 1020, a multi-position switch sensor 120 on circuit board 106 provides a first signal indicating whether multi-position switches 42 / 242 / 342 / 542 are in the forward, reverse, or intermediate position. The position is determined based on the range within which the magnetic flux reading of the multi-position switch sensor 120 falls. If the magnetic flux reading falls within the first range, multi-position switches 42 / 242 / 342 / 542 are in the forward position and motor 980 is rotating in the forward direction (block 1040). If the magnetic flux reading falls within the second range, multi-position switches 42 / 242 / 342 / 542 are in the reverse position and motor 980 is rotating in the reverse direction (block 1030). If the magnetic flux falls within the third range, multi-position switches 42 / 242 / 342 / 542 are in the intermediate position, and motor 980 is prevented from rotating. Alternatively, method 1000 returns to block 1010 to read the multi-position switch sensor 120.

[0089] At box 1050, the trigger sensor 116 is read. The reading from the trigger sensor 116 determines whether the trigger 38 has been actuated.

[0090] At box 1060, the reading from trigger sensor 116 is compared to a trigger threshold. If the reading from trigger sensor 116 is greater than the trigger threshold (e.g., some amount of pressure applied to trigger 38), motor 980 is powered to be driven proportionally to the reading from trigger sensor 116 (at box 1070). The direction of rotation of motor 980 is based on the motor state determined at box 1020. If the reading from trigger sensor 116 is less than the trigger threshold, method 1000 returns to box 1010 to read multi-position switch sensor 120.

[0091] Figure 12 This is a flowchart of a method 1100 for receiving sensor signals from trigger sensor 116 and multi-position switch sensor group 120B on circuit board 106B, and controlling the operating characteristics of power tool 10 based on the sensor signals.

[0092] In box 1110, the multi-position switch sensor 120B is read. The reading of the multi-position switch sensor 120B determines the position of the multi-position switches 42 / 242 / 342 / 542. Figure 3B In the illustrated embodiment, the multi-position switch sensor 120B measures the magnetic flux of the second magnet 98 of the multi-position switches 42 / 242 / 342 / 542 on a sensing axis A2 orthogonal to the switch axis S1. For example, in the intermediate position, the magnetic flux is measured as a decreasing value (e.g., minimum value) for both multi-position switch sensors 120B. When in the forward or reverse position, the magnetic flux is measured as an increasing value (e.g., maximum value) at one of the multi-position switch sensors 120B. For example, based on which of the multi-position switch sensors 120B has a low value, the controller 900 can determine whether to select forward or reverse.

[0093] At block 1120, the multi-position switch sensor 120B on circuit board 106B provides a first signal indicating whether the multi-position switch 42 / 242 / 342 / 542 is in the forward, reverse, or intermediate position. The position is determined based on the range within which each flux reading of the multi-position switch sensor 120B falls. For example, if both flux readings fall within the first range, the multi-position switch 42 / 242 / 342 / 542 is in the forward position and the motor is rotating in the forward direction (block 1140). If both flux readings fall within the second range, the multi-position switch 42 / 242 / 342 / 542 is in the reverse position and the motor is rotating in the reverse direction (block 1130). If the flux readings fall within the third range, the multi-position switch 42 / 242 / 342 / 542 is in the intermediate position, and the motor 980 is prevented from rotating. Conversely, method 1100 returns to block 1110 to read the multi-position switch sensor 120B.

[0094] At box 1150, the trigger sensor 116 is read. The reading from the trigger sensor 116 determines whether the trigger 38 has been actuated.

[0095] At box 1160, the reading from trigger sensor 116 is compared to a trigger threshold. If the reading from trigger sensor 116 is greater than the trigger threshold (e.g., a certain amount of pressure applied to trigger 38), trigger 38 has been actuated, and motor 980 is powered to be driven proportionally to the reading from trigger sensor 116 (at box 1170). The direction of motor rotation is based on the motor state determined at box 1120. If the reading from trigger sensor 116 is less than the trigger threshold, method 1100 returns to box 1110 to read multi-position switch sensor 120B.

[0096] Figure 13This is a flowchart of a method 1200 for receiving signals from trigger sensors 416A, 416B or 616A, 616B and controlling the speed of motor 980 based on the sensor signals.

[0097] In box 1210, the first trigger sensor 416A or 616A is read. Specifically, the first trigger sensor 416A or 616A measures the magnetic flux generated by the trigger magnet 360 or 560 of trigger 338 or 538.

[0098] At block 1220, the reading of the first trigger sensor 416A or 616A is compared with a trigger threshold. If the reading of the first trigger sensor 416A or 616A does not exceed the trigger threshold, method 1200 returns to block 1210 to read the first trigger sensor 416A or 616A. If the reading of the first trigger sensor 416A or 616A exceeds the trigger threshold, it is determined that trigger 338 or 538 is actuated, and method 1200 proceeds to block 1230. In some embodiments, the output of the first trigger sensor 416A or 616A is directly provided to the enable pin of the gate driver. When trigger 338 or 538 is actuated, the gate driver is enabled. If trigger 338 or 538 is not actuated, the gate driver is disabled.

[0099] At box 1230, the second trigger sensor 416B or 616B is read. Specifically, the second trigger sensor 416B or 616B measures the magnetic flux generated by the trigger magnet 360 or 560 of trigger 338 or 538.

[0100] At box 1240, the reading from the second trigger sensor 416B or 616B is used to calculate the desired motor speed. For example, the desired motor speed changes proportionally to the reading from the second trigger sensor 416B or 616B.

[0101] At box 1250, motor 980 is driven at the motor speed determined in box 1240.

[0102] Figure 14 Another embodiment of a first user input device or trigger 1438 having components similar to trigger 38 is shown, another embodiment of a second user input device or multi-position switch 1442 having components similar to multi-position switch 42, and an input device housing 1444. Figure 14The embodiments shown have the same reference numerals plus "1400", and the differences are explained below. An input device housing 1444 is located within the housing of a power tool 1410 (e.g., power tool 10) and includes a trigger opening 1448, a switch opening 1449, a cavity 1451, and a guide rail 1462. The trigger opening 1448 is formed on the front surface of the input device housing 1444 and configured to receive a portion of a trigger 1438. The switch opening 1449 is formed on the top surface of the input device housing 1444 and configured to receive a portion of a multi-position switch 1442. The guide rail 1462 is integrally formed on the front surface and partially supports axial movement of the trigger 1438. The cavity 1451 accommodates a portion of the trigger 1438, a portion of the multi-position switch 1442, and a circuit board 1506.

[0103] like Figure 14 As shown, trigger 1438 is partially housed within input device housing 1444 and extends partially beyond the input device housing 1444 and the surrounding housing of power tool 1410. Typically, trigger 1438 is in the initial position (fully extended), as... Figure 14As shown, the trigger 1438 is movable along the trigger axis T5 to change the operating characteristics (e.g., motor speed) of the power tool 1410. The range of motion of the trigger 1438 includes a dead zone in which the trigger 1438 can be partially displaced from its starting position without changing the operating characteristics of the power tool 1410. The trigger 1438 includes an actuable portion 1446, a track opening 1452, a post 1454, and a sensing element housing 1456. The actuable portion 1446 extends beyond the input device housing 1444 and is shaped to receive a user's finger. The track opening 1452 is formed in the actuable portion 1446 and is shaped to receive a protruding rail 1462. The post 1454 is integrally formed on the actuable portion 1446 and extends through the trigger opening 1448 into the input device housing. In other embodiments, the post 1454 may be separable from the actuable portion 1446 and may be inserted into the actuable portion 1446. The post 1454 and the guide rail 1462 are configured to support the axial movement of the trigger 1438 along the trigger axis T5. Additionally, the post 1454 includes a spring opening 1463 configured to receive an end of an elastic element 1464 configured to bias the trigger 1438 in a forward direction. In the illustrated embodiment, a sensing element housing 1456 is formed at the end of the post 1454 and houses a metal target 1459, a magnet 1460, and a trigger slider 1461, each configured to interact with a portion of the circuit board 1506. The metal target 1459 is configured to disrupt the magnetic field and is made of iron or a non-ferrous metal. As described further below, the magnet 1460 generates a magnetic flux detectable by the sensor. The trigger slider 1461 is a conductive metal member configured to contact the surface of the circuit board 1506.

[0104] like Figure 14-18 As shown, a multi-position switch 1442 is partially housed within an input device housing 1444 and extends partially beyond the input device housing 1444 and the surrounding housing of the power tool 1410. The multi-position switch 1442 is rotatable about a switch axis S3 and configured to hold multiple preset positions. Each position of the multi-position switch 1442 corresponds to the state of the power tool 1410 (e.g., motor rotation direction). The multi-position switch 1442 includes a switch body 1476, a plurality of positioning balls 1480, a ball spring 1484, and a switch slider 1488. The switch body 1476 is partially located within a switch opening 1449 and is engaged by the user to rotate the multi-position switch 1442 about the switch axis S3. Furthermore, as... Figure 15 and Figure 16As shown, the switch body 1476 accommodates a plurality of positioning balls 1480 and a ball spring 1484. In the illustrated embodiment, the switch body 1476 includes two positioning balls 1480, and the ball spring 1484 is located between the two positioning balls 1480. In other embodiments, the switch body 1476 may include more than two positioning balls 1480. The positioning balls 1480 are located in ball grooves 1492 of the input device housing 1444 and are biased onto the ball grooves 1492 by the ball springs 1484. The ball grooves 1492 include a set of first recesses 1496A, a set of second recesses 1496B, and a set of third recesses 1496C. Each set of recesses 1496A-C corresponds to one of the set positions of the multi-position switch 1442. In other embodiments, additional sets of recesses 1496 may be included to correspond to additional set positions of the multi-position switch 1442. Furthermore, as Figure 16-17 As shown, each set of notches 1496 is circumferentially spaced from each other in the ball groove 1492. In the illustrated embodiment, each set of notches 1496 includes two notches spaced 180 degrees apart, and its shape is adapted to accommodate a positioning ball 1480. When the positioning ball 1480 falls into one of the sets of notches 1496A-C, the switch body 1476 encounters additional rotational resistance compared to when the positioning ball is not in one of the sets of notches 1496A-C. This additional resistance is generated by the ball spring 1484 applying a biasing force to the positioning ball 1480 to hold it in the notches 1496A-C. Therefore, if the positioning ball 1480 is in one of the sets of notches 1496A-C, the orientation of the multi-position switch 1442 is maintained until the user applies sufficient force to the switch body 1476 to overcome the rotational resistance.

[0105] Figure 14-16 Figures 14 and 18 illustrate a switch slider 1488 located between a switch body 1476 and a circuit board 1506. The switch slider 1488 is circular and made of a conductive material. Additionally, the switch slider 1488 includes a plurality of protrusions 1504 extending from the remainder of the switch slider 1488 to contact a portion of the circuit board 1506. In the illustrated embodiment, the switch slider 1488 includes four protrusions 1504, all of which are aligned with each other. In other embodiments, the switch slider 1488 may include more or fewer than four protrusions 1504, not all of which are aligned with each other.

[0106] Figure 19A-B shows a first side 1512A and a second side 1512B of circuit board 1506. The first side 1512A faces the multi-position switch 1442 and includes a wake-up sensor 1514, a trigger sensor 1516, and a plurality of contact pads 1522. The second side 1512B faces the sensing element housing 1456 and includes a set of contact rails 1524 and a plurality of induction coils 1526. In some embodiments, circuit board 1506 includes only the wake-up sensor 1514 or one of the contact rails 1524 (e.g., the wake-up sensor 1514 is used to wake up the controller, or the set of contact rails 1524 is used to wake up the controller).

[0107] like Figure 19B As shown, contact rails 1524 are two parallel areas of exposed metal on circuit board 1506. Contact rails 1524 are configured to determine whether trigger 1438 has been displaced from its starting position along trigger axis T5. Specifically, contact rails 1524 detect the displacement of trigger 1438 through mechanical and electrical contact with trigger slider 1461. Furthermore, contact rails 1524 are divided into a starting section 1528, a dead section 1530, and an active section 1532. Figure 20A As shown, the starting section 1528 includes two contact pads that the trigger slider 1461 selectively contacts when the trigger 1438 is in the starting position. When the trigger slider 1461 is in contact, the two pads of the starting section 1528 are connected, but no signal is transmitted to the controller, indicating that the trigger 1438 is not pressed. In other embodiments, a start signal (e.g., a voltage signal) can be sent to the controller when the trigger slider 1461 contacts the two rails of the starting section 1528. The dead zone section 1530 is a rib-like region alternating between the contact pads and the insulating surface of the circuit board 1506. The dead zone section 1530 separates the starting section 1528 and the active section 1532 and contacts the trigger slider 1461 when the trigger 1438 is in the dead zone. In the illustrated embodiment, the dead zone section 1530 is rib-like and alternates between the conductive metal surface and the insulating top surface of the circuit board 1506. When the trigger slider 1461 passes through the conductive metal surface of the dead zone section 1530, no signal is sent to the controller, and the controller takes no action. In other embodiments, when the trigger slider 1461 passes through the dead zone section 1530, a dead zone signal (e.g., a voltage signal alternating between 0 and 3.3 volts) is sent to the controller to indicate that the trigger 1438 is in the dead zone. Figure 20BAs shown, the active section 1532 is a continuous portion of the contact rail 1524, and when the trigger 1438 is pressed through the dead zone, the active section 1532 contacts the trigger slider 1461. When the trigger slider 1461 contacts both rails of the active section 1532, a wake-up signal (e.g., a 3.3V or 5V voltage signal) is sent to the controller, and the controller switches between sleep mode and active mode.

[0108] The wake-up sensor 1514 is also configured to detect whether the trigger 1438 has been displaced along the trigger axis T5. In the illustrated embodiment, the wake-up sensor 1514 sends a wake-up signal that is redundant with the signal sent by the contact rail 1524. Furthermore, in the illustrated embodiment, the wake-up sensor 1514 is a digital Hall effect sensor and compares the measured magnetic flux of the magnet 1460 of the trigger 1438 with a threshold. As the trigger 1438 moves closer to the wake-up sensor 1514 along the trigger axis T5, the measured magnetic flux of the magnet 1460 increases. The wake-up sensor 1514 may be configured to output a pulse width modulation (“PWM”) signal, for example, based on the amount of sensed magnetic flux. In other embodiments, the wake-up sensor 1514 may be an analog Hall effect sensor or other types of non-contact sensors.

[0109] Trigger sensor 1516 is configured to measure the degree to which trigger 1438 has been displaced from its starting position. In the illustrated embodiment, trigger sensor 1516 is an inductive sensor configured to measure the inductance generated in induction coil 1526 as the metallic target 1459 of trigger 1438 moves. Trigger sensor 1516 sends a trigger displacement signal to the controller that is related to (e.g., proportional to) the measured inductance or change in inductance. Based on the trigger displacement signal, the controller sends corresponding power to rotate the motor at a desired speed. In other embodiments, trigger sensor 1516 may be a Hall effect sensor or other types of non-contact sensors.

[0110] like Figure 19A As shown, each of the plurality of contact pads 1522 is a partial annular region of exposed metal on circuit board 1506 and is configured to selectively contact the protrusion 1504 of switch slider 1488. The plurality of contact pads 1522 includes a first contact pad 1522A, a second contact pad 1522B, and a third contact pad 1522C. In the illustrated embodiment, the first contact pad 1522A and the second contact pad 1522B have equal areas, while the third contact pad 1522C has a larger area than the remaining contact pads 1522A-B. In other embodiments, the plurality of contact pads 1522 may include more or fewer than three contact pads, and each contact pad 1522 may have a unique or equivalent area.

[0111] During operation, the combination of contact pads 1522A-C engages and electrically connects with each other according to the position of the multi-position switch 1442. Specifically, if the multi-position switch 1442 is rotated such that the positioning ball 1480 engages with the first set of notches 1496A, the protrusion 1504 of the switch slider 1488 electrically connects the third contact pad 1522C to the insulating surface of the circuit board 1506. As a result, no signal is sent to the controller, and the motor does not rotate even if a trigger displacement signal is received. If the multi-position switch 1442 is rotated such that the positioning ball 1480 engages with the second set of notches 1496B, the protrusion 1504 of the switch slider 1488 electrically connects the third contact pad 1522C to the first contact pad 1522A. As a result, a first direction signal is sent to the controller, and the motor of the power tool 1410 will rotate in the first direction (e.g., forward). Finally, if the multi-position switch 1442 is rotated such that the positioning ball 1480 engages with the third set of notches 1496C, the protrusion 1504 of the switch slider 1488 is electrically connected to the third contact pad 1522C and the second contact pad 1522B. As a result, a second direction signal is sent to the controller, and the motor of the power tool 1410 will rotate in the second direction (e.g., in the opposite direction). In other embodiments, different connections between contact pads 1522A-C may correspond to changes in different operating characteristics of the power tool 1410.

[0112] Figure 21 Another embodiment of trigger 2138 and circuit board 2206 is shown. As described above, trigger 2138 has components similar to those of trigger 1438, and circuit board 2206 has components similar to those of circuit board 1506 that is paired with multi-position switch 1442 and input device housing 1444. Figure 21 The embodiments of the trigger 2138 and the circuit board 2206 have the same reference numerals plus "2100", the differences of which will be explained below.

[0113] like Figure 21 As shown, the trigger 2138 is partially housed within the input device housing 1444 and extends partially beyond the input device housing 1444 and the surrounding housing of the power tool 2110. Figure 21A trigger 2138 in its initial position and movable along the trigger axis T6 is also shown. The range of motion of trigger 2138 includes a dead zone in which trigger 2138 can be partially pressed without altering the operating characteristics of power tool 2110. Trigger 2138 includes an actuable portion 2146, a rail opening 2152, and a post 2154. Post 2154, together with rail 1462, is configured to support axial movement of actuable portion 2146 along trigger axis T6. In the illustrated embodiment, a first end of post 2154 is inserted into post opening 2155 formed in actuable portion 2146. A second end of post 2154, opposite the first end, is inserted into trigger opening 1448. Post 2154 also includes a magnet recess 2158, an elastic element retaining member 2165, and a trigger slider 2161. A magnet recess 2158 is formed adjacent to the second end of the post 2154 and faces the circuit board 2206. The magnet recess 2158 also accommodates a magnet 2160 in a direction orthogonal to the trigger shaft T6. A spring retaining member 2165 is formed on the second end of the post 2154 and maintains the alignment of the elastic element 2164 and the post 2154.

[0114] Figure 22A and 22B The first side 2212A and the second side 2212B of the circuit board 2206 are shown respectively. The first side 2212A faces the multi-position switch 1442 and includes a plurality of contact pads 1522, which are further composed of a first contact pad 1522A, a second contact pad 1522B and a third contact pad 1522C. The second side 2212B faces the post 2154 of the trigger 2138 and includes a set of trigger sensors 2216, a wake-up sensor 2214 and a set of contact rails 1524.

[0115] like Figure 22B As shown, the set of trigger sensors 2216 includes a first trigger sensor 2216A adjacent to the starting segment 1528 of the contact rail 1524 and a second trigger sensor 2216B adjacent to the active segment 1532 of the contact rail 1524. The two trigger sensors 2216A-B are aligned with each other along an axis parallel to the trigger axis T6 and the contact rail 1524. In the illustrated embodiment, each trigger sensor 2216 is a 3D digital Hall effect sensor configured to detect magnetic field strength along the X, Y, and Z axes. In other embodiments, trigger sensors 2216A-B may be 2D Hall effect sensors, analog Hall effect sensors, or other types of non-contact sensors. In further embodiments, the two trigger sensors 2216A / B may not be the same type of sensor. Furthermore, in the illustrated embodiment, trigger sensors 2216A-B communicate with the controller using an I2C bus. In other embodiments, trigger sensors 2216A-B may communicate with the controller using SPI.

[0116] In operation, trigger sensors 2216A-B are configured to determine the displacement of trigger 2138 from its starting position and output a corresponding signal. Specifically, as trigger 2138 moves along trigger axis T6, each trigger sensor 2216A-B measures the magnetic field strength of magnet 2160. Figure 23A The figure shows exemplary measurements of the magnetic field strength for each of the trigger sensors 2216A-B. Figure 23A The diagram shows that the measured magnetic field strength of the first trigger sensor 2216A decreases as the displacement distance of the trigger 2138 increases. Figure 23A It is also shown that the measured magnetic field strength of the second trigger sensor 2216B increases with the increase of the displacement distance of the trigger 2138. Next, the difference between the measured magnetic field strengths of the two trigger sensors 2216A-B is obtained (e.g., Figure 23B (As shown), and sends a single trigger displacement signal reflecting this difference to the controller. By relying on this set of trigger sensors 2216A / B to generate the trigger displacement signal, interference from other magnetic fields located inside or outside the power tool 2110 is reduced. Furthermore, the first sensor 2216A is configured to determine whether the trigger 2138 has moved beyond the dead zone. If the trigger 2138 moves beyond the dead zone, the first trigger sensor 2216A sends a wake-up signal to the controller.

[0117] The wake-up sensor 2214 is also configured to detect whether the trigger 2138 has been displaced through the dead zone. In the illustrated embodiment, the wake-up sensor 2214 sends a wake-up signal that is redundant with the signals sent by the contact rail 1524 and the first trigger sensor 2216A. Furthermore, in the illustrated embodiment, the wake-up sensor 2214 is a digital Hall effect sensor and compares the measured magnetic flux of the magnet 2160 of the trigger 1438 with a threshold. As the trigger 1438 moves closer to the wake-up sensor 2214 along the trigger axis T6, the measured magnetic flux of the magnet 1460 increases.

[0118] Figure 24 Another embodiment of a controller 2400 for power tools 1410 / 2110 is shown, which has components similar to those of controller 900. Figure 26The embodiments shown have the same reference numerals plus "2400", the differences of which will be explained below. The controller 2400 is electrically and / or communicatively connected to various modules or components of the power tool 1410 / 2110. For example, the controller 2400 shown is connected to an indicator 2445, a wake-up sensor 2447, a current sensor 2470, a speed sensor 2450, a temperature sensor 2472, a secondary sensor 2474 (e.g., a voltage sensor, accelerometer, torque sensor, or torque transducer, etc.), triggers 1438 / 2148, a multi-position switch 1442, a power switch network 2455, and a power input unit 2460.

[0119] The controller 2400 includes a sleep mode and an active mode. In sleep mode, the controller 2400 supplies power only to the wake-up sensor 2447 and measures only the output of the wake-up sensor 2447. The remaining modules and components are not powered, so the power tool 1410 / 2110 consumes less power in sleep mode compared to active mode. In active mode, all other sensors and gate drivers are powered. The sleep mode and active mode are determined by the wake-up signal from the wake-up sensor 2447.

[0120] exist Figure 14 In the illustrated embodiment, the wake-up signal is sent by a trigger slider 1461, which is electrically connected to the conductive region of the activation segment 1532. Alternatively, the wake-up signal can also be sent when the magnet 1460 is within a set distance of the wake-up sensor 1514. When within the set distance, the measured magnetic flux of the wake-up sensor 1514 exceeds a preset threshold.

[0121] exist Figure 21 In the illustrated embodiment, the wake-up signal is also sent by the trigger slider 2161, which is electrically connected to the contact rail 1524 of the activation section 1532. Alternatively, the first trigger sensor 2216A may also send the wake-up signal, or the wake-up sensor 2447 may send the wake-up signal when the magnet 2160 is within a set distance from the first trigger sensor 2216A or the wake-up sensor 2447 and the measured magnetic flux of the first trigger sensor 2216A or the wake-up sensor 2214 exceeds a preset threshold.

[0122] Once in active mode, the gate driver of controller 2400 is enabled, and motor 2480 can be driven to rotate the output (e.g., a driver) in response to user actuation of triggers 1438 / 2138. Figure 14 In the illustrated embodiment, when pressed, trigger 1438 changes the inductance sensed by trigger sensor 1516, and a speed signal is sent to controller 2400 to drive motor 2480 at a specific speed. Figure 21In the illustrated embodiment, pressing the trigger 2138 changes the magnetic flux sensed by the first and second trigger sensors 2216A / B, and a speed signal proportional to the difference between the magnetic flux readings of the first and second trigger sensors 2216A / B is sent to the controller 2400. The speed signal sent to the controller 2400 determines the speed at which the motor 2480 is driven.

[0123] Before rotating the motor 2480 based on the speed signal, the controller 2400 determines the rotation direction based on the position of the multi-position switch 1442. If the multi-position switch 1442 is in the first position, no direction signal is sent to the controller 2400, so the motor 2480 does not rotate even if a speed signal is received. If the multi-position switch is in the second position, a first direction signal is sent to the controller 2400, causing the motor 2480 to rotate in the first direction at a speed based on the speed signal. If the multi-position switch is in the third position, a second direction signal is sent to the controller 2400, causing the motor 2480 to rotate in the second direction at a speed based on the speed signal.

[0124] Figure 25 This is a flowchart of a method 2500 for determining whether to set the controller 2400 of power tools 1410 and 2110 to sleep mode or active mode.

[0125] In box 2510, the contact rail 1524 is read. The reading of the contact rail 1524 determines the position of the triggers 1438 and 2138. Specifically, the position of the triggers 1438 and 2138 is determined by the position of the trigger sliders 1461 and 2161 on the contact rail 1524.

[0126] At block 2515, contact rail 1524 determines the signal to be sent to the controller based on the position of trigger sliders 1461, 2161. No signal is generated when the trigger sliders are in the start section 1528 or the dead section 1530, and method 2500 proceeds to block 2520. A wake-up signal is generated by the trigger sliders 1461, 2161 of each rail electrically connected to the activation section 1532, and method 2500 proceeds to block 2525.

[0127] At block 2520, no signal is sent to controller 2400, and controller 2400 remains in sleep mode. In sleep mode, for example, the gate driver of controller 2400 is disabled. Method 2500 returns to block 2510 to read any changes in the signal received in contact rail 1524.

[0128] At block 2525, a wake-up signal is sent to controller 2400 to switch controller 2400 to active mode. In active mode, the gate driver of controller 2400 is powered, and motor 2480 can be powered. Method 2500 returns to block 2510 to read any changes in the signals received in contact rail 1524.

[0129] Figure 26 This is a flowchart of method 2600 for determining whether to set the controller 2400 of the power tool 1410 to sleep mode or active mode. For the power tool 1410, if method 2500 or method 2600 determines to wake up, the controller 2400 will switch to active mode.

[0130] In block 2610, the wake-up sensor 1514 is read. The reading of the wake-up sensor 1514 is used to determine whether the trigger 1438 has been displaced through the dead zone. In some embodiments, the wake-up sensor 1514 is a Hall effect sensor configured to measure the magnetic flux generated by the trigger magnet 1460, which changes as the trigger 1438 and the trigger magnet 1460 move along the trigger axis T5.

[0131] At box 2615, the reading from wake-up sensor 1514 is compared with a wake-up threshold. If the reading from wake-up sensor 1514 is lower than the wake-up threshold, method 2600 proceeds to box 2620; if the reading from wake-up sensor 1514 exceeds the wake-up threshold, method 2600 proceeds to box 2625.

[0132] At block 2620, controller 2400 receives no signal and remains in sleep mode. In sleep mode, the gate driver of controller 2400 is disabled. Method 2600 returns to block 2610 to read wake-up sensor 1514 to obtain any changes in the reading.

[0133] At block 2625, controller 2400 receives a wake-up signal and transitions to active mode. In active mode, the gate driver of controller 2400 is powered, and motor 2480 can be powered. Then, method 2600 proceeds to block 2630.

[0134] At box 2630, the reading from wake-up sensor 1514 is again compared with the wake-up threshold. If the reading from wake-up sensor 1514 remains above the wake-up threshold, method 2600 returns to box 2625 and continues to send a wake-up signal to controller 2400; if the reading from wake-up sensor 1514 drops below the wake-up threshold, method 2600 proceeds to box 2635.

[0135] In block 2635, controller 2400 stops receiving wake-up signals and transitions to sleep mode. For example, to transition controller 2400 to sleep mode, a sleep timer can be started. Once the sleep timer has elapsed (e.g., a threshold amount of time has elapsed), the gate driver is disabled and the rotation of motor 2480 stops. Method 2600 then returns to block 2610 to read wake-up sensor 1514 for any changes in the reading.

[0136] Figure 27 This is a flowchart of method 2700 for determining whether to set the controller 2400 of power tool 2110 to sleep mode or active mode. For power tool 2110, if method 2500 or method 2600 makes an appropriate decision, controller 2400 will switch to active mode.

[0137] At box 2710, the first trigger sensor 2216A is read. The reading from the first trigger sensor 2216A is used to determine whether the trigger 2138 has been displaced beyond the dead zone. The first trigger sensor 2216A measures, for example, the magnetic flux generated by the trigger magnet 2160. The magnetic flux measured by the first trigger sensor 2216A will change as the trigger 2138 and the trigger magnet 2160 move along the trigger axis T6.

[0138] At block 2715, the reading from the first trigger sensor 2216A is compared with a first wake-up threshold. If the reading from the first trigger sensor 2216A is greater than the first wake-up threshold, method 2700 proceeds to block 2720. If the reading from the first trigger sensor 2216A is less than the first wake-up threshold, method 2700 proceeds to block 2735. In some embodiments, the first trigger sensor 2216A is not used to wake up the controller 2400.

[0139] In block 2720, controller 2400 receives a wake-up signal and transitions to active mode. In active mode, the gate driver of controller 2400 is powered, and motor 2480 can be powered. Then, method 2700 proceeds to block 2725.

[0140] In box 2725, the wake-up sensor 2214 is read. The reading from the wake-up sensor 2214 also determines whether the trigger 2138 has been displaced beyond the dead zone. The wake-up sensor 2214 also measures the magnetic flux generated by the trigger magnet 2160, which will change as the trigger 2138 and the trigger magnet 2160 move along the trigger axis T6.

[0141] At block 2730, the reading from wake-up sensor 2214 is compared to a second wake-up threshold. If the reading from wake-up sensor 2214 is greater than the second wake-up threshold, method 2700 returns to block 2720, and a wake-up signal continues to be sent to controller 2400. If the reading from wake-up sensor 2214 is less than the second wake-up threshold, method 2700 proceeds to block 2735. In some embodiments, the first wake-up threshold and the second wake-up threshold have the same value. In other embodiments, the second wake-up threshold is greater than or less than the first wake-up threshold. In some embodiments, wake-up sensor 2214 does not provide a wake-up signal to controller 2400. Instead, the output from the wake-up sensor can be used to directly control the activation / deactivation state of the gate driver.

[0142] In block 2735, controller 2400 stops receiving wake-up signals and transitions to sleep mode. To transition controller 2400 to sleep mode, for example, a sleep timer is started. Once the sleep timer expires, the gate driver of controller 2400 is disabled, and the rotation of motor 2480 stops. Method 2700 then returns to block 2710 to read any changes in the reading of wake-up sensor 2214.

[0143] Therefore, the embodiments described in this utility model provide a power tool user interface including a first input unit and a second input unit. Various features and advantages are set forth in the following claims.

Claims

1. A power tool, characterized in that, include: case; A motor, which is at least partially disposed within the housing; A first user input device is partially disposed within the housing and configured to move along a first axis to multiple different positions; A second user input device is partially disposed within the housing and configured to move along a second axis; A controller configured to control the operating characteristics of the motor; and A circuit board connected to the controller, the circuit board comprising: A first sensor, located on a first side of the circuit board, is configured to sense the plurality of different positions of the first user input device. A second sensor, located on the first side of the circuit board, is configured to sense displacement along the second axis of the second user input device.

2. The power tool according to claim 1, characterized in that, The first user input device is a multi-position switch, and the first user input device includes a switch body, a first magnetic element, and a first elastic element.

3. The power tool according to claim 2, characterized in that: The switch body includes a recess configured to receive the first magnetic element; and the recess faces a first side of the circuit board.

4. The power tool according to claim 1, characterized in that, Each of the plurality of different locations sensed by the first sensor corresponds to the operating mode of the motor.

5. The power tool according to claim 1, characterized in that, The second user input device is a trigger for the power tool, and the second user input device includes a second magnetic element and a second elastic element.

6. The power tool as described in claim 1, characterized in that, The output characteristics of the motor are determined by the displacement sensed by the second sensor.

7. The power tool according to claim 1, characterized in that, The second user input device moves along the second axis, which is orthogonal to the first user input device moves along the first axis.

8. The power tool as described in claim 1, characterized in that, A third sensor is located on the first side of the circuit board and adjacent to the first sensor, and the third sensor is configured to sense the plurality of different positions of the first user input device.

9. The power tool as described in claim 1, characterized in that, The third sensor is located on the first side of the circuit board and adjacent to the second sensor, and the third sensor is configured to sense displacement along the second axis of the second user input device.

10. The power tool as described in claim 9, characterized in that, The third sensor generates a binary output based on the displacement of the second user input device along the second axis.

11. A power tool, characterized in that, include: case; A motor, which is at least partially disposed within the housing; A first user input device is partially disposed within the housing and configured to move along a first axis to multiple different positions; A second user input device is partially disposed within the housing and configured to move along a second axis; A controller configured to control the operating characteristics of the motor, the controller being mounted on a first circuit board; and A second circuit board is electrically connected to the first circuit board. The second circuit board includes a first sensor and a second sensor. The first sensor is configured to sense the plurality of different positions of the first user input device, and the second sensor is configured to sense displacement along the second axis of the second user input device.

12. The power tool as claimed in claim 11, characterized in that, A third sensor is located on and adjacent to the second sensor on the second circuit board, and the third sensor is configured to sense displacement along the second axis of the second user input device.

13. The power tool as described in claim 12, characterized in that, The third sensor generates a binary output based on the displacement of the second user input device along the second axis.

14. A power tool, characterized in that, include: case; A motor, which is at least partially disposed within the housing; A controller configured to control the operating characteristics of the motor; An input device housing, wherein the input device housing is located within the housing; A first user input device, partially located within the input device housing, displaceable along a first axis, and including a trigger magnet; A second user input device is partially located within the input device housing. The second user input device is rotatable about a second axis and includes a sliding plate. and A circuit board, located within the input device housing, comprises: A sensor, configured to sense the displacement of the first user input device along the first axis, Multiple contact pads configured to engage the slider of the second user input device, and A non-contact sensor configured to measure the displacement of the first user input device along the first axis.

15. The power tool as described in claim 14, characterized in that, The input device housing includes a positioning groove with multiple notches.

16. The power tool according to claim 15, characterized in that: The second user input device also includes a plurality of positioning balls and ball springs; and The plurality of positioning balls are located within the positioning grooves of the input device housing.

17. The power tool as claimed in claim 14, characterized in that, The slider of the second user input device is circular and includes a plurality of protrusions configured to engage the plurality of contact pads on the circuit board.

18. The power tool as claimed in claim 14, characterized in that, The non-contact sensor is a digital Hall effect sensor, which is configured to measure the magnetic flux of the trigger magnet when the first user input device moves along the first axis.

19. The power tool as claimed in claim 14, characterized in that, The non-contact sensor is an inductive sensor configured to measure changes in inductance as a metallic target of the first user input device moves along the first axis.

20. The power tool as claimed in claim 14, characterized in that, The sensor includes one or more contact rails configured to engage a second sliding piece of the first user input device.

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