Power tool with pulse arrangement

Abstract

A power tool comprising a motor, a pulse assembly configured to be driven by the motor, a temperature sensor, and a control unit. The temperature sensor is configured to output a signal related to a temperature of the power tool. The temperature of the power tool is related to a temperature of a fluid within the pulse assembly. The control unit is connected to the temperature sensor. The control unit is configured to determine the temperature of the power tool based on the signal from the temperature sensor and to control the power tool based on the temperature of the power tool when the temperature of the power tool exceeds a temperature threshold.

Description

RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 560,273, filed March 1, 2024, and U.S. Provisional Patent Application No. 63 / 658,143, filed June 10, 2024, the entire contents of which are hereby incorporated by reference. AREA

[0002] The embodiments described here refer to power tools. SUMMARY

[0003] Pulse power tools are capable of delivering high-speed rotating impacts to a workpiece by storing energy in a rotating mass and transferring it to an output shaft. Such pulse tools generally have an output shaft that may or may not accommodate a tool bit or engaging attachment. Pulse tools generally utilize the percussive transmission of high pulses transmitted via the output shaft using a variety of technologies, including electric, oil pulse, mechanical pulse, or a suitable combination thereof.

[0004] The power tools described herein comprise a housing, a motor positioned in the housing, an impulse assembly coupled to the motor to receive torque therefrom, the impulse assembly comprising a cylinder at least partially defining a chamber containing a hydraulic fluid, an anvil positioned at least partially in the chamber, and a hammer positioned at least partially in the chamber and engageable with the anvil to impart rotary impacts to the anvil, the hammer comprising a through-hole and a valve configured to control the flow of hydraulic fluid through the through-hole.

[0005] When the hydraulic fluid reaches a certain temperature, a pulse tool may experience thermal failure. In some cases, it is desirable to shut down the pulse tool before thermal failure occurs. However, it is difficult to directly measure the temperature of the hydraulic fluid. Therefore, the embodiments described herein provide a system and method for controlling a pulse tool using a specific temperature that correlates with a temperature of a fluid within the pulse mechanism. The determined temperature may be based on one or more signals from temperature sensors located external to the airflow circuit in the pulse tool (e.g.,one or more temperature sensors positioned on a circuit board for a lighting assembly), or one or more temperature sensors positioned on a circuit board for a Hall effect sensor.

[0006] The power tools described herein include a motor, a pulse assembly configured to be driven by the motor, a temperature sensor, and a control unit. The temperature sensor is configured to output a signal related to a temperature of the power tool. The temperature of the power tool is related to a temperature of a fluid in the pulse assembly. The control unit is connected to the temperature sensor. The control unit is configured to determine the temperature of the power tool based on the signal from the temperature sensor and to control the power tool based on the temperature of the power tool when the temperature of the power tool exceeds a temperature threshold.

[0007] In some aspects, the control unit is configured to either turn off the power tool or reduce the power of the power tool based on the temperature of the power tool.

[0008] In some aspects, the temperature sensor is positioned outside the airflow circuit within the power tool.

[0009] In some aspects, the temperature sensor is positioned on a printed circuit board (“PCB”) for a lighting assembly.

[0010] In some aspects, the temperature sensor is positioned on a Hall effect sensor printed circuit board (“PCB”).

[0011] In some aspects, the controller is further configured to, in response to the temperature of the power tool being below the temperature threshold and above or equal to a second temperature threshold, compare a period of time during which the temperature of the power tool is below the first temperature threshold and above or equal to the second temperature threshold to a time threshold, and to, in response to the period of time reaching the time threshold, deactivate the power tool.

[0012] The power tools described herein include a motor, a pulse assembly configured to be driven by the motor, a first temperature sensor, a second temperature sensor, and a controller. The first temperature sensor is configured to output a first signal related to a temperature of the power tool. The temperature of the power tool is related to a temperature of a fluid in the pulse assembly. The second temperature sensor is configured to output a second signal related to the temperature of the power tool. The controller is connected to the first temperature sensor and the second temperature sensor.The control unit is configured to determine the temperature of the power tool based on the first signal from the first temperature sensor and the second signal from the second temperature sensor and to control the power tool based on the temperature of the power tool when the temperature of the power tool is above a temperature threshold.

[0013] In some aspects, the control unit is configured to shut down the power tool to control the power tool based on the temperature of the power tool.

[0014] In some aspects, the first temperature sensor and the second temperature sensor are positioned outside of an airflow circuit within the power tool.

[0015] In some aspects, the first temperature sensor is positioned on a printed circuit board for a lighting assembly (“PCB”).

[0016] In some aspects, the second temperature sensor is positioned on a Hall effect sensor circuit board.

[0017] In some aspects, the controller is further configured to, in response to the temperature of the power tool being below the temperature threshold and above or equal to a second temperature threshold, compare a period of time during which the temperature of the power tool is below the first temperature threshold and above or equal to the second temperature threshold to a time threshold, and to, in response to the period of time reaching the time threshold, deactivate the power tool.

[0018] The methods described herein for controlling a power tool include receiving a signal from a temperature sensor associated with a temperature of the power tool, the temperature of the power tool being correlated with a temperature of a fluid in a pulse array, determining the temperature of the power tool based on the signal from the temperature sensor, and controlling the power tool based on the temperature of the power tool when the temperature of the power tool is greater than a temperature threshold.

[0019] In some aspects, controlling the power tool based on the temperature of the power tool includes turning off or shutting down the power tool or reducing a power of the power tool.

[0020] In some aspects, the temperature sensor is positioned remote from an airflow circuit within the power tool.

[0021] In some aspects, the temperature sensor is positioned on a circuit board for a lighting assembly.

[0022] In some aspects, the temperature sensor is positioned on a Hall effect sensor printed circuit board (“PCB”).

[0023] In some aspects, the method further comprises comparing, in response to the temperature of the power tool being less than the temperature threshold and greater than or equal to a second temperature threshold, a period of time for which the temperature of the power tool is less than the first temperature threshold and greater than or equal to the second temperature threshold with a time threshold, and deactivating the power tool in response to the period of time reaching the time threshold.

[0024] In some aspects, the temperature sensor is positioned within the pulse array.

[0025] In some aspects, the method further comprises receiving a second signal from a second temperature sensor related to the temperature of the power tool, wherein the temperature of the power tool is correlated to the temperature of the fluid within a pulse assembly.

[0026] Before any embodiments are explained in detail, it is to be understood that the embodiments are not limited in their application to the details of the configurations and arrangements of components set forth in the following description or illustrated in the accompanying drawings. The embodiments may be practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be considered limiting. The use of "including," "comprising," or "having," and variations thereof, is intended to encompass the items listed thereafter and their equivalents as well as additional items.Unless otherwise specified or limited, the terms "mounted," "connected," "supported," and "coupled," and variations thereof, are used generically and include both direct and indirect mountings, connections, supports, and couplings.

[0027] Unless the context of their use clearly indicates otherwise, the articles 'a', 'an', and 'the' should not be interpreted as 'one' or 'only'. Rather, these articles should be interpreted as 'at least one' or 'one or more'. Similarly, when referring to a noun previously introduced by the indefinite article 'a' or 'an', the terms 'the' or 'said' mean 'at least one' or 'one or more', unless usage clearly indicates otherwise.

[0028] Furthermore, it should be understood that embodiments may include hardware, software, and electronic components or modules, which, for purposes of discussion, may be illustrated and described as if the majority of the components were implemented solely in hardware. However, one of ordinary skill in the art, having read this detailed description, would recognize that, in at least one embodiment, the electronic-based aspects may be implemented in software (e.g., stored on a non-transitory computer-readable medium) that may be executed by one or more processing units, such as a microprocessor and / or application-specific integrated circuits ("ASICs"). Therefore, it should be understood that a variety of hardware- and software-based devices, as well as a variety of different structural components, may be used to implement the embodiments.For example, the "servers," "computing devices," "controllers," "processors," etc. described in the specification may include one or more processing units, one or more computer-readable media modules, one or more input / output interfaces, and various connections (e.g., a system bus) that connect the components.

[0029] Relative terms such as "about," "approximately," "substantially," etc., when used in connection with an amount or condition, would be understood by persons of ordinary skill in the art to include the stated value and have the meaning given by the context (e.g., the term includes at least the degree of error associated with the accuracy of measurement, the tolerances associated with the particular value [e.g., manufacturing, assembly, use, etc.], etc.). Such terminology should also be considered to disclose the range defined by the absolute values ​​of the two endpoints. For example, the phrase "from about 2 to about 4" also discloses the range "from 2 to 4." Relative terminology can refer to plus or minus a percentage (e.g., 1%, 5%, 10%) of a stated value.

[0030] It should be noted that while certain drawings illustrate hardware and software residing in particular devices, these depictions are for illustrative purposes only. Functionality described herein as being performed by one component may be performed by multiple components in a distributed manner. Likewise, functionality performed by multiple components may be consolidated and performed by a single component. In some embodiments, the depicted components may be combined or separated into separate software, firmware, and / or hardware. For example, logic and processing may be distributed among multiple electronic processors rather than residing in and executed by a single electronic processor.Regardless of how they are combined or divided, hardware and software components may be located on the same computing device or distributed among different computing devices connected by one or more networks or other suitable communication links. Likewise, a component described as performing a particular functionality may also perform additional functionality not described herein. For example, a device or structure "configured" in a particular manner is at least configured in that manner, but may also be configured in ways not explicitly listed.

[0031] Accordingly, in the claims, for example, where it is claimed that an apparatus, method, or system comprises a controller, control unit, electronic processor, computing device, logic element, module, memory module, communication channel or network, or other element configured in a particular way, for example to perform a plurality of functions, the claim or claim element should be construed to mean one or more of those elements, one of the one or more elements being configured as claimed, for example to perform one or more of said plurality of functions, such that the one or more elements as a set jointly perform the plurality of functions.

[0032] Further aspects of the disclosure will become apparent from consideration of the detailed description and the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a cross-sectional view of a power tool according to some embodiments. Fig. 2 is a cross-sectional view of a pulse assembly for the power tool of Fig. 1 according to some embodiments. Fig. Figure 3 is a schematic representation of the operation of the pulse arrangement of Fig. 2 according to some embodiments. Fig. 4 is a cross-sectional view of the power tool of Fig. 1 according to some embodiments. Fig. 5 shows a circuit board for a motor and a Hall effect sensor for the power tool of Fig. 1 according to some embodiments. Fig. 6 shows a circuit board for a light assembly for the power tool from Fig. 1 according to some embodiments. Fig. 7 is a cross-sectional view of the power tool of Fig. 1 according to some embodiments. Fig. Figure 8 shows a control system for the power tool of Fig. 1 according to some embodiments. Fig. 9 shows a method for controlling the power tool of Fig. 1 according to some embodiments. Fig. 10 shows a method for controlling the power tool of Fig. 1 according to some embodiments. Fig. 11 is a diagram showing the operation of the power tool of Fig. 1 according to some embodiments. Fig. 12 shows a method for controlling the power tool of Fig. 1 according to some embodiments. Fig. 13 is a diagram showing the operation of the power tool of Fig. 1 according to some embodiments. DETAILED DESCRIPTION

[0033] With reference to Fig. 1, a power tool (e.g., a pulse tool 10) embodying aspects of the present disclosure is illustrated. The pulse tool 10 includes a main housing 14 and a rotary pulse assembly 18 disposed within the main housing 14 (see Fig. 2). The pulse tool 10 also includes an electric motor 22 (e.g., a brushless DC motor) coupled to the pulse assembly 18 to impart torque thereto and positioned within the main housing 14, and a gear train (e.g., a single- or multi-stage planetary gear train) positioned between the motor 22 and the pulse assembly 18. In some embodiments, the pulse tool 10 is battery-operated and configured to be powered by a rechargeable power tool battery.

[0034] With reference to Fig. 1 and Fig. 2, the illustrated pulse assembly 18 includes a hammer 26 and an anvil 30. A driven end 26a of the hammer 26 is coupled to the electric motor 22 to receive torque therefrom, thereby rotating the hammer 26. In some embodiments, a gear train, such as a planetary gear train, may be provided between the electric motor 22 and the hammer 26 to effect a speed reduction and a torque increase from the electric motor 22 to the hammer 26. In such embodiments, the hammer 26 may be coupled to or integrally include a carrier of the planetary gear train.

[0035] With reference to Fig. 2, the hammer 26 includes flails 34 configured to impact the anvil 30 when the motor 22 drives the rotation of the hammer 26. In particular, the illustrated hammer 26 includes two flails 34. The flails 34 extend inwardly from an inner peripheral surface 38 of the hammer 26. The hammer 26 at least partially defines a hammer chamber 42 containing an incompressible fluid (e.g., hydraulic fluid, oil, etc.). The hammer chamber 42 is sealed and is also partially defined by an end cap 46 threadedly attached to a forward end 26b of the hammer 26 opposite the driven end 26a ( Fig. 1). The hydraulic fluid in the hammer chamber 42 can reduce the wear and noise of the pulse assembly 18 caused by the impact of the hammer 26 and the anvil 30.

[0036] The anvil 30 is at least partially located within the hammer chamber 42 and includes a blade assembly 50 and an output shaft 54 ​​having a hexagonal receptacle 58 therein for receiving a tool bit. The blade assembly 50 includes blades 62a, 62b configured to receive impacts from the hammer flails 34 and a spring 66 biasing each of the blades 62a, 62b into engagement with the inner peripheral surface 38 of the hammer 26.

[0037] The illustrated blade assembly 50 includes two blades 62a, 62b such that each blade 62a, 62b is configured to receive an impact from a corresponding hammer flail 34. Each of the blades 62a, 62b extends through the output shaft 54 ​​such that the blades 62a, 62b are configured to transmit the rotational impacts from the hammer flails 34 to the output shaft 54. In the illustrated embodiment, the blade assembly 50 includes a single spring 66 that biases both blades 62a, 62b. In some embodiments, the blade assembly 50 may include two springs such that each spring biases a corresponding blade 62a, 62b. The output shaft 54 ​​extends from the hammer chamber 42 through the end cap 46. The output shaft 54 ​​extends along an axis A1 and is configured to rotate about this axis.The output shaft 54 ​​defines an anvil chamber 70 and fill ports 74 that fluidly connect the anvil chamber 70 with the hammer chamber 42. The fill ports 74 can be intermittently opened and closed to permit and restrict the flow of hydraulic fluid between the hammer chamber 42 and the anvil chamber 70.

[0038] With reference to the Fig. 1-3, at the beginning of operation of the pulse tool 10, the fill ports 74 in the output shaft 54 ​​are open, allowing free flow of hydraulic fluid between the hammer chamber 42 and the anvil chamber 70. Therefore, the pressure in the hammer chamber 42 and the pressure in the anvil chamber 70 are equal at the beginning of operation. During operation, each of the hammer flails 34 intermittently applies rotational impacts to a corresponding one of the blades 62a, 62b to transmit successive rotational impacts to the output shaft 54. When the hammer flails 34 begin striking the blades 62a, 62b (i.e., a pulse start), the fill ports 74 may close, and the pressure of the hydraulic fluid in the anvil chamber 70 may rise rapidly, so that the pressure in the anvil chamber 70 is relatively higher than the pressure of the hydraulic fluid in the hammer chamber 42.As the impact progresses, the hammer flails 34 can rise and slide over the blades 62a, 62b, forcing the blades 62a, 62b against the bias of the spring 66 and against the relatively higher pressure of the fluid in the anvil chamber 70. The fluid in the anvil chamber 70 can be forced through a narrowed opening into the hammer chamber 42, allowing the blades 62a, 62b to move inward toward the axis A1. As the blades 62a, 62b move inward, the relatively higher pressure in the anvil chamber 70 can be relieved through the opening, allowing the fluid in the hammer chamber 42 and the anvil chambers 70 to move toward an equal level. The hydraulic fluid can thus slow and dampen the inward movement of the blades 62a, 62b and thereby increase the duration over which the hammer flails 34 engage the blades 62a, 62b.The hydraulic fluid can also reduce noise emissions and inhibit wear on the components of the hammer 26 and anvil 30 throughout the impact.

[0039] Once the hammer flails 34 extend beyond the blades 62a, 62b (e.g., at the end of a pulse), the springs 66 urge the blades 62a, 62b outward from the axis A1 and re-engage the inner peripheral surface 38 of the hammer 26. Additionally, the fill ports 74 may reopen, allowing hydraulic fluid to flow between the hammer chamber 42 and the anvil chamber 70. Because the spring 66 urges the blades 62a, 62b outward, the pressure in the anvil chamber 70 may be relatively lower than the pressure in the hammer chamber 42. Therefore, hydraulic fluid may flow from the hammer chamber 42 to the anvil chamber 70 until the pressures in the chambers 42 and 70 are equal. When the blades 62a, 62b are biased into engagement with the inner peripheral surface 38 of the hammer 26 and the pressures in each chamber 42, 70 are equal, the pulse assembly 18 is ready for another impact and for the repetition of the cycle.

[0040] Fig. 4 shows a cross-sectional view of the pulse tool 10. As in Fig. 4, the pulse tool 10 includes a first temperature sensor (e.g., a thermistor, a thermocouple, etc.) or a first plurality of temperature sensors (e.g., a thermistor, a thermocouple, etc.) 400 mounted on a Hall-effect sensor printed circuit board ("PCB"). The Hall-effect sensor PCB may be attached to a stator of a motor within the pulse tool 10. The pulse tool 10 also includes a second temperature sensor (e.g., a thermistor) or a second plurality of temperature sensors (e.g., thermistors) 405 mounted on a light assembly printed circuit board ("PCB"). In some embodiments, the temperature sensor 405 is attached to a stud plate.The temperature sensors 400, 405 can be used to indirectly measure a temperature of a liquid in the pulse assembly 18 or, in other words, to determine a temperature that correlates with the temperature of the liquid in the pulse assembly 18. Fig. 4 also shows the airflow paths 410, 415 for the pulse tool 10, which may affect the temperature measurements using the temperature sensor 405. In some embodiments, a transmission housing 420 for the transmission includes an additional temperature sensor 425 (e.g., a thermistor, thermocouple, etc.) coupled to the transmission housing 420.

[0041] Fig. 5 shows a motor 500 next to a circuit board 505 for a Hall-effect sensor for the pulse tool 10. The Hall-effect sensor circuit board 505 includes a plurality of Hall-effect sensors 510, which are positioned, for example, on a first side of the Hall-effect sensor circuit board 505. The Hall-effect sensor circuit board 505 includes one or more temperature sensors (e.g., thermistors, thermocouples, etc.) 515. In some embodiments, a single temperature sensor is implemented. In other embodiments, a plurality of temperature sensors are implemented. The temperature sensors 515 may be used to measure the temperature of a fluid in the pulse assembly 18. It should be noted that while each of the temperature sensors 515 in Fig. 5 as being positioned on the first side of the circuit board, in some embodiments, one or more of the temperature sensors 515 may be positioned on a second, opposite side of the circuit board. In some embodiments, the temperature sensors 515 may be positioned only on the second side of the Hall effect sensor circuit board.

[0042] Fig. 6 shows a nose cone 600 for the pulse tool 10 surrounding a light assembly circuit board 605. The light assembly circuit board 605 includes a plurality of lights or LEDs 610 positioned, for example, on a first side of the light assembly circuit board 605. The light assembly circuit board 605 includes one or more temperature sensors (e.g., thermistors, thermocouples, etc.) 615. In some embodiments, a single temperature sensor is positioned on the light assembly circuit board 605. In other embodiments, a plurality of temperature sensors are positioned on the light assembly circuit board 605. The temperature sensors 615 can be used to measure the temperature of a fluid in the pulse assembly 18. In some embodiments, the temperature sensors 615 are removed from or positioned away from an airflow circuit in the pulse tool 10.

[0043] Fig. 7 shows the pulse arrangement 18 of the pulse tool 10. In the Fig. In the embodiment shown in Figure 7, one or more temperature sensors (e.g., thermistors) 700 are positioned in the hammer chamber 42 of the pulse assembly 18.

[0044] As in Fig. 8, the pulse tool 10 includes the motor 22. The motor 22 actuates a driving device and enables the driving device to perform the respective task (e.g., providing rotational power to drive a fastener). The motor 22 may include a rotor and a stator. The rotor may be coupled to a motor shaft to transmit rotational motion to the output device directly or through one or more gears. A primary power source (e.g., a battery pack) 810 is coupled to the pulse tool 10 and provides electrical energy to power the motor 22. The motor 22 is powered based on the position of a trigger 830. When the trigger 830 is pressed, power is supplied to the motor 22, and when the trigger 830 is released, power is removed from the motor 22.In the illustrated embodiment, the trigger 830 extends partially along a length of a handle. In other embodiments, the trigger 830 extends the entire length of the handle or can be positioned elsewhere on the pulse tool 10. The trigger 830 is movably connected to the handle such that the trigger 830 moves relative to the tool housing. The trigger 830 is connected to a push rod engageable with a trigger switch 835. The trigger 830 moves in a first direction toward the handle when the trigger 830 is squeezed by the user. The trigger 830 is biased (e.g., with a spring) to move in a second direction away from the handle when the trigger 830 is released by the user.When the trigger 830 is pressed by the user, the push rod activates the trigger switch 835, and when the trigger 830 is released by the user, the trigger switch 835 is deactivated. In some embodiments, the trigger 830 is separate from the electrical trigger switch 835. In such embodiments, the trigger switch 835 may include, for example, a transistor. Additionally, in such electronic embodiments, the trigger 830 may not include a push rod for activating the mechanical switch. Instead, the electrical trigger switch 835 may be activated, for example, by a position sensor (e.g., a Hall-effect sensor) that communicates information about the relative position of the trigger 830 to the tool housing or the electrical trigger switch 835. The trigger switch 835 outputs a signal indicative of the position of the trigger 830.In some cases, the signal is binary and indicates that the trigger 830 is pressed or released. In other cases, the signal indicates the position of the trigger 830 with greater precision. For example, the trigger switch 835 may output an analog signal that varies between 0 and 5 volts depending on the extent to which the trigger 830 is pressed. For example, a 0 V output indicates that the trigger 830 is released, a 1 V output indicates that the trigger 830 is pressed 20%, a 2 V output signal means that the trigger 830 is pressed 40%, a 3 V output signal means that the trigger 830 is pressed 60%, a 4 V output signal means that the trigger 830 is pressed 80%, and a 5 V output signal means that the trigger 830 is pressed 100%. The signal output by the trigger switch 835 can be analog or digital.

[0045] As in Fig. 8, the pulse tool 10 includes a switching network 815, sensors 820, displays 840, a battery pack interface 805, a power supply unit 860, an electronic control unit 800, a wireless communication control unit 850, and a backup power source 855. The backup power source 855, in some embodiments, comprises a coin cell battery or other similar small, replaceable power source. The battery pack interface 805 is connected to the electronic control unit 800 and couples to the battery pack 810. The battery pack interface 805 includes a combination of mechanical (e.g., a battery pack receiving portion) and electrical components configured and operable to connect the pulse tool 10 to the battery pack 810 (e.g., mechanically, electrically, and communicatively). The battery pack interface 805 is connected to the power supply unit 860.The battery pack interface 805 transmits the power received from the battery pack 810 to the power supply unit 860. The power supply unit 860 includes active and / or passive components (e.g., voltage step-down regulators, voltage converters, rectifiers, filters, etc.) to regulate or control the power received via the battery pack interface 805 and delivered to the wireless communication control unit 850 and the control unit 800.

[0046] The switching network 815 enables the electronic control unit 800 to control the operation of the motor 22. Generally, when the trigger 830 is pulled, as indicated by an output of the trigger switch 835, electrical power is supplied from the battery pack interface 805 to the motor 22 via the switching network 815. When the trigger 830 is not pulled, no electrical power is supplied from the battery pack interface 805 to the motor 22.

[0047] In response to electronic control unit 800 receiving the activation signal from trigger switch 835, electronic control unit 800 activates switching network 815 to supply power to motor 22. Switching network 815 controls the amount of power available to motor 22, thereby controlling the speed and torque of motor 22. Switching network 815 may include numerous FETs, bipolar transistors, or other types of electrical switches. For example, switching network 815 may include a bridge with six FETs that receives pulse-width modulated ("PWM") signals from electronic control unit 800 to drive motor 22.

[0048] The sensors 820 are coupled to the electronic control unit 800 and transmit various signals to the electronic control unit 800 indicative of different parameters of the pulse tool 10 or the motor 22. The sensors 820 include, among others, Hall-effect sensors, such as one or more voltage sensors, one or more temperature sensors (e.g., temperature sensors 400, 405, 515, 615, 700), one or more torque sensors, etc. One or more signals from the temperature sensors 400, 405, 515, 615, 700 can be used by the control unit 800 to determine a temperature that correlates with a temperature of the fluid within the impact mechanism. The temperature of the fluid can be determined or estimated, for example, based on test data used to correlate these determined temperatures with internal fluid data (e.g.,Bench testing, manual measurement of fluid temperature, etc.). In some embodiments, the fluid temperature is not measured directly (i.e., indirect measurement). In other embodiments, the fluid temperature may be measured directly (e.g., using temperature sensors 700). Each Hall-effect sensor outputs motor feedback information to the electronic control unit 800, such as an indication (e.g., a pulse) when a motor rotor magnet rotates across the face of that Hall-effect sensor. Using the motor feedback information from the Hall-effect sensors, the electronic control unit 800 can determine the position, speed, and acceleration of the rotor. In response to the motor feedback information and the signals from the trigger switch 835, the electronic control unit 800 sends control signals to control the switching network 815 to drive the motor 22.For example, by selectively enabling and disabling the FETs of switching network 815, the power received via battery pack interface 805 is selectively applied to the stator coils of motor 22 to cause rotation of its rotor. The motor feedback information is used by electronic control unit 800 to ensure proper timing of the control signals to switching network 815 and, in some cases, to provide closed-loop feedback to maintain the speed of motor 22 at a desired level.

[0049] The indicators 840 are also coupled to the electronic control unit 800 and receive control signals therefrom for turning the power on and off or otherwise communicating information based on various states of the pulse tool 10. The indicators 840 include, for example, one or more light-emitting diodes ("LEDs") or a screen. The indicators 840 may be configured to display states or information associated with the pulse tool 10. For example, the indicators 840 are configured to display measured electrical characteristics of the pulse tool 10, the status of the pulse tool 10, the mode of the power tool, etc. The indicators 840 may also include elements that communicate information to a user through audible or tactile outputs.The work light LEDs 845 can also be controlled by the electronic control unit 800, for example to illuminate when the trigger 830 is actuated.

[0050] As described above, the electronic control unit 800 is electrically and / or communicatively connected to a plurality of components of the pulse tool 10. In some embodiments, the electronic control unit 800 includes a plurality of electrical and electronic components that power, control, and protect the components within the electronic control unit 800 and / or the pulse tool 10. For example, the electronic control unit 800 includes, among other things, a processing unit 865 (e.g., a microprocessor, a microcontroller, an electronic control unit, an electronic processor, or other suitable programmable device), a memory 870, input units 875, and output units 880. The processing unit 865 (herein, electronic processor 865) includes, among other things, a control unit 885, an arithmetic logic unit ("ALU") 890, and a plurality of registers 895 (in Fig. 8 as a group of registers). In some embodiments, the electronic control unit 800 is partially or entirely implemented on a semiconductor chip (e.g., a semiconductor with a field-programmable gate array [“FPGA”]), such as a chip developed by a register-transfer-level design process (“RTL”).

[0051] The memory 870 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 the data storage area may include combinations of different memory types, such as read-only memory ("ROM"), random access memory ("RAM") (e.g., dynamic RAM ("DRAM"), synchronous DRAM ("SDRAM"), etc.), electrically erasable programmable read-only memory ("EEPROM"), flash memory, a hard disk, an SD card, or other suitable magnetic, optical, or electronic devices. The electronic processor 865 is coupled to the memory 870 and executes software instructions that may be stored in a RAM of the memory 870 (e.g., during execution), a ROM of the memory 870 (e.g., on a generally permanent basis), or another non-transitory computer-readable medium such as another memory or a disc.The software included in the implementation of the pulse tool 10 may be stored in the memory 870 of the electronic control unit 800. The software includes, for example, firmware, one or more applications, program data, filters, rules, one or more program modules, and other executable instructions. The electronic control unit 800 is configured to, among other things, retrieve and execute instructions related to the control processes and methods described herein from the memory. The electronic control unit 800 is also configured to store information about the power tool in the memory 870, including operating data, information identifying the tool type, a unique identifier for the particular tool, and other information relevant to the operation or maintenance of the pulse tool 10. The information about tool usage, such asCurrent, motor speed, motor acceleration, motor direction, and number of impacts can be sensed or derived from the data output by sensors 820. Such power tool information can then be accessed by a user using an external device. In other designs, electronic control unit 800 includes additional, fewer, or different components.

[0052] The wireless communication control unit 850 is coupled to or integrated with the electronic control unit 800. In the illustrated embodiment, the wireless communication control unit 850 is located near the base of the pulse tool 10 to save space and ensure that the magnetic activity of the motor 22 does not interfere with the wireless communication between the pulse tool 10 and the external device.

[0053] Fig. 9 shows a process 900 for controlling the pulse tool 10. The process 900 begins by determining a temperature based on one or more signals from the temperature sensors 400, 405, 515, 615, 700 (STEP 905). In some embodiments, the determined temperature correlates with a temperature of a fluid within the pulse mechanism (e.g., pulse assembly 18). If the determined temperature at STEP 910 is greater than a temperature threshold, the controller 800 controls the pulse tool 10 based on the determined temperature (e.g., reduces an output of the pulse tool 10, turns off the pulse tool 10, or otherwise disables operation of the pulse tool 10) (STEP 915). In some embodiments, when multiple temperature sensors are used to determine the temperature correlated with the fluid in the pulse mechanism, one temperature sensor may be given more weight than the other.For example, the temperature sensors 405, 615 located outside the airflow path of the pulse tool 10 may be given greater weight (e.g., as a more reliable representation of the fluid temperature).

[0054] Fig. 10 illustrates a method 1000 for controlling the pulse tool 10 based on one or more signals from temperature sensors positioned external to the airflow circuit within the pulse tool 10. The process 1000 begins by determining a temperature based on one or more signals from temperature sensors 405, 615 located at a distal position on the pulse tool 10 remote from an airflow circuit within the pulse tool 10 (STEP 1005). In some embodiments, the determined temperature correlates to a temperature of a fluid within the pulse mechanism (e.g., pulse assembly 18). In some embodiments, the controller 800 correlates the determined temperature to the temperature of the fluid based on the specific heat capacity of the materials of the components positioned between the fluid and the temperature sensors 405, 615.If the determined temperature is greater than a temperature threshold at STEP 1010, the controller 800 controls the pulse tool 10 to shut down or otherwise deactivate it at STEP 1015. In some embodiments, the temperature of the fluid in the pulse mechanism is above, or likely to be above, a temperature acceptable for safe operation of the pulse tool 10 if the determined temperature is above the temperature threshold.

[0055] Fig. 11 shows a diagram 1100 of the operation of the pulse tool 10 based on one or more signals from temperature sensors positioned remotely from an airflow circuit within the pulse tool 10. A temperature threshold 1105 (e.g., 80°C) is illustrated. In response to the temperature determined based on one or more signals from temperature sensors positioned remotely from an airflow circuit within the pulse tool 10 reaching the temperature threshold 1105, the controller 800 controls the pulse tool 10 to shut down or otherwise disable the operation of the pulse tool 10. In some embodiments, the diagram 1100 corresponds to controlling the pulse tool 10 based on one or more temperature signals from the temperature sensors 405, 615.It should be noted that when the detected temperature reaches 80 °C, the temperature of the liquid in the pulse arrangement 18 may be significantly higher than 80 °C.

[0056] Fig. 12 is a process 1200 for controlling the pulse tool 10 based on one or more signals from temperature sensors positioned on the Hall-effect sensor circuit board 505. The process 1200 begins by determining a temperature based on one or more signals from the temperature sensors 400, 515 (STEP 1205) positioned on a Hall-effect sensor circuit board (e.g., the Hall-effect sensor circuit board 505). In some embodiments, the determined temperature correlates with a temperature of a fluid within the pulse mechanism (e.g., pulse assembly 18). However, factors may influence the temperature determined in STEP 1205, preventing a direct correlation between the determined temperature and the temperature of the fluid within the pulse mechanism. One such factor may be, for example, airflow generated by the rotor fan blade.

[0057] If the determined temperature is greater than or equal to a first temperature threshold in STEP 1110, the controller 800 controls the pulse tool 10 to shut down or otherwise deactivate it (STEP 1215). If the determined temperature is below a first temperature threshold in STEP 1210, the controller 800 compares the determined temperature to a second temperature threshold (STEP 1220). If the determined temperature is below the first temperature threshold but greater than or equal to the second temperature threshold in STEP 1220, the length of time the determined temperature is below the first temperature threshold but greater than or equal to the second temperature threshold is compared to a time threshold (STEP 1225).

[0058] When the time threshold has been reached at STEP 1225, the controller 800 controls the pulse tool 10 to shut down or otherwise deactivate (STEP 1215). In some embodiments, when the pulse tool 10 is shut down or otherwise deactivated, rapid saturation of a stator region may occur as heat is transferred from a gear case mechanism to a cooling fan of the pulse tool 10. The determined temperature based on signals from the temperature sensors 400, 515 positioned on the Hall-effect sensor circuit board 505 may increase to a temperature closer to the temperature of the fluid. Stopping the motor 22 generally results in an increase in the determined temperature based on signals from the temperature sensors 400, 515 positioned on the Hall-effect sensor circuit board 505.

[0059] If, at STEP 1220, the determined temperature is not greater than or equal to the second temperature threshold, the process 1200 returns to STEP 1205. If, at STEP 1225, the time threshold is not met, the process 1200 returns to STEP 1205. In some embodiments, if the determined temperature is below the first temperature threshold but above the second temperature threshold and the time threshold has not been met, the controller 800 drives the motor 22, the pulse assembly 18, or both, harder or faster to compensate for a loss of drive time when the pulse tool 10 is shut down due to the time threshold being met.In some embodiments, the controller 800 increases the speed of the motor 22, drives the pulse assembly 18 harder, or both, to compensate for changes in the performance of the pulse tool 10 due to an increase in the temperature of the fluid in the pulse assembly 18. In some embodiments, the controller 800 may calculate an optimal torque, an optimal speed, or both, to compensate for power losses due to the fluid viscosity changing with the fluid temperature. The controller 800 may increase the speed of the motor 22, drive the pulse assembly 18 harder, or both by performing field weakening (e.g., controlling a conduction angle, controlling phase advance, implementing negative excitation injection in a field-oriented motor control technique, etc.).

[0060] In some embodiments, the controller 800 notifies a user that the tool may be too hot, for example, via one or more of the indicators 1140, when the determined temperature is below the first temperature threshold but above or equal to the second temperature threshold and the time threshold has not been met. For example, a notification that the pulse tool 10 may be too hot may include the motor 22 coasting to a stop, emitting a sound, flashing a light (e.g., a work light LED 1145), a combination of the foregoing, or the like.

[0061] In some embodiments, the time threshold used in process 1200 is longer than the time applications of pulse tool 10 typically last. Therefore, a user may turn off or shut down pulse tool 10 before the time threshold is even reached at STEP 1225. However, the time required for pulse tool 10 to complete an application or task may increase if the temperature of the fluid in pulse assembly 18 is high. In some embodiments, instead of a time threshold, process 1200 may use a threshold number of revolutions of motor 22, a threshold number of cycles of pulse tool 10, or the like.

[0062] Fig. 13 shows a diagram 1300 of the operation of the pulse tool 10 based on the temperature determined based on one or more signals from temperature sensors positioned on the Hall effect sensor circuit board 505. A first temperature threshold 1305 (e.g., 75°C) and a second temperature threshold 1310 (e.g., 60°C) are shown. At point A, the control unit 800 determines that the determined temperature is greater than the second threshold but less than the first threshold. In such a case, a timer may be started and compared to a time threshold (e.g., 30 seconds). If the determined temperature remains between the two temperature thresholds for the duration of the time threshold, the pulse tool 10 may be shut down, for example, at point B.In some embodiments, hysteresis may be used to control thermal shutdown based on heat loss. At point C, the determined temperature reaches the first temperature threshold 1305, and the controller 800 controls the pulse tool 10 to shut down, for example, to force cooling at point D (e.g., a required temperature drop [e.g., 15°C] before the pulse tool 10 can be restarted). In some embodiments, cooling of the pulse tool 10 may be provided by a rotor fan. In some implementations, active cooling solutions that assist the movement of the motor 22, such as additional fans, thermoelectric coolers, liquid cooling pumps, or the like, may be employed to cool the pulse tool 10.In some embodiments, diagram 1300 corresponds to controlling the pulse tool 10 based on one or more temperature signals from the temperature sensors 400, 515.

[0063] As in Fig. 11 and Fig.13 by the temperature threshold 1105 of 80°C and the first temperature threshold 1305 of 75°C, respectively, a temperature threshold may be higher when a particular temperature is based on one or more signals from temperature sensors located away from an airflow circuit in the pulse tool 10 than a temperature threshold when the particular temperature is based on one or more signals from temperature sensors located, for example, on the Hall-effect sensor circuit board 505. For example, temperature sensors positioned on the Hall-effect sensor circuit board 505 are more easily affected by external factors such as airflow than temperature sensors positioned away from an airflow path in the pulse tool 10.

[0064] Processes 1000, 1200 can be implemented independently or in conjunction with one another. Therefore, one process 1000, 1200 can serve as a failover for the other process 1000, 1200, for example, in the event of a temperature sensor failure. In another example, measurements taken by temperature sensors 400, 515 positioned on a Hall-effect sensor circuit board 505 may be more easily influenced by external factors than measurements taken by temperature sensors 405, 615 positioned away from the airflow in pulse tool 10.For example, if a user of the pulse tool 10 uses compressed air to cool the pulse tool 10, the fluid in the pulse assembly 18 and the temperature sensors 405, 615 located away from the airflow in the pulse tool 10 may not be cooled as quickly by the compressed air as the temperature sensors 400, 515 located on a Hall-effect sensor circuit board 505. Therefore, in this example, a temperature determined based on one or more signals from the temperature sensors 405, 615 located away from an airflow circuit in the pulse tool 10 may more accurately reflect the temperature of the fluid in the pulse assembly 18 than a temperature determined based on one or more signals from the temperature sensors 400, 515 positioned on a Hall-effect sensor circuit board 505.In some embodiments, the temperature thresholds described herein are static values ​​(e.g., 75°C). In some embodiments, temperature sensors 400, 405, 515, 615, 700 can be used to measure temperature regardless of whether trigger 1130 is pulled.

[0065] In some embodiments, the controller 800 is configured to determine a relationship between heat dissipation and the time since the last use of the pulse tool 10. In some embodiments, one or more of the temperature thresholds may be dynamically modified (e.g., based on the operating mode, ambient temperature, etc.). For example, the pulse tool 10 may include a real-time clock, a coin-cell battery, or both, and the controller 800 may adjust one or more of the temperature thresholds based on whether the pulse tool 10 is currently running or has recently stopped running, based on battery life, the duty cycle of an application, a time since the last use of the pulse tool 10, and a relationship between heat dissipation and time.

[0066] In some embodiments, if a temperature produces inaccurate or unrealistic readings, the controller 800 may ignore the readings from any or all of the temperature sensors 400, 405, 515, 615, 700 and operate the pulse tool 10 without restriction (without performing processes 900, 1000, or 1200). During unrestricted use, the pulse tool 10 may experience a thermal failure, but until that occurs, the user's workflow is uninterrupted.

[0067] Thus, the embodiments described herein provide, among other things, a power tool with a pulse assembly. Various features and advantages are set forth in the following claims. QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] US 63 / 560,273

[0001] US 63 / 658,143

[0001]

Claims

[1] A power tool comprising: an engine; a pulse assembly configured to be driven by the motor; a temperature sensor configured to output a signal associated with a temperature of the power tool, wherein the temperature of the power tool is correlated with a temperature of a fluid in the pulse assembly; and a control unit connected to the temperature sensor, the control unit being configured to: the temperature of the power tool is determined based on the signal from the temperature sensor and in response to the temperature of the power tool being above a temperature threshold, to control the power tool based on the temperature of the power tool. [2] The power tool of claim 1, wherein the control unit is configured to control the power tool based on the temperature of the power tool to either turn off the power tool or reduce the power of the power tool. [3] The power tool of claim 1, wherein the temperature sensor is positioned outside an air flow circuit in the power tool. [4] The power tool of claim 3, wherein the temperature sensor is positioned on a printed circuit board for a light assembly (“PCB”). [5] The power tool of claim 1, wherein the temperature sensor is positioned on a Hall effect sensor printed circuit board ("PCB"). [6] The power tool according to claim 1, wherein the control unit is further configured to in response to the temperature of the power tool being below the temperature threshold and above or equal to a second temperature threshold, comparing a period of time during which the temperature of the power tool is below the first temperature threshold and above or equal to the second temperature threshold with a time threshold; and to deactivate the power tool in response to the time duration reaching the time threshold. [7] A power tool comprising: an engine; a pulse assembly configured to be driven by the motor; a first temperature sensor configured to output a first signal associated with a temperature of the power tool, wherein the temperature of the power tool is correlated with a temperature of a fluid within the pulse assembly; a second temperature sensor configured to output a second signal related to the temperature of the power tool, wherein the temperature of the power tool is related to the temperature of the fluid in the pulse assembly; and a control unit connected to the first temperature sensor and the second temperature sensor, the control unit being configured to: the temperature of the power tool is determined on the basis of the first signal from the first temperature sensor and the second signal from the second temperature sensor and in response to the temperature of the power tool being greater than a temperature threshold, controlling the power tool based on the temperature of the power tool. [8] The power tool according to claim 7, wherein the control unit is configured to control the power tool based on the temperature of the power tool to turn off the power tool. [9] The power tool of claim 7, wherein the first temperature sensor and the second temperature sensor are positioned outside of an air flow circuit within the power tool. [10] The power tool of claim 9, wherein the first temperature sensor is positioned on a circuit board for a light assembly. [11] The power tool of claim 10, wherein the second temperature sensor is positioned on a Hall effect sensor circuit board. [12] The power tool according to claim 7, wherein the control unit is further configured to in response to the temperature of the power tool being below the temperature threshold and above or equal to a second temperature threshold, comparing a period of time during which the temperature of the power tool is below the first temperature threshold and above or equal to the second temperature threshold with a time threshold; and to deactivate the power tool in response to the time duration reaching the time threshold. [13] A method for controlling a power tool, the method comprising: Receiving a signal from a temperature sensor relating to a temperature of the power tool, wherein the temperature of the power tool is correlated with a temperature of a fluid in a pulse arrangement; Determining the temperature of the power tool based on the signal from the temperature sensor and in response to the temperature of the power tool being greater than a temperature threshold, to control the power tool based on the temperature of the power tool. [14] The method of claim 13, wherein controlling the power tool based on the temperature of the power tool comprises turning off the power tool or reducing a power of the power tool. [15] The method of claim 13, wherein the temperature sensor is positioned outside of an airflow circuit in the power tool. [16] The method of claim 15, wherein the temperature sensor is positioned on a circuit board for a light assembly. [17] The method of claim 15, wherein the temperature sensor is positioned on a Hall effect sensor circuit board. [18] The method of claim 13, further comprising: Comparing, in response to the temperature of the power tool being below the temperature threshold and above or equal to a second temperature threshold, a period of time during which the temperature of the power tool is below the first temperature threshold and above or equal to the second temperature threshold with a time threshold; and Deactivating, in response to the time duration reaching the time threshold, the power tool. [19] The method of claim 13, wherein the temperature sensor is positioned within the pulse array. [20] The method of claim 13, further comprising: Receiving a second signal from a second temperature sensor related to the temperature of the power tool, wherein the temperature of the power tool is correlated to the temperature of the fluid within a pulse assembly.

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