Power tool with comprehensive motor power adjustment during the impact process

Abstract

A power tool can include a housing, a trigger, a motor, an impact mechanism, and an electronic processing unit configured to detect trigger actuation and, in response to the trigger actuation, control the motor with an initial motor output, detect the first impact of the impact mechanism, and store a count of impacts. The power tool can further: control the motor with a second motor output in response to the impact of the impact mechanism; detect a second impact of the impact mechanism and increase the number of impacts; compare the number of impacts with an impact threshold; control the motor with a third motor output in response to the number of impacts being below the impact threshold; and stop the motor in response to the number of impacts being greater than or equal to the impact threshold.

Description

Related registrations

[0001] This application claims precedence over the preliminary US patent application No. 63 / 716,982, filed on November 6, 2024, the entire contents of which are hereby incorporated by reference. Area

[0002] This registration relates to striking tools. Summary

[0003] The striking tools described herein comprise a housing, a trigger, a motor within the housing (the motor comprising a rotor and a stator, the rotor being coupled to a motor shaft), and a striking mechanism comprising a hammer coupled to the motor shaft and an anvil configured to receive blows from the hammer. The tool includes an output drive device coupled to the anvil and configured for rotation, as well as an electronic control unit comprising a memory and an electronic processing unit.The electronic control unit is configured to detect a trigger activation, control the motor with an initial motor output in response to the trigger activation, detect a first impact of the striking mechanism, store the impact count of the striking mechanism in memory, control the motor with a second motor output in response to the impact of the striking mechanism, detect a second impact of the striking mechanism, increase the impact count, compare the impact count with an impact threshold, control the motor with a third motor output in response to the impact count being below the impact threshold (the third motor output being greater than the second motor output), and stop the motor in response to the impact count being greater than or equal to the impact threshold.

[0004] In some aspects, the first engine power is a maximum engine power and the second engine power is a minimum engine power.

[0005] In some aspects, at least one of the first motor power, the second motor power and the third motor power is determined by the electronic processing unit using at least one element selected from the group consisting of a pulse width modulation value, a speed setpoint, a motor line angle and a motor phase angle.

[0006] In some aspects, the electronic control unit is configured to control the motor with the second energy by reducing the duty cycle of the pulse width modulation signal.

[0007] In some aspects, the electronic control unit is configured to control the motor with the second power using one or more setpoints for speed control in a closed control loop.

[0008] In some aspects, the electronic processing unit is further configured to control the motor with the third motor power when the number of strokes is an even number.

[0009] In some aspects, the third engine output is greater than the second engine output by a predetermined value.

[0010] In some aspects, the third motor power is calculated by the electronic processing unit using an algorithm.

[0011] In some aspects, the algorithm includes at least one selected value from the group consisting of the total number of strokes recorded by the electronic processing unit, a current measurement of the motor, a voltage measurement of the motor, a value for the revolutions per minute of the motor, and a running time of the motor.

[0012] The methods described herein relate to the control of a striking tool, comprising a housing, a trigger, a motor within the housing, a striking mechanism with a hammer and an anvil configured to receive blows from the hammer, and an electronic control unit with memory and an electronic processing unit. The method includes detecting a triggering of the trigger using the electronic processing unit, controlling the motor using the electronic processing unit with an initial motor output in response to the triggering of the trigger, detecting an initial blow of the striking mechanism using the electronic processing unit, and storing a blow count of the striking mechanism in the memory.The method comprises controlling the motor with a second power output in response to the impact of the impact mechanism using the electronic processing unit, detecting a second impact of the impact mechanism using the electronic processing unit, increasing the impact count using the electronic processing unit, and comparing the impact count to an impact threshold using the electronic processing unit. The method also includes controlling the motor with a third motor power output using the electronic processing unit in response to the impact count being below the impact threshold, where the third motor power output is greater than the second motor power output, and stopping the motor using the electronic processing unit in response to the impact count being greater than or equal to the impact threshold.

[0013] In some aspects, at least one of the first motor power, the second motor power and the third motor power is determined by the electronic processing unit using at least one value selected from the group consisting of a pulse width modulation value, a speed setpoint, a motor line angle and a motor phase angle.

[0014] In some aspects, the procedure further includes detecting the impact time of the impact mechanism using the electronic processing unit, determining using the electronic processing unit whether the impact time of the impact mechanism is within a predetermined range, and reducing the power supplied to the motor using the electronic processing unit in response to the impact time of the impact mechanism being outside the predetermined range.

[0015] In some aspects, the procedure further includes calculating an engine power value for the third engine power using the electronic processing unit, increasing the engine power value using the electronic processing unit in response to increasing the number of strokes, and controlling the engine with a third engine power using the electronic processing unit.

[0016] In some aspects, the electronic processing unit increases the motor power value by a predetermined amount in response to every two increments of the stroke count.

[0017] The striking tool described herein comprises a housing, a trigger, a motor within the housing (the motor comprising a rotor and a stator, the rotor being coupled to a motor shaft), and a striking mechanism comprising a hammer coupled to the motor shaft and an anvil configured to receive blows from the hammer. The tool also includes an output drive device coupled to the anvil and configured for rotation, as well as an electronic control unit comprising a memory and an electronic processing unit.The electronic control unit is configured to detect when the trigger is activated, control the motor at maximum power in response to the trigger activation, detect the first strike of the striking mechanism, store the strike count in memory, control the motor at minimum power in response to the strike of the striking mechanism, detect the second strike of the striking mechanism, increase the strike count, compare the pulse counter with a pulse threshold, control the motor at medium power (between minimum and maximum power) in response to a pulse counter that is less than the pulse threshold, and stop the motor in response to a pulse counter that is greater than or equal to the pulse threshold.

[0018] In some aspects, the electronic control unit is further configured to detect the impact time of the impact mechanism, determine whether the impact time of the impact mechanism is within a predetermined range, and reduce the power supplied to the motor if the impact time of the impact mechanism is outside the predetermined range.

[0019] In some aspects, the striking tool further comprises one or more sensors configured to detect the first strike of the striking mechanism and output a signal to the electronic control unit, wherein the one or more sensors of the striking mechanism include at least one sensor selected from the group consisting of a hammer displacement sensor, an anvil rotation sensor or a current measuring sensor.

[0020] In some aspects, the maximum motor power is calculated by the electronic processing unit using at least one element selected from the group consisting of a pulse width modulation value, a speed setpoint, a motor line angle, a motor phase angle, a current in the quadrature axis direction, or a current in the direct axis direction.

[0021] In some aspects, the minimum engine power is a preset power value stored in memory, and the maximum engine power is calculated by the electronic processing unit.

[0022] In some aspects, the average motor power is based on an algorithm that includes the number of strokes of the impact mechanism.

[0023] In some aspects, the algorithm is selected from at least one of the group consisting of a linear function, a stepwise linear function, and a polynomial function.

[0024] Before individual embodiments are explained in detail, it should be understood that the applications of these embodiments are not limited to the details of the configurations and arrangements of components set forth in the following description or illustrated in the accompanying drawings. The embodiments can be practiced or implemented in various ways. It should also be understood that the wording and terms used herein are for descriptive purposes only and should not be considered restrictive. The use of "including," "comprising," or "with," and variations thereof, is intended to encompass the elements listed thereafter and their equivalents, as well as additional elements.Unless otherwise specified or limited, the terms “mounted”, “connected”, “supported” and “coupled”, as well as variations thereof, are used in a broader sense and include both direct and indirect assemblies, connections, supports and couplings.

[0025] Unless the context of their use clearly indicates otherwise, the articles "ein", "eine", and "das" should not be interpreted as "one" or "only one". Rather, these articles should be interpreted as "at least one" or "one or more". Likewise, the terms "der" or "bekannter", when referring to a noun previously introduced by the indefinite article "ein" or "eine", mean "at least one" or "one or more", unless the context clearly indicates otherwise.

[0026] Furthermore, it should be understood that embodiments may include hardware, software, and electronic components or modules, which, for illustrative purposes, may be presented and described as if most components were implemented exclusively in hardware. However, a person skilled in the art would recognize, based on this detailed description, that in at least one embodiment, the electronic aspects may be implemented in software (e.g., stored on a non-transient, computer-readable medium) that can be executed by one or more processing units, such as a microprocessor and / or application-specific integrated circuits (“ASICs”). Therefore, it should be noted 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, “servers”, “computers”, “control units”, “processors”, etc., described in the description 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.

[0027] Relative terms such as "about," "approximately," "essentially," etc., used in connection with a quantity or condition, would be understood by a person skilled in the art to include the stated value and to have the meaning given by the context (e.g., the term includes at least the degree of error associated with the accuracy of the measurement, tolerances [e.g., manufacturing, assembly, use, etc.] associated with the stated value, etc.). Such terms should also be understood as indicating the range defined by the absolute values ​​of the two endpoints. For example, the expression "from about 2 to about 4" also indicates the range "from 2 to 4." The relative terms may refer to plus or minus a percentage (e.g., 1%, 5%, 10%) of a stated value.

[0028] It should be understood that while certain drawings depict hardware and software within specific devices, these representations are for illustrative purposes only. Functions described here as being performed by a single component may be performed by multiple components in a distributed manner. Likewise, functions performed by multiple components may be consolidated and performed by a single component. In some embodiments, the components shown may be combined or separated into separate software, firmware, and / or hardware. For example, instead of residing in and being performed by a single electronic processing unit, logic and processing may be distributed across multiple electronic processing units.Regardless of how they are combined or subdivided, hardware and software components can reside on the same computer device or be distributed across different computer devices connected by one or more networks or other suitable communication links. Likewise, a component described as performing a particular function may also perform additional functions not described here. For example, a device or structure that is “configured” in a certain way is at least configured in that way, but may also be configured in other, unspecified ways.

[0029] Accordingly, if, for example, a device, method, or system is claimed that comprises a controller, control unit, electronic processing unit, computing device, logic element, module, memory module, communication channel, network, or other element configured in a certain way to perform, for example, multiple functions, the claim or claim element should be interpreted as meaning one or more such elements, each of which is configured as claimed, for example, to perform one or more of the aforementioned functions, such that the one or more elements perform the functions together as a group.

[0030] Further aspects of different embodiments become clear by considering the detailed description and the accompanying drawings. Brief description of the drawings Fig. Figure 1 shows a striking tool according to the embodiments described here. Fig. Figure 2 is a schematic diagram of a control unit of the impact tool. Fig. 1. Fig. 3A and Fig. Figure 3B shows a hammer and an anvil of a striking mechanism of the striking tool. Fig. 1. Fig. Figure 4 is a flowchart of a process for controlling a percussion tool according to the embodiments described herein. Fig. Figure 5 is a flowchart of a process for controlling a percussion tool according to the embodiments described herein. Fig. Figure 6 is a diagram of the performance of a percussion tool according to the embodiments described herein. Fig. Section 7 is a comparison of the predictability of impact events according to the embodiments described herein. Detailed description

[0031] Fig. Figure 1 shows a power tool 100, in particular an impact tool (e.g., an impact wrench, an impact driver, a rotary hammer, etc.) used to generate rotational power (e.g., to drive a bit). The impact tool 100 comprises an upper main body 105, a handle 110, a battery pack receptacle 115, a mode pad 120, an output drive device 125, a trigger 130, a work light 135, and a forward / reverse selector switch 140. The housing of the impact tool 100 (e.g., the main body 105 and the handle 110) is made, for example, of a durable and lightweight plastic material or metal. The drive device 125 is made, for example, of a metal (e.g., steel). In some embodiments, the drive device 125 on the impact tool 100 is a receptacle configured to receive a bit.The battery pack intake section 115 is configured to accommodate a battery pack (e.g., the battery pack 210 from . Fig. 2) receives and is connected to the power supply that powers the impact tool 100. The battery pack receiving section 115 includes an engagement structure with a mechanism that secures the battery pack and a terminal block for electrically connecting the battery pack to the impact tool 100. The mode pad 120 allows a user to select a mode for the impact tool 100 and displays the currently selected mode to the user, such as modes associated with different torque levels or impact thresholds.

[0032] As in Fig. As shown in Figure 2, the impact tool 100 also includes a motor 205. The motor 205 actuates the drive device 125 and provides the output torque to drive the bit. A primary power source or battery pack 210 is coupled to the impact tool 100 and provides electrical power to supply the motor 205. The motor 205 is powered based on the position of the trigger 130. When the trigger 130 is pressed, the motor 205 is powered, and when the trigger 130 is released, the motor 205 is no longer powered. In the illustrated embodiment, the trigger 130 extends partially along the length of the handle 110. In other embodiments, however, the trigger 130 may be positioned at a different location on the impact tool 100 or extend over a different length along the handle.The trigger 130 is movably connected to the handle 110, such that the trigger 130 moves relative to the tool housing. The trigger 130 moves in a first direction towards the handle 110 when the trigger 130 is pressed by the user. The trigger 130 is biased (e.g., by a spring) so that, in a second direction, the trigger 130 moves away from the handle 110 when the trigger 130 is released by the user. In some embodiments, a push rod activates the release switch 215 when the trigger 130 is pressed by the user, and the release switch 215 is deactivated when the trigger 130 is released by the user. In other embodiments, the trigger 130 is coupled to an electrical release switch 215. In such embodiments, the release switch 215 may, for example, comprise a transistor.Additionally, in such electronic embodiments, the trigger 130 may not include a pushrod for activating the mechanical switch. Instead, the electrical trigger 215 can be activated, for example, by a position sensor (e.g., a Hall effect sensor) that provides information about the relative position of the trigger 130.

[0033] The trigger switch 215 outputs a signal indicating the position of the trigger 130. In some cases, the signal is binary, indicating either that the trigger 130 is pressed or released. In other cases, the signal indicates the position of the trigger 130 with greater accuracy. For example, the trigger switch 215 can output an analog signal that varies between 0 and 5 volts, depending on the degree to which the trigger 130 is pressed.

[0034] For example, an output voltage of 0 V indicates that the trigger 130 is released, an output of 1 V indicates that the trigger 130 is pressed 20%, an output of 2 V indicates that the trigger 130 is pressed 40%, an output of 3 V indicates that the trigger 130 is pressed 60%, an output of 4 V indicates that the trigger 130 is pressed 80%, and an output of 5 V indicates that the trigger 130 is pressed 100%. In other words, the force with which the user operates the trigger 130 can determine the power supplied at the output of the motor 205. The signal output by the release switch 215 can be analog or digital.

[0035] As also in Fig. As shown in Figure 2, the impact tool 100 comprises a switching network 220, sensors 225, displays 230, a battery pack interface 235, a power input unit 240, a control unit 245, and a wireless communication control unit 250. The battery pack interface 235 is connected to the control unit 245 and couples to the battery pack 210. The battery pack interface 235 comprises a combination of mechanical (e.g., the battery pack receiving section 115) and electrical components configured and operable to connect the impact tool 100 to the battery pack 210 (e.g., mechanically, electrically, and communicatively). The battery pack interface 235 is coupled to the power input unit 240. The battery pack interface 235 transmits the current received from the battery pack 210 to the power input unit 240. The power input unit 240 comprises active and / or passive components (e.g.,Voltage reduction regulators, voltage converters, rectifiers, filters, etc.) to regulate or control the power received via the battery pack interface 235 and forwarded to the wireless communication controller 250 and the controller 245.

[0036] The switching network 220 enables the control unit 245 to control the operation of the motor 205. When the trigger 130 is pressed, indicated by an output of the trip switch 215, electrical current is supplied from the battery pack interface 235 to the motor 205 via the switching network 220. When the trigger 130 is not pressed, no electrical current is supplied from the battery pack interface 235 to the motor 205. In response to the control unit 245 receiving the activation signal from the trip switch 215, the control unit 245 activates the switching network 220 to supply power to the motor 205. The switching network 220 controls the amount of current available to the motor 205, thereby regulating the speed, torque, and power output of the motor 205.The switching network 220 can include a variety of switches, such as field-effect transistors (“FETs”), bipolar junction transistors, or other types of electrical switches. For example, the switching network 220 can include a six-FET bridge that receives pulse-width modulated (PWM) signals from the control unit 245 (or another gate driver) to drive the motor 205.

[0037] The sensors 225 are coupled to the control unit 245 and transmit various signals to it, indicating different parameters of the impact tool 100 and / or the motor 205. The sensors 225 include Hall effect sensors 225A, current sensors 225B, impact sensors 225C, and other sensors, such as one or more voltage sensors, one or more temperature sensors, and one or more torque sensors. Each Hall effect sensor 225A outputs motor feedback information to the control unit 245, for example, a reading (e.g., a pulse) when a magnet of the motor rotor rotates over the surface of this Hall effect sensor. Based on the motor feedback information from the Hall effect sensors 225A, the control unit 245 can determine the position, speed, and / or acceleration of the rotor.The electronic processing unit 255 can detect that the impact tool 100 is in operation based on the actuation of the trigger 130 or on output signals from Hall effect sensors indicating that the motor 205 is rotating. The electronic processing unit 255 can also detect impact events using the impact sensors 225C. The impact sensors 225C can include a hammer translation sensor, an anvil rotation sensor, a current sensor (e.g., battery current, motor current, or similar), vibration patterns of the impact tool 100 measured by a sensor, etc. In some embodiments, the impact sensors include one or more inductive sensors, one or more Hall effect sensors, etc. In some embodiments, impact events can be detected using limit parameters, machine learning algorithms, or one-dimensional Kalman filters.

[0038] In response to the motor feedback information and the signals from the trip switch 215, the control unit 245 sends control signals to control the switching network 220 and drive the motor 205. For example, by selectively activating and deactivating the FETs of the switching network 220, the energy received via the battery pack interface 235 is selectively applied to the stator coils of the motor 205 to set its rotor in motion. The control unit 245 uses the motor feedback information to ensure the correct timing of the control signals to the switching network 220 and, in some cases, to provide closed-loop feedback to maintain the speed of the motor 205 at a desired level.

[0039] The displays 230 are also coupled to the control unit 245 and receive control signals from the control unit 245 to switch themselves on and off or otherwise transmit information based on various states of the impact tool 100. The displays 230 include, for example, one or more light-emitting diodes (“LEDs”) or a screen. The displays 230 can be configured to show states of the impact tool 100 or related information. For example, the displays 230 are configured to show measured electrical properties of the impact tool 100, the status of the impact tool 100, the mode of the power tool, etc. The displays 230 can also include elements to convey information to a user through acoustic or tactile outputs.

[0040] As described above, the control unit 245 is electrically and / or communicatively connected to a plurality of modules or components of the impact tool 100. In some embodiments, the control unit 245 comprises a plurality of electrical and electronic components that supply power, control, and protect the components and modules within the control unit 245 and / or the impact tool 100. For example, the control unit 245 includes, among other things, a processing unit 255 (e.g., a microprocessor, a microcontroller, an electronic control unit, an electronic processing unit, or another suitable programmable device), a memory 260, input units 265, and output units 270. The processing unit 255 (here: electronic processor 255) includes, among other things, a control unit 255A, an arithmetic logic unit (“ALU”) 255B, and a plurality of registers 255C (in Fig. 2 (represented as a group of registers). In some embodiments, the control unit 245 is partially or completely implemented on a semiconductor chip (e.g., an FPGA [Field-Programmable Gate Array] semiconductor chip), for example, a chip developed by an RTL (Register Transfer Level) design process. The electronic processing unit 255, the memory 260, and the input units 265 and output units 270 are electronically and communicatively interconnected via one or more buses, such as a common bus 275.

[0041] Memory 260 is a non-volatile, computer-readable medium and comprises, for example, a program memory area 260A and a data memory area 260B. Program memory area 260A and data memory area 260B can comprise 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, physical, or electronic storage devices. The electronic processing unit 255 is connected to memory 260 and executes software instructions stored in RAM of memory 260 (e.g., during execution), ROM of memory 260 (e.g., during program execution), or ROM of memory 260 (e.g., during program execution).on a generally permanent basis) or on another non-transient, computer-readable medium, such as another memory or a disc. The software included in the implementation of the impact tool 100 can be stored in the memory 260 of the control unit 245. The software includes, for example, firmware, one or more applications, program data, filters, rules, one or more program modules, and other executable commands.

[0042] The control unit 245 is configured to retrieve and execute commands from memory relating to the control processes and procedures described herein. The control unit 245 is also configured to store information about the power tool in memory 260, including operating data, information identifying the tool type, a unique identifier for the respective tool, and other information relevant to the operation or maintenance of the impact tool 100. Tool usage information, such as current, motor speed, motor acceleration, motor direction, and number of impacts, can be acquired or derived from data output by the sensors 225. A user can then access this power tool information with an external device. In other embodiments, the control unit 245 includes additional, fewer, or different components.

[0043] The wireless communication controller 250 is coupled to the control unit 245 and comprises a radio transceiver and an antenna. In some embodiments, it may include memory, an electronic processing unit, and input / output elements similar to, but independent of, those previously described in relation to the control unit 245. The radio transceiver and the antenna work together to send and receive wireless messages to and from the external device. In some embodiments, the wireless communication control unit 250 is a Bluetooth® controller. In other embodiments, the wireless communication control unit 250 communicates using other protocols (e.g., Wi-Fi, cellular protocols, a proprietary protocol, etc.) over a different type of wireless network.For example, the 250 radio communication control unit can be configured to communicate via Wi-Fi over a wide area network such as the internet or a local network, or via a pico network (e.g., using infrared or NFC communication). Communication via the 250 radio communication control unit can be encrypted to protect the data exchanged between the 100 impact tool and an external device / network from third parties.

[0044] The Fig. 3A and Fig. Figure 3B shows a striking mechanism 300, which is an example of a striking mechanism for the striking tool 100. Based on the design of the striking mechanism 300 of the striking tool 100, the motor 205 rotates by at least a certain number of degrees between strikes (i.e., 180 degrees for the striking mechanism 300). The striking mechanism 300 comprises a hammer 305 with outwardly projecting projections 310 and an anvil 315 with outwardly projecting projections 320. The anvil 315 is coupled to the output drive device 125. During operation, a strike occurs when the anvil 315 encounters a certain resistance (e.g., when driving a fastener into a workpiece). When this resistance is reached, the hammer 305 continues to rotate. A spring coupled to the back of the hammer 305 causes the hammer 305 to detach from the anvil 315 by axial retraction.After disengagement, the hammer 305 moves forward both axially and rotationally to engage (i.e., strike) the anvil 315 again. When the striking mechanism 300 is actuated, the hammer prongs 310 strike the anvil prongs 320, for example, every 180 degrees. Accordingly, when the striking tool 100 strikes, the hammer 305 rotates without the anvil 315, strikes the anvil 315, and then rotates a certain amount with the anvil 315 before the process is repeated.

[0045] The control unit 245 can determine how far the hammer 305 and the anvil 315 have rotated together by monitoring the rotation angle of the motor 205 shaft between blows. For example, when the striking tool 100 drives an armature into a softer joint, the hammer 305 can rotate 225 degrees between blows. In this example of 225 degrees, 45 degrees of the rotation includes the hammer 305 and the anvil 315 engaged with each other, and 180 degrees includes only the rotation of the hammer 305 before the hammer heads 310 strike the anvil 315 again. The control unit 245 also monitors the start of the striking operations and the torque supplied per blow during operation to control the motor. This process is described in more detail below.

[0046] Fig. Figure 4 is a flowchart of a process 400 for controlling the impact tool 100. The process 400 begins in step 405 with the actuation of the trigger 130, as previously described. The motor 205 then runs at full speed (e.g., when driving a fastener with minimal resistance). If no impact is detected (step 410), the control unit 245 supplies the maximum available power to the motor 205 (step 415). In some embodiments, the maximum power output is a value stored in memory 260 (e.g., MAX_VALS). The maximum power can also be calculated by the electronic processing unit 255 using parameters of the impact tool 100, such as a pulse width modulation value (e.g., a duty cycle percentage) of the motor 205, a speed setpoint (rpm) of the motor 205, a motor line angle, a motor phase angle, a current in the quadrature axis direction (e.g.,Iq), a current in the direct axis direction (e.g., Id), or any combination thereof. Once a stroke of the impact mechanism 300 is detected in step 415, the control unit 245 begins counting the strokes of the impact mechanism 300 (step 420) and reduces the power supplied to the motor 205 to a predetermined limit (step 425). The predetermined threshold can, for example, be a minimum amount of motor power required to rotate the motor 205 (e.g., MIN_VALS). The minimum power can also be calculated by the electronic processing unit 255 using parameters similar to those of the minimum power. In some embodiments, the minimum power is a value stored in memory 260. The control unit 245 can reduce the power supplied to the motor by decreasing the duty cycle of the PWM signal or by using setpoints for closed-loop speed control.

[0047] With each impact detected by the impact mechanism 300, the control unit 245 increases the power supplied to the motor 205. This increase can be linear or non-linear. In a linear power increase, the control unit 245 can increase the motor power by a fixed value per impact. For example, after an impact event, the control unit 245 can increase the motor power supplied by the motor 205 by 1%, 2%, 5%, or the like. In a non-linear power increase, the motor power can be increased based on an equation or algorithm (e.g., a polynomial equation, an exponential function, a logarithmic function, etc.).For example, the electronic processing unit 255 can calculate the motor energy based on the total number of detected strokes, current / voltage measurements of the motor 205 as detected by the sensors 225, a speed value of the motor 205, a running time of the motor 205, or any combination thereof. The control unit 245 can increase the motor power by increasing the duty cycle of the PWM signal, increasing the speed control target of the closed-loop control system, increasing the parameters for attenuating the motor's field, or increasing the parameters for field-oriented control. In some embodiments, the power is increased every two strokes or every three or more strokes. In some embodiments, the power is increased for every even number of strokes (e.g., every second stroke). In other embodiments, the energy is increased for every odd number of strokes.

[0048] The control unit 245 then proceeds to drive the motor 205 (step 430). The blow count is stored in memory 260 and incremented for each detected blow in step 435 (e.g., BLOW_COUNT). The control unit 245 then compares the blow count with a predetermined threshold (e.g., BLOW_THRESHOLD) in step 440. If the blow count is below the threshold, the control unit 245 sets and increases the motor power in step 445 before returning to monitoring the blows (in step 430). In some embodiments, determining the motor power also includes the blow count. If the blow count is equal to or greater than the threshold, the control unit 245 stops the motor 205 and terminates the operation of the impact tool 100 (step 450).

[0049] Fig. Figure 5 is a flowchart of a process 500 for controlling the impact tool 100, similar to the one relating to Fig. Process 400, as described in section 4, begins in step 505 with the actuation of the trigger 130, as previously described. The motor 205 runs at full speed, and if no impact is detected (step 510), the control unit 245 supplies the maximum available power to the motor 205 (step 515). Similar to process 400, the maximum power output is a value stored in memory 260 (e.g., MAX_VALS). The maximum power can also be calculated by the electronic processing unit 255 using parameters of the impact tool 100, such as a pulse width modulation value (e.g. duty cycle percentage) of the motor 205, a speed setpoint of the motor 205, a motor line angle, a motor phase angle, a quadrature axis direction current (e.g. Iq), a direct axis direction current (e.g. Id) or any combination thereof.As soon as a strike of the striking mechanism 300 is detected in step 510, the control unit 245 begins counting the strikes of the striking mechanism 300 (step 520) and reduces the power supplied to the motor 205 to a predetermined limit (step 525). Similar to process 400, the predetermined threshold can, for example, be a minimum amount of motor power required to rotate the motor 205 (e.g., MIN_VALS). The minimum energy can also be calculated by the electronic processing unit 255 using parameters similar to those of the minimum energy. In some embodiments, the minimum power quantity is a value stored in memory 260.

[0050] For each detected impact of the impact mechanism 300, the control unit 245 increases the power supplied to the motor 205. As described in relation to process 400, this increase can be linear or non-linear. The control unit 245 then continues to drive the motor 205 (step 525) and monitors further impacts of the impact mechanism 300 (step 530). The impact count is stored in memory 260 and incremented for each detected impact (in step 535) (e.g., IMPACT_COUNT). In step 540, the control unit 245 then compares the impact count with a predetermined threshold (e.g., IMPACT_THRESHOLD). If the impact count is equal to or greater than the predetermined threshold, the control unit 245 stops the motor 205 and terminates the operation of the impact tool 100 (step 545).If, however, the number of strokes is below the specified limit, the control unit 245 adjusts the motor power (in step 550) to a power value between the minimum and maximum motor power, based on an equation (e.g., a linear function, a stepwise linear function, a polynomial function, etc.) that includes the total number of strokes (e.g., the value stored as STRIKE_COUNT). In some embodiments, this power level is referred to as the average motor power.

[0051] The control unit 245 also monitors the impact timing of the impact mechanism 300. For example, the impact timing of impact mechanism 300 can be defined as "normal" or "abnormal" depending on when the hammer 305 exerts force on the anvil 315. A normal impact timing can be determined by the control unit 245 based on a setpoint (as selected by the mode pad 120) or based on a predetermined range. For example, if the impact timing is outside a predetermined range, the control unit 245 can determine that the impact timing is abnormal. The control unit can also determine an abnormal timing if the impact events do not correspond to a predetermined pattern that corresponds to the motor speed.If the control unit 245 determines that the striking time is normal, the process returns to step 530 in step 555, where the control unit 245 continues to monitor the strikes of the striking mechanism 300. However, if the control unit 245 determines (step 555) that the striking time is not normal (e.g., if a faulty strike has occurred, the hammer has crashed, the hammer position exceeds a maximum limit, there is an abnormal motor speed pattern, etc.), the control unit reduces the motor power for the next striking event (step 560). The reduction in motor power can be a linear reduction in energy or a non-linear reduction in energy, similar to the increase in motor power described earlier with respect to processes 400 and 500.

[0052] Fig. Figure 6 is a diagram 600 of the power supplied during the operation of the impact tool 100 using procedures 400 and 500. Graph 600 illustrates the power output 605 (shown as a total percentage) and the motor speed (e.g., rpm) 610 (e.g., of motor 205) delivered by the motor 205 over time 615. As previously described, power is supplied to the motor 205 when the trigger 130 is pressed (e.g., at 620 in diagram 600). When an impact is detected (e.g., at 625 in diagram 600), such as in step 415 of process 400 or step 515 of process 500, the motor power is reduced to a minimum value. As previously described, the minimum value can be a preset value, for example 60% of the motor power, or based on a target speed for the motor, for example 12,500 rpm. If impacts are detected during operation (e.g.,At 630 in diagram 600, the number of blows is increased and the power output is increased as described previously. Once the target number of blows is reached (e.g., at 635 in diagram 600), the control unit 245 stops the motor 205 and terminates the operation of the impact tool 100.

[0053] Fig. Figure 7 is a graphical representation of the comparison between impact events using the 400, 500 procedure and impacts without using the 400, 500 procedure. Fig.Figure 7 includes a graph 700 of the torque per impact event using standard procedures and a graph 750 of the torque per impact event using procedures 400 and 500, as previously described. Graph 700 includes a Y-axis 705 for torque in foot-pounds (lb) and an X-axis 710 for time in seconds (s). The impacts 715 recorded by user 100 during operation of the impact tool 100 are shown, along with an average impact curve 720 of all impacts 715 over time. As shown, the average impact curve 720 starts at approximately 600 ft-lb torque at 0 seconds and increases to approximately 660 ft-lb torque at 2.5 seconds.

[0054] In contrast to Graph 700, which uses standard processes, Graph 750 illustrates the torque per impact event using Process 400, 500. Graph 750 includes similar axes: a Y-axis 755 for torque in foot-pounds (ft-lb) and an X-axis 760 for time in seconds (s). Also shown are the impacts 765 of impact tool 100 and an average impact curve 770 of all impacts 765 over time. As shown, the average impact curve 770 starts at approximately 0 ft-lb torque at 0 seconds and increases to approximately 500 ft-lb torque at 1.7 seconds. It is noteworthy that the torque per impact using Process 400, 500, as shown in Graph 750, is demonstrably less variable than when Process 400, 500 is not used.As the comparison shows, counting the blows and increasing the power, as described in the previously described procedures 400 and 500, achieves highly accurate control of the impact tool 100. By increasing the motor's power, the impact tool 100 can make each torque output more predictable (e.g., closer to the average) and more efficient, resulting in an improved and optimized experience.

[0055] The following are examples of the revelation described here. It should be understood that each of the examples can be combined to include some or all of the features of another example. Likewise, each of the features of the illustrations described here can be included in any combination with any of the examples.

[0056] Example 1. A striking tool comprising a housing, a trigger, and a motor within the housing, the motor comprising a rotor and a stator, the rotor being connected to a motor shaft; a striking mechanism comprising a hammer connected to the motor shaft and an anvil configured to receive blows from the hammer; an output drive device connected to the anvil and configured to rotate; and an electronic control unit comprising a memory and an electronic processing unit, the electronic control unit being configured to: detect the actuation of the trigger, control the motor in response to the actuation of the trigger with a first motor power, detect a first blow of the striking mechanism, store a blow count of the striking mechanism in the memory, control the motor in response to the blow of the striking mechanism with a second motor power;Detecting a second stroke of the striking mechanism, increasing the number of strokes; comparing the number of strokes with a stroke threshold, controlling the motor with a third motor power in response to the stroke count being below the stroke threshold, the third motor power being greater than the second motor power; and stopping the motor in response to the stroke count being greater than or equal to the stroke threshold.

[0057] Example 2. The impact tool from Example 1, where the first motor power is a maximum motor power and the second motor power is a minimum motor power.

[0058] Example 3. The impact tool from one of Examples 1-2, wherein at least one of the first motor power, the second motor power and the third motor power is determined by the electronic processing unit using at least one value selected from the group consisting of a pulse width modulation value, a speed setpoint, a motor line angle and a motor phase angle.

[0059] Example 4. The impact tool from one of Examples 1-3, wherein the electronic control unit controls the motor with the second motor power by reducing the duty cycle of the pulse width modulation signal.

[0060] Example 5. The impact tool from one of Examples 1 to 4, wherein the electronic control unit controls the motor with the second motor power using one or more setpoints for speed control in a closed control loop.

[0061] Example 6. The impact tool from one of Examples 1 to 5, wherein the electronic processing unit is further configured to control the motor with the third motor power when the number of impacts is increased by two.

[0062] Example 7. The impact tool from one of Examples 1 to 6, wherein the third motor power is greater than the second motor power by a predetermined value.

[0063] Example 8. The impact tool from one of Examples 1 to 7, wherein the third motor power is calculated by the electronic processing unit using an algorithm.

[0064] Example 9. The impact tool from Example 8, wherein the algorithm includes at least one value selected from the group consisting of the total number of impacts detected by the electronic processing unit, a current measurement of the motor, a voltage measurement of the motor, a value for the revolutions per minute of the motor, and a running time of the motor.

[0065] Example 10. Method for controlling a striking tool, comprising a housing, a trigger, a motor within the housing, a striking mechanism with a hammer and an anvil configured to receive blows from the hammer, and an electronic control unit with a memory and an electronic processing unit, wherein the method comprises: detecting an actuation of the trigger using the electronic processing unit; controlling the motor with a first motor output in response to the actuation of the trigger using the electronic processing unit; detecting a first blow of the striking mechanism using the electronic processing unit; storing a blow count of the striking mechanism in the memory; controlling the motor using the electronic processing unit with a second motor output in response to the blow of the striking mechanism;Detecting a second strike of the striking mechanism using the electronic processing unit; increasing the number of strikes using the electronic processing unit; comparing the number of strikes with a strike threshold using the electronic processing unit; controlling the motor with a third motor power in response to the number of strikes being below the strike threshold, the third motor power being greater than the second motor power; and stopping the motor using the electronic processing unit in response to the number of strikes being greater than or equal to the strike threshold.

[0066] Example 11. The method according to Example 10, wherein at least one of the first motor power, the second motor power and the third motor power is determined by the electronic processing unit using at least one value selected from the group consisting of a pulse width modulation value, a speed setpoint, a motor line angle and a motor phase angle.

[0067] Example 12. The method according to any of Examples 10-11, wherein the method further comprises: detecting a strike time of the striking mechanism using the electronic processing unit; determining, using the electronic processing unit, whether the strike time of the striking mechanism is within a predetermined range; and reducing the power supplied to the motor using the electronic processing unit in response to the fact that the strike time of the striking mechanism is outside the predetermined range.

[0068] Example 13. The method according to one of Examples 10-12, wherein the method further comprises: calculating an engine power value for the third engine power using the electronic processing unit, increasing the engine power value using the electronic processing unit in response to increasing the stroke count, and controlling the engine with a third engine power using the electronic processing unit.

[0069] Example 14. Method according to claim 13, wherein the electronic processing unit increases the motor power value by a predetermined amount after every two increments of the stroke count.

[0070] Example 15. A striking tool comprising: a housing; a trigger; a motor within the housing, the motor comprising a rotor and a stator, the rotor being coupled to a motor shaft; a striking mechanism comprising a hammer coupled to the motor shaft and an anvil configured to receive blows from the hammer; an output drive device coupled to the anvil and configured to rotate; and an electronic control unit comprising a memory and an electronic processing unit, the electronic control unit being configured to: detect the actuation of the trigger, control the motor in response to the actuation of the trigger at maximum motor power, detect an initial blow of the striking mechanism, store a blow count of the striking mechanism in the memory, control the motor in response to the blow of the striking mechanism at minimum motor power.Detecting a second strike of the striking mechanism, increasing the number of strikes, comparing the number of strikes with a strike threshold, controlling the motor with a medium motor power in response to the number of strikes being below the strike threshold, the medium motor power being between the minimum motor power and the maximum motor power, and stopping the motor in response to the number of strikes being greater than or equal to the strike threshold.

[0071] Example 16. The impact tool from Example 15, wherein the electronic control is further configured to: detect an impact time of the impact mechanism; determine whether the impact time of the impact mechanism is within a predetermined range; and reduce the power supplied to the motor if the impact time of the impact mechanism is outside the predetermined range.

[0072] Example 17. The striking tool from one of Examples 15-16, further comprising: one or more sensors configured to detect the first strike of the striking mechanism and to output a signal to the electronic control unit, wherein the one or more sensors of the striking mechanism include at least one sensor selected from the group consisting of a hammer translation sensor, an anvil rotation sensor or a current measuring sensor.

[0073] Example 18. The impact tool from one of Examples 15-17, wherein the maximum motor power is calculated by the electronic processing unit using at least one element selected from the group consisting of a pulse width modulation value, a speed setpoint, a motor line angle, a motor phase angle, a current in the quadrature axis direction or a current in the direct axis direction.

[0074] Example 19. The impact tool from one of Examples 15-18, wherein the minimum motor energy is a preset power value stored in memory, and the maximum motor energy is calculated by the electronic processing unit.

[0075] Example 20. The striking tool from one of Examples 15-19, wherein the mean motor energy is based on an algorithm that includes an algorithm that incorporates the number of strikes of the striking mechanism.

[0076] The embodiments described here include systems and methods for controlling power tools with impact mechanisms. Various features and advantages of the invention are set forth in the following claims. QUOTES INCLUDED IN THE DESCRIPTION

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

[0000] US 63 / 716,982

[0001]

Claims

[1] A striking tool includes: a case; a trigger; a motor inside the housing, wherein the motor comprises a rotor and a stator, the rotor being coupled to a motor shaft; a striking mechanism comprising a hammer connected to the shaft and an anvil configured to receive blows from the hammer; an output drive device connected to the anvil and designed for rotation; and an electronic control unit comprising a memory and an electronic processing unit, wherein the electronic control unit is configured to: Detecting the activation of the trigger, Controlling the motor with an initial motor output in response to the activation of the trigger, Capturing the first strike of the striking mechanism, Storing a stroke count of the striking mechanism in memory, Controlling the motor with a second motor power in response to the impact of the impact mechanism; Capturing a second strike of the striking mechanism, Increase the number of strokes; Comparing the number of blows with a blow threshold value, Controlling the motor with a third motor power in response to the blow count being below the blow threshold, where the third motor power is greater than the second motor power; and The motor stops in response to the number of impacts being greater than or equal to the impact threshold. [2] The impact tool according to claim 1, wherein the first motor power is a maximum motor power and the second motor power is a minimum motor power. [3] The impact tool according to claim 1, wherein at least one of the first motor power, the second motor power and the third motor power is determined by the electronic processing unit using at least one value selected from the group consisting of a pulse width modulation value, a speed setpoint, a motor line angle and a motor phase angle. [4] The impact tool according to claim 1, wherein the electronic control unit is configured to control the motor with the second motor power by reducing the duty cycle of a pulse width modulation signal. [5] The impact tool according to claim 1, wherein the electronic control unit is configured to control the motor with the second motor power using one or more setpoints for speed control in a closed control loop. [6] The impact tool according to claim 1, wherein the electronic processing unit is further configured to control the motor with the third motor power when the number of impacts is increased by two. [7] The impact tool according to claim 1, wherein the third motor power is greater than the second motor power by a predetermined value. [8] The impact tool according to claim 1, wherein the third motor power is calculated by the electronic processing unit using an algorithm. [9] The impact tool according to claim 8, wherein the algorithm comprises at least one value selected from the group consisting of the total number of impacts detected by the electronic processing unit, a current measurement of the motor, a voltage measurement of the motor, a value for the revolutions per minute of the motor and a running time of the motor. [10] Method for controlling a striking tool comprising a housing, a trigger, a motor inside the housing, a striking mechanism with a hammer and an anvil configured to receive blows from the hammer, and an electronic control unit with a memory and an electronic processing unit, wherein the method comprises: Detecting the activation of the trigger using the electronic processing unit; Controlling the motor with an initial motor output in response to the activation of the trigger using the electronic processing unit; Capturing the first strike of the striking mechanism using the electronic processing unit; Storing a stroke count of the striking mechanism in memory; Controlling the motor with a second power source using the electronic processing unit in response to the impact of the impact mechanism; Capturing a second strike of the striking mechanism using the electronic processing unit; Increasing the number of strokes using the electronic processing unit; Comparing the number of blows with a blow threshold using the electronic processing unit; Controlling the motor with a third motor power in response to the blow count being below the blow threshold, where the third motor power is greater than the second motor power; and The motor is stopped using the electronic processing unit in response to the number of impacts being greater than or equal to the impact threshold. [11] Method according to claim 10, wherein at least one of the first motor power, the second motor power and the third motor power is determined by the electronic processing unit using at least one value selected from the group consisting of a pulse width modulation value, a speed setpoint, a motor line angle and a motor phase angle. [12] The method of claim 10, further comprising: Capturing the impact time of the impact mechanism using the electronic processing unit; Determine, using the electronic processing unit, whether the impact time of the impact mechanism lies within a predetermined range; and Reducing the power supplied to the motor using the electronic processing unit in response to the fact that the impact timing of the impact mechanism is outside the predetermined range. [13] The method of claim 10, further comprising: Calculating an engine power value for the third engine power using the electronic processing unit, Increasing the motor power value using the electronic processing unit in response to an increase in the number of blows and Controlling the engine with a third engine power using the electronic processing unit. [14] Method according to claim 13, wherein the electronic processing unit increases the motor power value by a predetermined amount after each two increases in the number of strokes. [15] A striking tool includes: a case; a trigger; a motor inside the housing, wherein the motor comprises a rotor and a stator, the rotor being coupled to a motor shaft; a striking mechanism comprising a hammer connected to the shaft and an anvil configured to receive blows from the hammer; an output drive device connected to the anvil and designed for rotation; and an electronic control unit comprising a memory and an electronic processing unit, wherein the electronic control unit is configured to: Detecting the activation of the trigger, Controlling the motor with maximum motor power in response to the activation of the trigger, Capturing the first strike of the striking mechanism, Storing a stroke count of the striking mechanism in memory, Controlling the motor with minimum power in response to the impact of the impact mechanism; Capturing a second strike of the striking mechanism, Increase the number of strokes; Comparing the number of blows with a blow threshold value, Controlling the motor with a medium motor power in response to the blow count being below the blow threshold, the medium motor power being between the minimum motor power and the maximum motor power; and The motor stops in response to the number of impacts being greater than or equal to the impact threshold. [16] The impact tool according to claim 15, wherein the electronic control unit is further configured such that it: a striking point of the striking mechanism; determines whether the impact time of the striking mechanism lies within a predetermined range; and the power supplied to the motor is reduced if the impact time of the impact mechanism is outside the predetermined range. [17] The striking tool according to claim 15, further comprising: one or more sensors configured to detect the first strike of the striking mechanism and send a signal to the electronic control unit, wherein the one or more sensors of the impact mechanism comprise at least one sensor selected from the group consisting of a hammer translation sensor, an anvil rotation sensor or a current measuring sensor. [18] The impact tool according to claim 15, wherein the maximum motor power is calculated by the electronic processing unit using at least one element selected from the group consisting of a pulse width modulation value, a speed setpoint, a motor line angle, a motor phase angle, a current in the quadrature axis direction or a current in the direct axis direction. [19] The impact tool according to claim 15, wherein the minimum motor power is a preset power value stored in memory and the maximum motor power is calculated by the electronic processing unit. [20] The impact tool according to claim 15, wherein the mean motor power is based on an algorithm that includes the number of impacts of the impact mechanism.

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