Impact tools and control modes

Abstract

An impact power tool comprises a motor disposed in a housing; a power switch actuatable by a user to control power delivery to the motor; a controller configured to control operation of the motor; an output member configured to be rotated when the motor is operated; and an impact mechanism configured to be driven by the motor. The controller is configured to receive a signal that corresponds to a fastening torque setting, determine when the impact mechanism starts applying rotational impacts to the output member, and determine a time duration during which impacting is to be performed based on a fastening torque setting. The controller is configured to allow power to be delivered to the motor for the time duration and then to reduce or shut off power to the motor at the end of the time duration.

Description

P-US-TN-2023-0197-PCT - 0029-128W01IMPACT TOOLS AND CONTROL MODESRELATED APPLICATIONS

[0001] This application claims priority to US Provisional Application No. 63 / 709,391, filed October 18, 2024, titled Impact Tools and Control Modes, which is incorporated by reference herein in its entirety. This application also incorporates by reference, in their entirety, the following commonly owned patent applications: U.S. Patent Application No. 18 / 140,514, filed April 27, 2023, titled “Impact Tools and Control Modes,” U.S. Patent Application No. 18 / 493,589, filed October 24, 2023, titled “Impact Tools and Control Modes”, U.S. Patent Application No. 17 / 551,596 (which is now U.S. Patent No. 11,855,567), filed December 15, 2021, titled “Impact Tools and Control Modes,” U.S. Patent Application No. 17 / 571,264 (which is now U.S. Patent No. 12,212,264), filed January 7, 2002, titled “Impact Tools and Control Modes,” U.S. Patent Application No. 17 / 571,246 (which his now U.S. Patent No. 12015364), filed January 7, 2022, titled “Impact Tools and Control Modes”, U.S. Provisional Patent Application No. 63 / 127,595, filed December 18, 2020, titled “Impact Tools and Control Modes,” and International Patent Application No. PCT / US2021 / 063503, filed December 15, 2021, titled “Impact Tools and Control Modes.”TECHNICAL FIELD

[0002] This application relates to powered impact tools, such as impact drivers and impact wrenches, and control modes for them.BACKGROUND

[0003] Electric rotary impact tools, such as impact drivers and impact wrenches are used for driving / tightening (threaded) fasteners such as screws, nuts, and bolts. These electric rotary impact tools are known. An example of such a rotary impact tool is shown and described in U.S. Patent Application Publication No. 2019 / 0344411 (now patented as U.S. Patent No. 11,904,441), which are both incorporated herein by reference in their entirety. Such rotary impact tools have an electric motor, a transmission, and a rotary impact mechanism for driving a tool output member in order to rotate a fastener.4863-3868-8442. vl2P-US-TN-2023-0197-PCT - 0029-128W01

[0004] When operating under a no-load condition or when operating at low fastening torque, the rotary impact mechanism rotates the tool output member without impacting. When the torque on the fastener exceeds a torque threshold, the impact mechanism applies intermittent rotary impacts to the output member and to the fastener. In certain applications it is desired to secure a fastener to a specific predetermined torque, however, conventional impact tools cannot provide an accurate and repeatable fastening torque.SUMMARY

[0005] In some aspects, the techniques described herein relate to an impact tool including: a housing; a motor disposed in the housing; a controller configured to control operation of the motor; an output member configured to be rotated when the motor is operated to rotatably drive a fastener; and an impact mechanism configured to be driven by the motor, the impact mechanism including a hammer and an anvil coupled to the output member, wherein the hammer applies intermittent rotational impacts to the anvil; wherein the controller is configured to: determine a time duration for performing the intermittent rotational impacts according to a torque setting; and reduce or terminate power to the motor when a length of time after a start of the intermittent rotational impacts meets the time duration.

[0006] In some aspects, the techniques described herein relate to an impact tool, wherein the controller is configured to determine the torque setting according to a selection of at least one of a speed setting or a level setting.

[0007] In some aspects, the techniques described herein relate to an impact tool, wherein the level setting corresponds to an amount of torque or energy transmitted from the impact tool to a fastener during the intermittent rotational impacts.

[0008] In some aspects, the techniques described herein relate to an impact tool, wherein the impact tool further includes an interface coupled to the housing that is configured to receive the selection of the speed setting and the level setting.

[0009] In some aspects, the techniques described herein relate to an impact tool, wherein the speed setting corresponds to a maximum no-load speed of the motor.

[0010] In some aspects, the techniques described herein relate to an impact tool, wherein the speed setting includes at least three speed settings and the level setting includes at least three level settings that correspond to at least nine torque settings.P-US-TN-2023-0197-PCT - 0029-128W01

[0011] In some aspects, the techniques described herein relate to an impact tool, wherein the controller is further configured to determine the time duration according to a sensed motor speed.

[0012] In some aspects, the techniques described herein relate to an impact tool, wherein the controller is configured to determine the time duration according to the torque setting and a comparison of the sensed motor speed to a predetermined motor speed.

[0013] In some aspects, the techniques described herein relate to an impact tool, wherein the controller is configured to increase the time duration when the sensed motor speed is less than the predetermined motor speed.

[0014] In some aspects, the techniques described herein relate to an impact tool, wherein the controller is configured to: compare the sensed motor speed to the predetermined motor speed during the intermittent rotational impacts; and dynamically adjust the time duration during the intermittent rotational impacts according to the comparison.

[0015] In some aspects, the techniques described herein relate to an impact tool, wherein the predetermined motor speed is a motor speed that corresponds to the torque setting.

[0016] In some aspects, the techniques described herein relate to an impact tool, wherein the predetermined motor speed includes a plurality of motor speeds that correspond to the torque setting, including a motor speed at a beginning of the intermittent rotational impacts and a motor speed during the intermittent rotational impacts.

[0017] In some aspects, the techniques described herein relate to an impact tool, wherein the controller is further configured to determine the time duration according to at least one of a sensed motor speed and battery information.

[0018] In some aspects, the techniques described herein relate to an impact tool, wherein the battery information is at least one of battery identification information or battery state information.

[0019] In some aspects, the techniques described herein relate to an impact tool, wherein the battery state information includes at least one of state of charge, impedance, temperature, or age.

[0020] In some aspects, the techniques described herein relate to an impact tool, wherein the controller is configured to determine a time duration that is different from a predetermined timeP-US-TN-2023-0197-PCT - 0029-128W01 duration when the battery information is different from predetermined battery information corresponding to the torque setting.

[0021] In some aspects, the techniques described herein relate to an impact tool, wherein the controller is configured to determine a time duration that is shorter than a predetermined time duration when the battery information includes a battery identification indicating a higher capacity battery than a predetermined battery identification corresponding to the torque setting.

[0022] In some aspects, the techniques described herein relate to an impact tool, wherein the controller is configured to determine a time duration that is longer than a predetermined time duration when the battery information includes battery state information indicating a lower battery capacity than a predetermined battery capacity corresponding to the torque setting.

[0023] In some aspects, the techniques described herein relate to an impact tool, wherein the hammer applies the intermittent rotational impacts to the anvil when a torque on the output member reaches or exceeds a trip torque.

[0024] In some aspects, the techniques described herein relate to an impact tool including: a housing; a motor disposed in the housing; a controller configured to control operation of the motor; an output member configured to be rotated when the motor is operated to rotatably drive a fastener; and an impact mechanism configured to be driven by the motor, the impact mechanism including a hammer and an anvil coupled to the output member, wherein the hammer applies intermittent rotational impacts to the anvil; wherein the controller is configured to: determine a cumulative impact energy transmitted to a workpiece by the impact mechanism according to a sensed motor speed during the intermittent rotational impacts; and reduce or terminate power to the motor when the determined cumulative impact energy meets a target total impact energy.

[0025] In some aspects, the techniques described herein relate to an impact tool, wherein the controller is configured to determine the target total impact energy according to a selection of at least one of a speed setting or a level setting.

[0026] In some aspects, the techniques described herein relate to an impact tool, wherein the hammer applies the intermittent rotational impacts to the anvil when a torque on the output member reaches or exceeds a trip torque.

[0027] In some aspects, the techniques described herein relate to a method for operating an impact power tool having an impact mechanism configured to be driven by a motor, the impactP-US-TN-2023-0197-PCT - 0029-128W01 mechanism including a hammer and an anvil coupled to an output member, wherein the hammer applies intermittent rotational impacts to the anvil, the method including: determining a time duration for performing the intermittent rotational impacts according to a torque setting; and reducing or terminating power to the motor when a length of time after a start of the intermittent rotational impacts meets the time duration.

[0028] In some aspects, the techniques described herein relate to a method, the method further including determining the torque setting according to a user selection of at least one of a speed setting or a time setting.

[0029] In some aspects, the techniques described herein relate to a method, wherein the hammer applies the intermittent rotational impacts to the anvil when a torque on the output member reaches or exceeds a trip torque.

[0030] In some aspects, the techniques described herein relate to an impact tool including: a housing; a motor disposed in the housing; a controller configured to control operation of the motor; an output member configured to be rotated when the motor is operated to rotatably drive a fastener; an impact mechanism configured to be driven by the motor, the impact mechanism including a hammer and an anvil coupled to the output member, wherein the hammer applies intermittent rotational impacts to the anvil; and an interface coupled to the housing that is configured to receive a selection of a speed setting and a time setting; wherein the controller is configured to determine a torque setting according to the selection of the speed setting and the time setting.

[0031] In some aspects, the techniques described herein relate to an impact tool, wherein the controller is further configured to: determine a time duration for performing the intermittent rotational impacts according to the torque setting; and reduce or terminate power to the motor when a length of time after a start of the intermittent rotational impacts meets the time duration.

[0032] In some aspects, the techniques described herein relate to an impact tool, wherein the hammer applies the intermittent rotational impacts to the anvil when a torque on the output member reaches or exceeds a trip torque.

[0033] In some aspects, the techniques described herein relate to an impact tool, wherein the speed setting corresponds to a maximum no-load speed of the motor.

[0034] In some aspects, the techniques described herein relate to an impact tool, wherein interface is configured to enable selection among at least a first speed setting, a second speedP-US-TN-2023-0197-PCT - 0029-128W01 setting and a third speed setting, which corresponds to a maximum no-load speed of the motor that is a low speed, a medium speed, and a high speed, respectively.

[0035] In some aspects, the techniques described herein relate to an impact tool, wherein the interface enables selection among a plurality of time settings.

[0036] In some aspects, the techniques described herein relate to an impact tool, wherein the plurality of time settings are indicated by a plurality of light sources.

[0037] In some aspects, the techniques described herein relate to an impact tool, wherein the time setting is presented as a progression of the plurality of light sources for longer time durations.

[0038] In some aspects, the techniques described herein relate to an impact tool, wherein, when none of the plurality of light sources are on, there is no time limit for impacting.

[0039] In some aspects, the techniques described herein relate to an impact tool, wherein the time settings are set in variable combination with the selected speed setting to deliver a wide range of fastening torque settings.

[0040] In some aspects, the techniques described herein relate to an impact tool, wherein the controller is configured to determine when the impact mechanism starts applying rotational impacts to the output member, and to determine a time duration during which impacting is to be performed based on a sensed impact rate, a sensed motor speed, and the fastening torque setting.

[0041] In some aspects, the techniques described herein relate to an impact tool, wherein the controller is configured to allow power to be delivered to the motor for the time duration and then to reduce or shut off power to the motor at an end of the time duration.

[0042] In some aspects, the techniques described herein relate to an impact tool, wherein the time duration is not equal to the time setting.

[0043] In some aspects, the techniques described herein relate to an impact tool, wherein the selected speed setting corresponds to a maximum no-load speed of the motor.

[0044] In some aspects, the techniques described herein relate to an impact tool including: a housing; a motor disposed in the housing; a controller configured to control operation of the motor; an output member configured to be rotated when the motor is operated to rotatably drive a fastener; and an impact mechanism configured to be driven by the motor, the impactP-US-TN-2023-0197-PCT - 0029-128W01 mechanism including a hammer and an anvil coupled to the output member, wherein the hammer applies intermittent rotational impacts to the anvil; wherein the controller is configured to: determine a time duration for performing the intermittent rotational impacts according to a selection of a speed setting and a time setting; and reduce or terminate power to the motor when a length of time after a start of the intermittent rotational impacts meets the time duration.

[0045] In some aspects, the techniques described herein relate to an impact tool, wherein the hammer applies the intermittent rotational impacts to the anvil when a torque on the output member reaches or exceeds a trip torque.

[0046] In some aspects, the techniques described herein relate to an impact tool, wherein the time duration is different from the time setting.

[0047] In some aspects, the techniques described herein relate to an impact tool, wherein the speed setting corresponds to a no-load motor speed and the controller is configured to deliver power to the motor to achieve the no-load motor speed.

[0048] In some aspects, the techniques described herein relate to an impact tool, wherein the time duration is determined from a look-up table that is based on the speed setting and the time setting.

[0049] In some aspects, the techniques described herein relate to an impact tool, further includes a speed sensor configured to detect a speed of the motor and output a sensed motor speed.

[0050] In some aspects, the techniques described herein relate to an impact tool, wherein the speed sensor is a rotational speed sensor.

[0051] In some aspects, the techniques described herein relate to an impact tool, wherein the controller is further configured to determine the time duration according to a sensed motor speed, wherein the sensed motor speed is at least one of an average motor speed, a peak motor speed, or a peak-to-peak motor speed, determined during a sensed time period.

[0052] In some aspects, the techniques described herein relate to an impact tool, wherein the speed sensor includes Hall sensors that magnetically sense magnetic flux of a rotor magnet as a rotor is rotated, and wherein the controller is configured to measure an angular position of the rotor based on information from the Hall sensors and to control a commutation of the motor according to the measured angular position.P-US-TN-2023-0197-PCT - 0029-128W01

[0053] In some aspects, the techniques described herein relate to an impact tool, wherein an impact rate is determined from an output of the Hall sensors.

[0054] In some aspects, the techniques described herein relate to an impact tool, wherein the output of the Hall sensors includes periodic accelerations and decelerations of the motor that are caused by the rotational impacts impacted by the impact power tool.

[0055] In some aspects, the techniques described herein relate to an impact tool, further includes a current sensor configured to detect an amount of electric current drawn by the motor to drive the motor.

[0056] In some aspects, the techniques described herein relate to an impact tool, wherein an impact rate is determined from an output of the current sensor.

[0057] In some aspects, the techniques described herein relate to an impact tool, wherein the output of the current sensor includes periodic changes in the current drawn by the motor that are caused by the rotational impacts impacted by the impact power tool.

[0058] In some aspects, the techniques described herein relate to an impact tool, wherein the speed setting and the time setting correspond to a fastening torque setting.

[0059] In some aspects, the techniques described herein relate to an impact tool, wherein the fastening torque setting includes a user selected fastening torque setting.

[0060] In some aspects, the techniques described herein relate to an impact tool, further includes an interface coupled to the housing, wherein the interface is actuatable by a user to select the speed setting and the time setting, and wherein the controller is configured to determine the fastening torque setting based on the speed setting and the time setting.

[0061] In some aspects, the techniques described herein relate to an impact tool, wherein, for a constant fastening torque setting, the time duration decreases as the motor speed increases.

[0062] In some aspects, the techniques described herein relate to an impact tool, wherein, for a constant fastening torque setting, the time duration increases as the motor speed decreases.

[0063] In some aspects, the techniques described herein relate to an impact tool, wherein, for a constant impact rate and a constant motor speed, the time duration decreases as the fastening torque setting decreases.P-US-TN-2023-0197-PCT - 0029-128W01

[0064] In some aspects, the techniques described herein relate to an impact tool, wherein, for a constant impact rate and a constant motor speed, the time duration increases as the fastening torque setting increases.

[0065] In some aspects, the techniques described herein relate to an impact power tool including: a housing; a motor disposed in the housing; a controller configured to control operation of the motor; an output member configured to be rotated when the motor is operated to rotatably drive a fastener; an impact mechanism configured to be driven by the motor, the impact mechanism including a hammer and an anvil coupled to the output member, wherein the hammer applies intermittent rotational impacts to the anvil; and an interface coupled to the housing that is configured to receive a selection of a speed setting and a time setting; wherein the controller is configured to determine a time duration for performing the intermittent rotational impacts according to the selection of the speed setting and the time setting.

[0066] In some aspects, the techniques described herein relate to an impact tool, wherein the hammer applies the intermittent rotational impacts to the anvil when a torque on the output member reaches or exceeds a trip torque.

[0067] In some aspects, the techniques described herein relate to an impact power tool including: a housing; a motor disposed in the housing; a controller configured to control operation of the motor; an output member configured to be rotated when the motor is operated to rotatably drive a fastener; and an impact mechanism configured to be driven by the motor, the impact mechanism configured to rotationally drive the output member when a torque on the output member is less than a trip torque and to apply rotational impacts to the output member when the torque on the output member reaches or exceeds the trip torque; wherein the controller is configured to receive a signal that corresponds to a fastening torque setting, determine when the impact mechanism starts applying rotational impacts to the output member, and determine a time duration during which impacting is to be performed based on a sensed motor speed and the fastening torque setting, and wherein the controller is configured to allow power to be delivered to the motor for the time duration and then to reduce or shut off power to the motor at an end of the time duration.

[0068] In some aspects, the techniques described herein relate to an impact tool, wherein the sensed motor speed is at least one of an average motor speed, a peak motor speed, or a peak- to-peak motor speed, determined during a sensed time period.P-US-TN-2023-0197-PCT - 0029-128W01

[0069] In some aspects, the techniques described herein relate to an impact tool, further includes a speed sensor configured to detect a speed of the motor and output the sensed motor speed.

[0070] In some aspects, the techniques described herein relate to an impact tool, wherein the speed sensor is a rotational speed sensor.

[0071] In some aspects, the techniques described herein relate to an impact tool, wherein the speed sensor includes Hall sensors that magnetically sense magnetic flux of a rotor magnet as a rotor is rotated, and wherein the controller is configured to measure an angular position of the rotor based on information from the Hall sensors and to control a commutation of the motor according to the measured angular position.

[0072] In some aspects, the techniques described herein relate to an impact tool, wherein the sensed motor speed is determined from an output of the Hall sensors.

[0073] In some aspects, the techniques described herein relate to an impact tool, wherein the output of the Hall sensors includes periodic accelerations and decelerations of the motor that are caused by the rotational impacts impacted by the impact power tool.

[0074] In some aspects, the techniques described herein relate to an impact tool, further includes a current sensor configured to detect an amount of electric current drawn by the motor to drive the motor.

[0075] In some aspects, the techniques described herein relate to an impact tool, wherein the sensed motor speed is determined from an output of the current sensor.

[0076] In some aspects, the techniques described herein relate to an impact tool, wherein the output of the current sensor includes periodic changes in the current drawn by the motor that are caused by the rotational impacts impacted by the impact power tool.

[0077] In some aspects, the techniques described herein relate to an impact tool, wherein the fastening torque setting includes a predetermined fastening torque setting.

[0078] In some aspects, the techniques described herein relate to an impact tool, wherein the fastening torque setting includes a user selected speed setting and a user selected time setting.

[0079] In some aspects, the techniques described herein relate to an impact tool, wherein the fastening torque setting includes a user selected fastening torque setting.P-US-TN-2023-0197-PCT - 0029-128W01

[0080] In some aspects, the techniques described herein relate to an impact tool, further includes a mode change interface coupled to the housing, wherein the mode change interface is actuatable by the user to select a speed setting and a time setting, and wherein the controller is configured to determine the user selected fastening torque setting based on the selected speed setting and the selected time setting.

[0081] In some aspects, the techniques described herein relate to an impact tool, wherein, for a constant impact rate and a constant fastening torque setting, the time duration decreases as the motor speed increases.

[0082] In some aspects, the techniques described herein relate to an impact tool, wherein, for a constant impact rate and a constant fastening torque setting, the time duration increases as the motor speed decreases.

[0083] In some aspects, the techniques described herein relate to an impact tool, wherein, for a constant fastening torque setting, the time duration decreases as the motor speed increases.

[0084] In some aspects, the techniques described herein relate to an impact tool, wherein, for a constant fastening torque setting, the time duration increases as the motor speed decreases.

[0085] In some aspects, the techniques described herein relate to an impact tool, wherein, for a constant motor speed, the time duration decreases as the fastening torque setting decreases.

[0086] In some aspects, the techniques described herein relate to an impact tool, wherein, for a constant motor speed, the time duration increases as the fastening torque setting increases.

[0087] In an aspect, an impact power tool is provided. The impact power tool comprises a housing; a motor disposed in the housing; a power switch coupled to the housing and actuatable by a user to control power delivery to the motor; a controller configured to control operation of the motor; an output member configured to be rotated when the motor is operated to rotatably drive a fastener; and an impact mechanism configured to be driven by the motor. The impact mechanism is configured to rotationally drive the output member when a torque on the output member is less than a trip torque and to apply rotational impacts to the output member when the torque on the output member reaches or exceeds the trip torque. The controller is configured to receive a signal that corresponds to a fastening torque setting, determine when the impact mechanism starts applying rotational impacts to the output member, and determine a time duration during which impacting is to be performed based on a sensed impact rate, a sensed motor speed, and the fastening torque setting. The controller is configured to allow power toP-US-TN-2023-0197-PCT - 0029-128W01 be delivered to the motor for the time duration and then to reduce or shut off power to the motor at the end of the time duration.

[0088] Implementations of the foregoing aspects may include one or more of the following features.

[0089] The impact power tool may further comprise a speed sensor configured to detect a speed of the motor and output the sensed motor speed. The speed sensor may be a rotational speed sensor. The sensed motor speed may be at least one of an average motor speed, a peak motor speed, or a peak-to-peak motor speed, determined during a sensed time period. The speed sensor may include Hall sensors that magnetically sense magnetic flux of a rotor magnet as a rotor is rotated. The controller may be configured to measure an angular position of the rotor based on information from the Hall sensors and to control a commutation of the motor according to the measured angular position. The impact rate may be determined from an output of the Hall sensors. The output of the Hall sensors may include periodic accelerations and decelerations of the motor that are caused by the rotational impacts impacted by the impact power tool. The impact power tool may further comprise a current sensor configured to detect an amount of electric current drawn by the motor to drive the motor. The impact rate may be determined from an output of the current sensor. The output of the current sensor may include periodic changes in the current drawn by the motor that are caused by the rotational impacts impacted by the impact power tool.

[0090] The fastening torque setting may comprise a predetermined fastening torque setting. The fastening torque setting may comprise a user selected speed setting and a user selected time setting. The fastening torque setting may comprise a user selected fastening torque setting.

[0091] The impact power tool may further comprise a mode change interface coupled to the housing. The mode change interface may be actuatable by the user to select a speed setting and a time setting. The controller may be configured to determine the user selected fastening torque setting based on the selected speed setting and the selected time setting.

[0092] For a constant impact rate and a specified fastening torque setting, the time duration may decrease as the motor speed increases. For a constant impact rate and a constant fastening torque setting, the time duration may increase as the motor speed decreases. For a constant motor speed and a constant fastening torque setting, the time duration may decrease as the impact rate increases. For a constant motor speed and a constant fastening torque setting, the time duration may increase as the impact rate decreases. For a constant fastening torque setting,P-US-TN-2023-0197-PCT - 0029-128W01 the time duration may decrease as at least one of the impact rate or the motor speed increases. For a constant fastening torque setting, the time duration may increase as at least one of the impact rate or the motor speed decreases. For a constant impact rate and a constant motor speed, the time duration may decrease as the fastening torque setting decreases. For a constant impact rate and a constant motor speed, the time duration may increase as the fastening torque setting increases.

[0093] In another aspect, a method for operating an impact power tool having an impact mechanism configured to be driven by the motor, the impact mechanism configured to rotationally drive the output member when a torque on the output member is less than a trip torque and to apply rotational impacts to the output member when the torque on the output member reaches or exceeds the trip torque, is provided. The method comprises receiving a user input of a fastening torque setting; determining when the impact mechanism starts applying rotational impacts to the output member; determining an impact rate of the impact mechanism; determining a speed of the motor; determining a time duration for impacting based on (a) the determined impact rate, (b) the determined motor speed; and (c) the fastening torque setting; and delivering power to the motor for the time duration and then reducing or shutting off power to the motor at the end of the time duration.

[0094] In yet another aspect, an impact power tool is provided. The impact power tool comprises a housing; a motor disposed in the housing; a power switch coupled to the housing and actuatable by a user to control power delivery to the motor; a controller configured to control operation of the motor; an output member configured to be rotated when the motor is operated; an impact mechanism configured to be driven by the motor, the impact mechanism configured to rotationally drive the output member when a torque on the output member is less than a trip torque and to apply rotational impacts to the output member when the torque on the output member reaches or exceeds the trip torque; and a mode change interface coupled to the housing. The mode change interface is actuatable by the user to select a speed setting and a time setting. The controller is configured to determine a fastening torque setting based on the selected speed setting and the selected time setting .

[0095] Implementations of the foregoing aspects may include one or more of the following features.

[0096] The selected speed setting may correspond to a maximum no-load speed of the motor. The mode change interface may be configured to enable selection among at least a first speedP-US-TN-2023-0197-PCT - 0029-128W01 setting, a second speed setting and a third speed setting, which corresponds to a maximum no- load speed of the motor that is a low speed, a medium speed, and a high speed, respectively. The mode change interface may enable selection among a plurality of time settings. The plurality of time settings may be indicated by a plurality of light sources. The selected time setting may be presented as a progression of the light sources for longer time durations. When none of the plurality of light sources are on, there may be no time limit for impacting. The time settings may be set in variable combination with the selected speed setting to deliver a wide range of fastening torque settings.

[0097] The controller may be configured to determine when the impact mechanism starts applying rotational impacts to the output member, and to determine a time duration during which impacting is to be performed based on a sensed impact rate, a sensed motor speed, and the fastening torque setting. The controller may be configured to allow power to be delivered to the motor for the time duration and then to reduce or shut off power to the motor at the end of the time duration. The time duration may be not equal to the time setting. The selected speed setting may correspond to a maximum no-load speed of the motor.

[0098] In yet another aspect, an impact power tool is provided. The impact power tool comprises a housing; a motor disposed in the housing; a power switch coupled to the housing and actuatable by a user to control power delivery to the motor; a controller configured to control operation of the motor; an output member configured to be rotated when the motor is operated to rotatably drive a fastener; and an impact mechanism configured to be driven by the motor. The impact mechanism is configured to rotationally drive the output member when a torque on the output member is less than a trip torque and to apply rotational impacts to the output member when the torque on the output member reaches or exceeds the trip torque. The controller is configured to receive one or more signals that correspond to a user selected speed setting and a user selected time setting, determine when the impact mechanism starts applying rotational impacts to the output member, and determine a time duration during which impacting is to be performed based on a determined impact rate, a sensed motor speed, the speed setting, and the time setting. The controller is configured to allow power to be delivered to the motor for the time duration and then to reduce or shut off power to the motor at the end of the time duration.

[0099] Implementations of the foregoing aspects may include one or more of the following features.P-US-TN-2023-0197-PCT - 0029-128W01

[0100] The time duration may be different from the time setting. The speed setting may correspond to a no-load motor speed and the controller may be configured to deliver power to the motor to achieve the no-load motor speed. The time duration may be determined from a look-up table that is based on the sensed impact rate, the sensed motor speed, the speed setting, and the time setting. The impact power tool may further comprise a speed sensor configured to detect a speed of the motor and output the sensed motor speed. The speed sensor may be a rotational speed sensor. The sensed motor speed may be at least one of an average motor speed, a peak motor speed, or a peak-to-peak motor speed, determined during a sensed time period. The speed sensor may include Hall sensors that magnetically sense magnetic flux of a rotor magnet as a rotor is rotated. The controller may be configured to measure an angular position of the rotor based on information from the Hall sensors and to control a commutation of the motor according to the measured angular position. The impact rate may be determined from an output of the Hall sensors.

[0101] The output of the Hall sensors may include periodic accelerations and decelerations of the motor that are caused by the rotational impacts impacted by the impact power tool. The impact power tool may further comprise a current sensor configured to detect an amount of electric current drawn by the motor to drive the motor. The impact rate may be determined from an output of the current sensor. The output of the current sensor includes periodic changes in the current drawn by the motor that are caused by the rotational impacts impacted by the impact power tool. The user selected speed setting and the user selected time setting may correspond to a fastening torque setting. The fastening torque setting may comprise a user selected fastening torque setting.

[0102] The impact power tool may further comprise a mode change interface coupled to the housing. The mode change interface may be actuatable by the user to select the user speed setting and the user selected time setting. The controller may be configured to determine the user selected fastening torque setting based on the user selected speed setting and the user selected time setting.

[0103] For a constant impact rate and a constant fastening torque setting, the time duration may decrease as the motor speed increases. For a constant impact rate and a constant fastening torque setting, the time duration may increase as the motor speed decreases. For a constant motor speed and a constant fastening torque setting, the time duration may decrease as the impact rate increases. For a constant motor speed and a constant fastening torque setting,P-US-TN-2023-0197-PCT - 0029-128W01 the time duration increases as the impact rate decreases. For a constant fastening torque setting, the time duration may decrease as at least one of the impact rate or the motor speed increases. For a constant fastening torque setting, the time duration may increase as at least one of the impact rate or the motor speed decreases. For a constant impact rate and a constant motor speed, the time duration may decrease as the fastening torque setting decreases. For a constant impact rate and a constant motor speed, the time duration may increase as the fastening torque setting increases.

[0104] In yet another aspect, an impact power tool is provided. The impact power tool comprises a housing; a motor disposed in the housing; a power switch coupled to the housing and actuatable by a user to control power delivery to the motor; a controller configured to control operation of the motor; an output member configured to be rotated when the motor is operated; an impact mechanism configured to be driven by the motor, the impact mechanism configured to rotationally drive the output member when a torque on the output member is less than a trip torque and to apply rotational impacts to the output member when the torque on the output member reaches or exceeds the trip torque; and a mode change interface coupled to the housing. The mode change interface is actuatable by the user to select a speed setting and a time setting. The controller is configured to determine a time duration for impacting based on the selected speed setting and the selected time setting.

[0105] Advantages may include one or more of the following. The impact tools and methods may lead to improved control and speed of fastening operation, while increasing power delivered when needed for impacting and reducing the use of unneeded power, thus saving energy, being more efficient, and protecting tool components from damage. These and other advantages and features will be apparent from the description, the drawings, and the claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0106] FIG. l is a perspective view of an example impact power tool.

[0107] FIG. 2 is a side view of the impact tool of FIG. 1 with a portion of the housing removed.

[0108] FIG. 3 is an exploded view of motor, transmission, and impact mechanism of the impact tool of FIG. 1.P-US-TN-2023-0197-PCT - 0029-128W01

[0109] FIG. 4 is a high level block diagram of a control system for the impact tool of FIG. 1.

[0110] FIG. 5 is a view of an example user interface of the impact tool of FIG. 1, where the user interface includes a precision control mode, a wood fastening control mode, a time setting selector to select one or more of five possible time settings, and a speed setting selector to select one or more of three possible speed settings.

[0111] FIG. 6 is an example look-up table that may be used by a controller of the impact power tool to determine a desired fastening torque setting, where the example look-up table includes the five possible time settings that can be selected using the time setting selector as shown in the user interface of FIG. 5 and three possible speed settings that can be selected using the speed setting selector as shown in the user interface of FIG. 5.

[0112] FIG. 7 is a view of another example user interface of the impact tool of FIG. 1, where the user interface includes a precision control mode, a wood fastening control mode, a time setting selector to select one or more of four possible time settings and a speed setting selector to select one or more of two possible speed settings.

[0113] FIG. 8 is a view of another example user interface of the impact tool of FIG. 1, where the user interface includes a precision control mode, a wood fastening control mode, a time setting selector to select one or more of four possible time settings and a speed setting selector to select one or more of two possible speed settings.

[0114] FIG. 9 is a view of another example user interface of the impact tool of FIG. 1, where the user interface includes a precision control mode, a time setting selector to select one or more of four possible time settings and a speed setting selector to select one or more of two possible speed settings.

[0115] FIG. 10 is an example look-up table that may be used by the controller of the impact power tool to determine a desired fastening torque setting, where the example look-up table includes the four possible time settings that can be selected using the time setting selector as shown in the user interface of FIGS. 7, 8, or 9 and two possible speed settings that can be selected using the speed setting selector as shown in the user interface of FIGS. 7, 8, or 9.

[0116] FIG. 11 A is a view of another example user interface of the impact tool of FIG. 1, where the user interface includes selections for different types of anchors (e.g., SD1 and SD2 / 4 / 6) and selections for different sizes of anchors (e.g., 3 / 8 inch, 1 / 2 inch, 5 / 8 inch, etc.),P-US-TN-2023-0197-PCT - 0029-128W01 wherein each combination of anchor type and anchor size may be associated with a specific torque value in the impact power tool’s memory.

[0117] FIG. 1 IB shows an example look-up table that may be used by the controller of the impact power tool to determine a desired fastening torque setting, where the example lookup table includes the three possible anchor sizes that can be selected as shown in the user interface of FIG. 11A and two anchor type settings that can be selected as shown in the user interface of FIG. 11 A.

[0118] FIG. 12 is a view of another example user interface of the impact tool of FIG. 1;

[0119] FIG. 13A is a view of another example user interface of the impact tool of FIG. 1, where the user interface includes a precision control mode, a wood fastening control mode, and a speed setting selector to select one or more of two possible speed settings.

[0120] FIG. 13B shows an example time control programmed blink pattern corresponding to the user interface of FIG. 13 A.

[0121] FIG. 14 shows impact detection using motor hall sensors , wherein impacting events can be seen via acceleration / deceleration in motor speed.

[0122] FIGS. 15A and 15B show impact detection using current sensor(s), where impacting events can be seen via periodic spikes in the bus current.

[0123] FIG. 16 is a plot of motor torque curves for the motor of the impact tool of FIG. 1 for different battery packs and different battery pack state of charge and illustrates the influence of the battery pack on the motor speed at which intermittent rotational impacts occur.

[0124] FIG. 17 shows dynamic rotor speed measurement while impacting in accordance with an example of the present patent application.

[0125] FIG. 18 shows relationship between output torque and time in accordance with an example of the present patent application.

[0126] FIG. 19 shows an example look-up table or matrix in accordance with an example of the present patent application.

[0127] FIG. 20 shows an example graph of a resulting controlled torque for different combinations of speed and time settings.P-US-TN-2023-0197-PCT - 0029-128W01

[0128] FIG. 21 includes example tables of scalar values for modifying a set speed and / or a set time duration according to battery identification information, state of charge, and target total impact energy.

[0129] FIGs. 22-24 are flowcharts of example methods of operating a power tool such as the impact tool of FIG. 1.

[0130] FIG. 25 is a flowchart of an example method for performing a calibration procedure with the impact tool of FIG. 1 to determine settings and operating parameters that result in a target torque for a specific fastener type and material type.DETAILED DESCRIPTION

[0131] Referring to FIGS. 1 and 2, in an example, an impact power tool or impact tool 10 may include an impact driver or an impact wrench that is used for driving / tightening (threaded) fasteners such as screws, nuts, and bolts. The impact power tool 10 may be an electric rotary impact power tool. The impact power tool 10 may have a housing 12 having a front end portion 14 and a rear end portion 16. The housing 12 includes a motor housing portion 18 that contains a (rotary) motor 20 and a transmission housing portion 22 that contains a transmission 23 and an impact mechanism 24. In one example, the motor 20 may be a brushless motor. The motor 20 may be disposed in the housing 12.

[0132] The transmission 23 and the impact mechanism 24 transmit rotary motion from the motor 20 to an output member or an output spindle 26, as described in greater detail below. The output member 26 may be configured to be rotated when the motor 20 is operated. The output member 26 may be configured to be rotated when the motor 20 is operated to rotatably drive a fastener. Coupled to the output member 26 is a tool holder 29 for retaining a tool bit (e.g., a drill bit or a screw driving bit, not shown). The output member 26 and the tool holder 29 together define and extend along a tool axis X. As shown, the tool holder 29 includes a hex bit retention mechanism. Further details regarding example tool holders are set forth in commonly-owned U.S. Patent No. 8,622,401, which is incorporated herein by reference in its entirety.

[0133] Extending downward and slightly rearward of the housing 12 is a handle 30 in a pistol grip formation. The handle 30 has a proximal portion 32 coupled to the housing 12 and a distal portion 34 coupled to a battery receptacle 28. The motor 20 may be powered by anP-US-TN-2023-0197-PCT - 0029-128W01 electrical power source, such as a DC power source or battery / battery pack (not shown), that is coupled to the battery receptacle 28, or by an AC power source. A trigger 36 is coupled to the handle 20 adjacent the housing 12. The trigger 36 connects the electrical power source to the motor 20 via a controller 40 and may control an amount of power delivery to the motor 20, as described in greater detail below. The trigger 36 may be interchangeably referred to as power switch or a user-actuatable power switch. The power switch 36 may be coupled to the housing 12 and may be actuatable by a user to control power delivery to the motor 20.

[0134] The controller 40 may be configured to control power delivery to the motor 20 in response to actuation of the trigger / power switch 36. The controller 40 may be configured to control operation of the motor 20. A light unit (e.g., an LED) 38 may be disposed on the front end portion 14 of the housing 12, just below the tool holder 29 to illuminate an area in front of the tool holder 29. Alternatively, the light unit 38 may be disposed on a front end portion of the battery receptacle 28 Power delivery to the light unit 38 may be controlled by the trigger 36 and the controller 40, or by a separate switch on the impact power tool 10.

[0135] Referring also to FIG. 3, in an example, the transmission 23 may be a planetary transmission that includes a pinion or sun gear 44 that is coupled to an output shaft 46 of the motor 20 and that extends along the tool axis X. One or more planet gears 48 surround and have teeth that mesh with the teeth on the sun gear 44. An outer ring gear 50 is rotationally fixed to the housing 12 and centered on the tool axis X with its internal teeth meshing with the teeth on the planet gears 48. The planet gears 48 are pivotally coupled to a planet carrier 52. When the motor 20 is energized, it causes the motor output shaft 46 and the sun gear 44 to rotate about the tool axis X. Rotation of the sun gear 44 causes the planet gears 48 to orbit the sun gear 44 about the tool axis X, which in turn causes the planet carrier 52 to rotate about the tool axis X at a reduced speed relative to the rotational speed of the motor output shaft 46. In the illustrated example, only a single planetary stage is shown. It should be understood that the transmission may include multiple planetary stages that may provide for multiple speed reductions, and that each stage can be selectively actuated to provide for multiple different output speeds of the planet carrier. Further, the transmission 23 may include a different type of gear system such as a parallel axis transmission or a spur gear transmission.

[0136] In an example, the impact mechanism 24 may be configured to be driven by the motor 20. The impact mechanism 24 may be configured to rotationally drive the output member 26. The impact mechanism 24 is configured to selectively apply the rotational impacts to theP-US-TN-2023-0197-PCT - 0029-128W01 output member 26 when a torque on the output member 26 exceeds a threshold or a torque threshold. That is, the output member 26 may be configured to receive rotational impacts from the impact mechanism 24 during rotation of the output member 26. The output member 26 may be configured to be rotated when the motor 20 is operated to rotatably drive a fastener.

[0137] The impact mechanism 24 may be configured to rotationally drive the output member 26 when a torque on the output member 26 is less than a trip torque and to apply rotational impacts to the output member when the torque on the output member reaches or exceeds the trip torque. In an example, the torque threshold may be the trip torque. The trip torque may be a torque at which the impact mechanism 24 transitions from smooth rotational output to intermittent rotational impacts. This may be based on mechanical characteristics of the impact mechanism 24 and may be independent of the torque setting and control performed electronically using time, impact rate, speed, and the torque setting. As would be appreciated by a person of ordinary skill in the art, the term “trip torque” is well-known in the art and the trip torque may be easily differentiated, by a person of ordinary skill in the art, from the electronic torque setting.

[0138] The impact mechanism 24 may include a cam shaft 54 extending along the tool axis X and fixedly coupled to the planet carrier 52 so that they rotate together. Received over the cam shaft 54 is a cylindrical hammer 56 that is configured to move rotationally and axially relative to the cam shaft 54. The cam shaft 54 also has a front end 58 of smaller diameter that is rotatably received in an axial opening 60 in the output member 26. Fixedly coupled to a rear end of the output member 26 is an anvil 62 having two radial projections 64. The hammer 56 has two hammer projections 66 on its front end that lie in the same rotational plane as the radial projections 64 of the anvil 62 so that each hammer projection 66 may engage a corresponding anvil projection 64 in a rotating direction.

[0139] Formed on an outer wall of the cam shaft 54 is a pair of rear-facing V-shaped cam grooves 68 with their open ends facing toward the rear end portion 16 of the housing 12. A corresponding pair of forward-facing V-shaped cam grooves (not shown) is formed on an interior wall of the hammer 56 with their open ends facing toward the front end portion 14 of the housing 12. A ball 72 is received in and rides along each of the cam grooves 68, 70 to couple the hammer 56 to the cam shaft 54. A compression spring 74 is received in a cylindrical recess 76 in the hammer 56 and abuts a forward face of the planet carrier 52. The spring 74P-US-TN-2023-0197-PCT - 0029-128W01 biases the hammer 56 toward the anvil 62 so that the so hammer projections 66 engage the corresponding anvil projections 64.

[0140] At low torque levels, the impact mechanism 24 transmits torque to the output member 26 in a continuous rotary motion. When at the low torque levels, the compression spring 74 maintains the hammer 56 in its most forward position so that the hammer projections 66 engage the anvil projections 64. This causes the cam shaft 54, the hammer 56, the anvil 62 and the output spindle to rotate together as a unit about the tool axis X so that the output member 26 has substantially the same rotational speed as the cam shaft 54. This patent application refers to this operation as a rotary operation.

[0141] As the torque increases to a transition torque threshold (or the trip torque), the impact mechanism 24 transmits rotational impacts to the output member 26. At torque that is greater than or equal to the transition torque threshold, the hammer 56 moves axially rearwardly against the force of the spring 74. This decouples the hammer projections 66 from the anvil projections 64. Thus, the anvil 62 continues to spin freely on its axis without being driven by the motor 20 and transmission 23, so that it coasts to a slightly slower speed. Meanwhile, the hammer 56 continues to be driven at a higher speed by the motor 20 and the transmission 23. As this occurs, the hammer 56 moves axially rearwardly relative to the anvil 62 by the movement of the balls 72 rearwardly in the V-shaped cam grooves 68. When the balls 72 reach their rearmost position in the V-shaped cam grooves 68, 70 the spring 74 drives the hammer 56 axially forward with a rotational speed that exceeds the rotational speed of the anvil 62. This causes the hammer projections 66 to rotationally strike the anvil projections 64, imparting a rotational impact to the output member 26. This impacting operation repeats as long as the torque on the output member 26 continues to exceed the transition torque threshold. This patent application refers to this operation as an impact operation.

[0142] The transition torque threshold for when the impact mechanism 24 transitions from the rotary operation to impact operation is a function of various factors, including the mechanical characteristics of the components of the impact mechanism 24, such as the inertia of the hammer 56 and the force of the spring 74, motor performance characteristics, such as motor speed or acceleration, and external characteristics, such as the tightness of the joint at the workpiece, the fastener, and / or loading of the output spindle. Thus, under different conditions of operation, the transition torque threshold may vary.P-US-TN-2023-0197-PCT - 0029-128W01

[0143] Referring also to FIG. 4, in an example of a control mode, the trigger / power switch 36 connects the (electrical) power source 291 to the motor 20 via the controller 40 that controls power delivery to the motor 20. The controller 40 may include a microprocessor, microcontroller, or other control circuit, a memory device (such as a ROM, RAM, or flash memory device) coupled to the controller 40, and a motor driving circuit (such as an H-bridge circuit, a half-bridge circuit, or an inverter circuit).

[0144] The motor 20 may be a brushless DC motor with Hall sensors that magnetically sense the magnetic flux of a rotor magnet as the rotor is rotated. That information is sent to the controller 40, which in turn measures the angular position of the rotor based on the sensor information and controls the commutation of the motor according to the angular position. Motor speed and / or power may be controlled, e.g., by open loop and / or closed loop control based on input from the Hall sensors, from the selected mode of operation, and from the position of the trigger / power switch 36. In addition, motor speed and / or power may be controlled by adjusting the conduction band and / or advance angle (CBAA) values based on a desired power and / or speed output of the motor 20. Further, when using CBAA in open loop and closed loop speed and / or power control, the speed and / or power may further be adjusted by changing the duty cycle or Npulse width modulation (PWM) signal sent to the motor 20 via an inverter circuit. An example implementation of the use of CBAA and PWM in open loop and closed loop speed and power control is disclosed in U.S. Patent Application Publication No. 2018 / 0248507, which is herein incorporated by reference in its entirety.

[0145] It should be understood, that other aspects and examples of the present patent application may be utilized using a motor assembly without a Hall board, i.e., a BLDC motor that is sensorlessly controlled. Examples of sensorless motor commutation control are six-step trapezoidal commutation using the induced motor voltage signals, sinusoidal control, and field- orientated control. Reference is made to U.S. Patent Application Publication No. 2020 / 0389108, which is herein incorporated by reference in its entirety, for a description of sensorless sinusoidal and field-oriented motor control. Also, reference is made to U.S. Patent No. 10,99,0583, which is herein incorporated by reference in its entirety, for a description of sensorless motor control using the motor induced voltage. An advantage of the Hall board design described in this disclosure is that it allows sensed trapezoidal control of a compact motor that is volumetrically equivalent to a sensorless motor capable of outputting the same power performance. However, other aspects of the present patent application, for example, theP-US-TN-2023-0197-PCT - 0029-128W01 nested support plate, the rotor assembly, and the rear end cap design described below, may be implemented for use with a sensorless brushless motor.

[0146] The trigger / power switch 36 may allow the user to adjust the motor power or speed within a range of powers or motor speeds depending on trigger position (e.g., variable speed operation) or may cause the motor 20 to run at a constant power or constant speed when one or more the motor control modes are selected. Based on the selected mode and / or trigger position, the controller 40 controls the power delivered to the motor 20 by controlling power or by controlling one or more parameters or analogues of power, such as current, voltage, resistance, duty cycle of a pulse width modulation (PWM) signal, motor speed, and / or torque. The term power is used in this application in a generic manner to refer to power or to any of these or other parameters or analogues of power.

[0147] The impact power tool 10 (e.g., impact wrench) can produce an approximate fastening torque with a known fastener, a known joint, and a known socket by controlling the variables of applied speed and time of impacting. This fastening torque control may be selected via a user interface 42 on the power tool 10 or may be selected via a remote device 50 (FIG. 4) (e.g., a mobile phone, tablet, computer, etc. via a wired and / or wireless connection to the power tool and / or the battery pack (e.g., thru a Bluetooth connection via a mobile app).

[0148] Referring to FIGS. 5 and 7-9, coupled to the housing 12 is a user interface 42, also referred to herein as a mode change interface. The user interface 42 is configured to include a fastening torque control capability. The user interface 42 may include mode select user interface or mode change user interface. The user interface 42 may be coupled to the housing 12 of the impact power tool 10. In an implementation, the user interface 42 may be actuatable by the user to select a fastening torque setting. In another implementation, the user interface 42 may be actuatable by the user to select at least one of a speed setting and / or a time setting, also referred to herein as a level setting or torque level setting, or impact energy level setting. The controller 40 may be configured to determine a fastening torque setting or a user selected fastening torque setting, or a target total impact energy setting based on the selected speed setting and / or the selected time setting.

[0149] The user interface 42 may also be operatively coupled / connected to the controller 40 as shown in FIG. 4. The user interface 42 may include one or more elements 43a, 43b such as user actuatable controls, switches, pushbutton switches, buttons, knobs, slides, or levers, etc., that allow the user to select among several operation modes of the motor 20 and / orP-US-TN-2023-0197-PCT - 0029-128W01 to select among several time settings, as described in further detail below. The switches 43a and 43b may be operatively coupled / connected to the controller 40 and may be configured provide input to the controller 40.

[0150] For example, as shown in FIG. 5, a mode select button 43a may allow the user to select among a low speed mode / setting, a medium speed mode / setting, a high speed mode / setting, a first control mode, and a second control mode. The low speed control mode, the medium speed control mode, and the high speed control mode may be a speed 1 control mode, or Speed 1, a speed 2 control mode, or or Speed 2, or a speed 3 control mode, or Speed 3. One of the first control mode and the second control mode may be a precision control mode, and the other of the first control mode and the second control mode may be a wood fastening control mode. That is, the mode select button 43a may be configured to operate by cycling through the modes of precision control, wood fastening control, speed 1 control, speed 2 control, and speed 3 control. For example, the speed 1 may include a motor speed from approximately 10000 RPM to approximately 14999 RPM; the speed 2 may include a motor speed from approximately 15000 RPM to approximately 19999 RPM; and the speed 3 may include a motor speed more than approximately 20000 RPM.

[0151] The precision control mode may include “control mode 9” in U.S. Patent Application Publication Serial No. 17 / 551,596, which is incorporated by reference herein in its entirety. The precision control mode may include Precision Wrench™ mode in DEWALT DCF896 Impact Wrench. In an example, in the precision control mode, the motor is run at a selected full speed (based on trigger pull and the speed selected) until detection of first impact. After detection of the first impact, the motor speed is reduced or turned off for a predetermined time period, after which the motor is again driven at the selected full speed.

[0152] The wood fastening control mode may be a soft joint mode / application. A soft joint application may generally include drilling a hole in wood, sinking a very large fastener, e.g., a timber screw, etc. The soft joint mode is described in detail as mode 3 in the commonly assigned U.S. Patent No. 11,855,567 (“the ‘567 Patent”), which is incorporated by reference herein in its entirety. In an example, an element of the user interface 42, such as the mode select button 43a may be used to select any one or more of the modes disclosed in the ‘567 Patent.

[0153] Referring to FIG. 5, the element 43b may allow the user to select among a first time setting, or , or Time 1, or level 1, a second time setting, or Time 2, or level 2, a third time setting, or , or Time 3 or level 3, a fourth time setting, or , or Time 4, or level 4, and a fifth timeP-US-TN-2023-0197-PCT - 0029-128W01 setting, or Time 5, or level 5. For example, the element 43b of the user interface 42 may be configured to operate by cycling through the first time setting, the second time setting, the third time setting, the fourth time setting, and the fifth time setting. In an example, the first time setting, the second time setting, the third time setting, the fourth time setting, and the fifth time setting each may include the same time setting, or level setting. In another example, the first time setting, the second time setting, the third time setting, the fourth time setting, and the fifth time setting may each may include different time settings or level settings, for example, ranging in duration from shortest to longest, or of varying torque levels, or of varying target total impact energy levels. In an example, the time settings may not be specific time duration values and may be relative selections or values or levels or time settings (e.g., 1, 2, 3, 4, etc.). In an example, an actual time value for a duration of time over which the power tool 10 performs an operation may be determined, or calculated, or selected according to the selected time selection or level selection, for example, via a data structure or look-up table according to one or more of the selected speed, the selected time, and / or other parameters. For example the controller may determine an actual time value to perform an operation according to values in a data structure such as a look-up table stored in memory.

[0154] The user interface 42 may also include a plurality of indicia 45 for indicating to the user the selected mode / setting of operation of the tool 10 and a plurality of indicia 49 for indicating to the user the selected time setting. The plurality of indicia 45 or 49 may be an example of a display 47 as shown in FIG. 4. The display 47 may be operatively coupled / connected to the controller 40 as shown in FIG. 4 and may be configured receive output from the controller 40. For example, FIG. 5 shows the speed 2 control mode and the third time setting are selected.

[0155] An example data structure in the form of a look-up table 600 that correlates the time settings of FIG. 5, e.g., the first time setting, or Time 1, the second time setting, or Time 2, the third time setting, or Time 3, the fourth time setting, or Time 4, and the fifth time setting and the speed control modes of FIG. 5, e.g., speed control mode Speed 1, speed control mode or Speed 2, and speed control mode Speed 3 is shown in FIG. 6. The controller 40 may be configured to use the look-up table 600 to determine a desired fastening torque setting. For example, when the speed 2 control mode, Speed 2, and the third time setting ,Time 3, are selected , the controller 40 may be configured to determine, using look-up table 600, that the desired fastening torque setting is desired torque 8. The table 600 includes five rows and three columns corresponding to five time settings and three speed control modes. Table 600 isP-US-TN-2023-0197-PCT - 0029-128W01 provided by way of example and any of a variety of other dimensions of data structures such as look-up tables including other numbers of time settings and / or speed control modes may be used, for example, depending an application of the impact power tool 10.

[0156] As shown in FIG. 5, the user interface 42 may also include an element in the form of a light control switch 41. The light control switch 41 may be a user actuatable control element, for example, a pushbutton switch, knob, slide or button, etc. that allows the user to select among various modes of operation of the light unit 38 (FIG. 1), e.g., to vary the duration of lighting and intensity of lighting. That is, the light control switch 41 may be configured to operate by cycling through various modes of operation of the light unit 38. The light control switch 41 may also be referred to as LED / light control. As with other aspects of the examples disclosed herein, the light control switch 41 may be optional. By way of example, the user interfaces of FIGS. 8-9, 11 A, and 13A do not include the light control switch 41, while the user interfaces of FIGS. 5, 7, and 12 include the light control switch 41.

[0157] In the examples shown in FIGS. 7 and 8, the switch 43a may allow the user to select among a low speed mode / setting, a high speed mode / setting, a first control mode, and a second control mode. One of the low speed control mode and the high speed control mode may be a speed 1 control mode, or Speed 1, and the other of the low speed control mode and the high speed control mode may be a speed 2 control mode, or Speed 2. One of the first control mode and the second control mode may be a precision control mode, and the other of the first control mode and the second control mode may be a wood fastening control mode. For example, the low speed may include a motor speed from about 10000 RPM to about 14999 RPM and the high speed may include more than about 20000 RPM. That is, the mode select button 43a may be configured to operate by cycling through the modes of precision control, wood fastening control, speed 1 control, and speed 2 control.

[0158] In another example, as shown in FIG. 9, the switch 43a may allow the user to select among a low speed mode / setting, a high speed mode / setting, and a wood fastening control mode. One of the low speed control mode and the high speed control mode may be a speed 1 control mode, or Speed 1, and the other of the low speed control mode and the high speed control mode may be a speed 2 control mode, or Speed 2. For example, the low speed may include a motor speed from about 10000 RPM to about 14999 RPM and the high speed may include more than about 20000 RPM. That is, the mode select button 43a may beP-US-TN-2023-0197-PCT - 0029-128W01 configured to operate by cycling through the modes of wood fastening control, speed 1 control, and speed 2 control.

[0159] As shown in FIGS. 7-9, the user interface 42 may be configured to enable selection among at least a first speed setting and a second speed setting. The motor speed for a given motor speed setting may be a maximum no-load speed. As shown in FIG. 5, the user interface 42 may be configured to enable selection among at least a first speed setting, a second speed setting and a third speed setting, which may correspond to a maximum no-load speed of the motor 20 at a low speed, a medium speed, and a high speed, respectively. The motor speed may be controlled via a closed loop speed control in which a controller, such as a controller 40 (FIG. 4), controls a speed of the motor according to a sensed motor speed and the speed setting.

[0160] Referring to FIGS. 7-9, the switch 43b may allow the user to select among a first time setting , or Time 1, a second time setting , or Time 2, a third time setting , or Time 3, and a fourth time setting “, or Time 4. That is, the time setting select button 43b may be configured to operate by cycling through the first time setting, the second time setting, the third time setting, and the fourth time setting.

[0161] FIG. 10 shows an example data structure in the form of a look-up table 1000 that may be an example data structure for use with the example user interfaces 42 shown in FIGS. 7-9.exampleor Speed 2 The controller 40 may be configured to determine a fastening torque setting according to values stored in the look-up table 1000. For example, when the speed 2 control mode or Speed 2 and the fourth time setting , or Time 4 are selected, the controller 40 may determine, according to the look-up table 1000, that the desired fastening torque setting is desired torque 8. FIG. 10 shows 4 (rows) by 2 (columns) look-up table for four time settings (shown in, for example, FIGS. 7-9) and for two speed control modes (shown in, for example, FIGS. 7-9) by way of example. A number of time settings and speed control modes may vary, for example, according to a given application an example impact power tool such as impact power tool 10 is configured for.

[0162] The user interface 42 may enable selection among a plurality of time settings. For example, five time settings are shown and described above with respect to FIG. 5, while four time settings are shown and described above with respect to FIGS. 7-9. In an example, the plurality of time settings may be indicated by one or more light emitting elements. In an example, a selected time setting may be presented as a progression of light emitting elements corresponding to a duration of time. When no light emitting elements are on, a time setting hasP-US-TN-2023-0197-PCT - 0029-128W01 not been selected and the controller 40 will not apply a time duration limit for impacting. In an example, any one of a plurality of time settings may be selected in variable combination with any one of a plurality of speed settings to deliver a wide range of fastening torque settings. As described below, a time duration for performing an impact operation may not be equal to a user-selected time setting. In an example, a time duration and a time setting may be correlated to one another.

[0163] FIG. 11 A shows an example user interface 42 for use in a rotary impact power tool that is configured to set concrete screw anchors, the example user interface 42 incudes one or more indicators 45 for indicating different types of anchors (e.g., SD1 or SD2 / 4 / 6) and one or more indicators 49 for indicating different sizes of anchors (e.g., 3 / 8 inch , ’A inch, 5 / 8 inch, etc.). That is, for an impact power tool that is designed specifically for installing certain concrete anchors, the user can select the type of anchor to be installed (e.g., SD1 or SD2 / 4 / 6) and select the size of anchor (3 / 8 inch, 1 / 2 inch, or 5 / 8 inch).

[0164] As shown in FIG. 11 A, the switch 43a may allow the user to select among different types of anchors (e.g., wedge anchors). For example, in the illustrated example, different types of the wedge anchors may include wedge anchor type 1 , or SD 1 ,”, wedge anchor type 2, or SD2, wedge anchor type 3, or SD4, wedge anchor type 4, or SD6, etc. In an example, the wedge anchor types SD2 / 4 / 6 may be indicated by a single indicator 45 that indicates a selected anchor type according to one of a plurality of light characteristics, such as one of a plurality of light intensities, light emitting patterns or color. In an example, the user interface may include two or more indicators 45 for indicating a selection of the wedge anchor types SD2 / 4 / 6. In an example, the switch 43a may allow the user to select among different types of wedge anchors sizes (e.g., 3 / 8 inch, 1 / 2 inch, or 5 / 8 inch). In an example, the user interface may include two or more switches 43 a for selecting between different types of wedge anchors sizes (3 / 8 inch, 1 / 2 inch, or 5 / 8 inch). FIG. 1 IB shows an example data structure in the form of an example look-up table 1100 that includes 4 (rows) and 3 (columns) for four wedge anchor types (SD1, SD2, SD4, or SD6) and three wedge anchor sizes (3 / 8 inch, 1 / 2 inch, or 5 / 8 inch). In an example, the number of wedge anchor sizes and the number of wedge anchor types may vary. In an example, the switch 43a may allow a user to select among anchor types and sizes other than the example types and sizes shown in FIG. 11 A.

[0165] The example look-up table 1100 includes a plurality of desired torque settings, e.g., desired torque settings 1-12 that correspond to combinations of selected anchor size andP-US-TN-2023-0197-PCT - 0029-128W01 selected anchor type. Each combination of anchor type and size may be associated with a specific fastening torque value / setting of the example look-up table 1100. The example lookup table 1100 or other data structure may be stored in memory located on the tool 10 or located in a remote device in communication with the tool 10 such that the controller 40 may determine a desired torque according to a selected anchor type and anchor size. The controller 40 control the motor speed and a time duration of an impact operation to achieve a desired preset torque for a selected type and size of concrete anchor.

[0166] Other user interfaces may be pictorial, whereby pushing a picture of a thick bolt indicates to the tool to use a specific high fastening torque, whereas pushing a picture of a thin bolt indicates to the tool to use a specific low fastening torque.

[0167] FIG. 12 shows an example user interface 42 that may include an element 120 for selecting a wood driving mode and an element 122 for selecting an LED control. The user interface 42 may also include an element 124 for selecting speed 1 and selecting among a plurality of levels for speed 1 and an element 126 for selecting speed 2 and selecting among a plurality of levels for speed 2. The example user interface may also include an indicator 128 in the form of a bolt, in which each thread 128a-128f indicates a different level. In an example, element 124 or element 126 may be repeatedly selected to cycle through the plurality of levels in combination with a selected speed. The selected speed may be indicated by a light indication at element 124 for speed 1 or a light indication at element 126 for speed 2. The selected level may be indicated by a light indication at one or more of threads 128a-128f. For example, for speed 1, the element 124 may be repeatedly pressed / actuated which may increment the light indications displayed in the bolt indicator 128 with higher levels corresponding to a greater number of the threads 128a-128f illuminated. For speed 2, element 126 may be repeatedly selected to cycle through a plurality of levels in combination with speed 2. As the speed 2 element 126 is repeatedly selected, a torque level or time level may increase in combination with additional threads 128a-128f being illuminated to provide an indication of a higher torque level or time level.

[0168] FIG. 13 A shows an example user interface 42 which may include a mode select button 43 a for selecting among a plurality of modes that may include a wood fastening control mode, a speed 1 , a speed 2 , and a speed 3 . The user interface 42 may include one or more indicators 45 for indicating the selected mode, for example, indicator 13a for indicating the wood fastening control mode, and indicators 134, 135, and 136 for indicating speed 1, speedP-US-TN-2023-0197-PCT - 0029-128W012, and speed 3, respectively. In an example, the speed 1 may include from 10000 RPMto 14999 RPM; the speed 2 may include from 15000 RPM to 19999 RPM; and the speed 3 may include more than 20000 RPM. In its default state, there is no time control limit applied to the speeds 1, 2 and 3. That is, push button 43a can be pressed to cycle through speeds 1, 2, and 3 with the selected speed number being illuminated. Push button 43b can be pressed to cycle through time or level values, which may not be an actual time duration of impacting but rather an approximation or qualitative selection that may be used, together with a selected speed, to determine a selected torque or desired torque, or torque setting, or target total impact energy, from which a time duration for an impact operation may be determined, for example, from a look-up table as discussed above. The selected time may be indicated by illuminating one or more of the bands on the bolt icon 45.

[0169] In one example, one press of the button 43b may be torque level 1, one more press of the button 43b may be torque level 2, and so on. In one example, one press of the button 43b may be time level 1, one more press of the button 43b may be time level 2, and so on. This may be presented to the user in the form of a blink pattern. For example, as shown in FIG. 13B, if the user selects the time level 3, three blinks will be displayed to the user followed a blank / stop. This blink pattern then repeats. Similarly, if the user selects the time level 5, five blinks will be displayed to the user followed a blank / stop. This blink pattern then repeats. In an example, the blink pattern may be provided by one or more of the indicators 45. In an example, the blink pattern is provided by one of indicators 134-136 corresponding to the speed that has been selected.

[0170] Referring to FIGS. 13A and 13B, when the mode select button 43a is pressed / selected, one of the indicators 45 flashes (e.g., at a rate of 1Hz). With a precision control mode selected, in forward, once the first impact is detected, the motor will be stopped or power to the motor is reduced for a predetermined period of time (e.g., 0.5 seconds to 2 seconds) after which motor power is restored and impacting is resumed. In reverse, the speed will be reduced when it is detected that the fastener has broken free. The user may have the capability to add a time control to the precision control function with the following scheme. The user long presses the mode select button 43a for a duration (e.g., 2 seconds), at which time a light indicator, such as the light unit 38 (FIG. 1) will flash once and one or more of the indicators 45 will flash rapidly (e.g., at a rate of 4Hz) to indicate the tool 10 has entered a programming mode. The user releases the mode select button 43a and with each subsequent short button press, programs the time limit where one press corresponds to, e.g., one second ofP-US-TN-2023-0197-PCT - 0029-128W01 additional time of impacting. To set the time, after the final short button press, the user will long press the mode select button 43a for 2 seconds to lock in the accumulated time of impacting. The light unit 38 will flash to indicate the tool 10 has left programming mode. One more of the indicators 45 will now flash at a slower rate (e.g., 2 Hz) to indicate it is in a programmed state with the user set time control. Additionally, the 2 Hz rate will flash for a count of the time control seconds set and then have a pause of Is before repeating the flash pattern, which is illustrated in Figure 13B (i.e., time control programmed blink pattern). To reset the tool 10 to its default precision control function with no time control limit, the user will long press the mode select button 43a for 2 seconds and then again, with no short button presses, press the mode select button 43a again for 2 seconds (i.e., no time programming = default).

[0171] In the time control programmed state, the tool 10 may perform the following:(a) perform precision rundown in forward until impacting is detected and pause for 0.5 seconds;(b) impact at the set speed for the set time control value; (c) on completion of the time control limit, the light unit 38 will flash once; and (d) if the user releases the trigger before the time control limit, the tool will flash the light unit 38 at a rate of 4 Hz for a period of 2 seconds and be inoperable during that period.

[0172] The range of programmable time control values may be from 1 second to 10 seconds in increments of 1 second. In an example, no time control is applied in reverse. The tool 10 will be inoperable in programming mode. In an example, the time control can be applied to all of the speed modes, but in some examples, may not be applied to a wood fastening control mode. In an example, the programmed time control limits may be stored and applied when the power tool 10 is turned off and on. The state of charge of the battery may or may not be considered in adjusting for the time control limit.

[0173] Aspects of the present disclosure include systems configured to approximate a fastening torque setting using a power tool such as the rotary impact tool 10, such as an impact driver or impact wrench, without requiring any additional sensors not typically incorporated in an impact driver or wrench and that has minimal additional cost and complexity. For example, power tools of the present disclosure may be configured to approximate a fastening torque setting without the use of a torque sensor.

[0174] Aspects of the present disclosure include power tools with controllers that are configured to implement a fastening torque control algorithm. Fastening torque controlP-US-TN-2023-0197-PCT - 0029-128W01 algorithms of the present disclosure may be implemented using motor commutation sensors such as, for example, rotor position sensors or motor speed sensors, such as one or more Hall sensors, and / or a current sensing circuit. A power tool such as the electric rotary impact tool 10 may include motor control software that accurately controls the tool 10 to deliver a torque or total impact energy that approximates a predetermined fastening torque or a user selected fastening torque. The existing Hall sensors and current sensing circuit are used for commutating a motor and sensing motor position and speed. In an example, in response to receiving 1) a user input indicative of a target fastening torque value / setting, and 2) an output generated by a tool’s electric motor 20 rotor position sensor(s) and / or an output generated by a current sensor forming part of the tool’s motor control system, the controller 40 may be configured to control the electric rotary impact tool 10 to secure a fastener to the selected fastening torque. The present disclosure may be configured to approximate a user selected fastening torque using only the motor commutation sensors / parameters.

[0175] Fastening torque may be a function of multiple factors such as shown in Equation (1) below. These factors may include impact rate, impact energy per impact, and time impacting. The fastening torque may be interchangeably referred to as output torque.Fastening torque = / (impact rate, impact energy per impact, time impacting)Equation (1)

[0176] Each of the factors (i.e., impact rate, impact energy per impact, and time impacting) are described in detail below.

[0177] The impact rate may be interchangeably referred to as impacts per minute (IPM) or number of impacts per minute (IPM). Impact rate is a function of motor speed, and battery state, where the battery state may include one or more of open circuit voltage (OCV), state of charge (SOC), battery pack resistance (DCR), battery pack impedance, battery pack age, battery pack type (ID), and battery pack temperature as shown in Equation (2) below.Impact Rate = / (motor speed, battery state, such as open circuit voltage (OCV), battery pack resistance (DCR), battery pack temperature, etc.)Equation(2)P-US-TN-2023-0197-PCT - 0029-128W01

[0178] The impact rate may be determined directly by monitoring motor speed such as, for example, by monitoring (a) output from the Hall sensors of the tool’s electric motor 20 and / or (b) output generated by a current sensor in the tool’s motor control module.

[0179] The impact rate may be determined from the output of the Hall sensors or from the current sensors, which can be used to determine back-EMF signals generated by the motor, for example, if the motor is sensorless, or does not include a rotor position sensor. The output of the Hall sensors or current sensors may indicate periodic accelerations and decelerations of the motor 20 that are caused by the impact mechanism applying rotational impacts on an output member of the power tool 10 when a torque at the output member reaches or exceeds a trip torque. FIG. 14 is a graph of rotor speed versus time according to an output of a motor speed sensor such as a Hall sensor. Impacting events can be seen in FIG. 14 via the periodic deceleration / acceleration in the speed of the motor 20. That is, FIG. 14 shows periodic accelerations and decelerations of the impact power tool’s electric motor 20 based on the Hall sensor output that are caused by rotary impacts imparted by the impact power tool 10 in use.

[0180] The impact rate alternatively may be determined from an output of a current sensor. The impact power tool 10 may further comprise the current sensor configured to detect an amount of electric current drawn by the motor 20 to drive the motor 20. The output of the current sensor may include periodic changes in the current drawn by the motor 20 that are caused by the impact mechanism applying rotational impacts on an output member of the power tool 10 when a torque at the output member reaches or exceeds a trip torque. FIGs. 15A and 15B show impact detection via current sensing / sensor when the power tool is impacting. FIG. 15A and 15B show bus current versus time during an impact operation, in which the bus current signal contains variations or current spikes that correspond to impacts, or the hammer striking the anvil. FIG. 15A shows a first case in which the bus current is hitting a current clip, which results in relatively constant peak values. FIG. 15B shows a second case at a lower current where the bus current is not hitting a current clip and there are additional variations in the current associated with phase change or sector change. The controller 40 may be configured to detect the initiation of impacting by monitoring the motor speed and / or bus current signal and detecting the change in the motor speed and / or current signal due to impacting.

[0181] Impact energy is a function of rotor speed and a constant as shown in Equation (3) below. That is, the impact energy is a function of the impact power tool’s average motor speed during impacting and a constant, where the constant is particular to the mechanicalP-US-TN-2023-0197-PCT - 0029-128W01 characteristics of the impact mechanism of a specific rotary impact tool. Such a constant depends on multiple mechanical characteristics such as sizes and mass of impact components, inertia of the hammer, spring constant, etc. which differ from a tool model to other tool model. It can be assumed that all tools of the same model number have the same impact energy constant. Based on the motor speed (that can also be determined from the Hall sensor output and / or the current sensor output as discussed above) and the constant, the tool’s controller 40 may be configured to determine the impact energy transmitted by the power tool to a fastener during an impact operation. The impact energy may interchangeably be referred to as impact energy per impact. The impact energy per impact can be approximated from the existing Hall motor commutation sensors since they can directly sense motor speed and with the impact mechanism properties being known.Impact Energy or Impact Energy per Impact = / (rotor speed, constant)Equation(3)

[0182] The speed sensor may be configured to detect a speed of the motor 20 and output the sensed motor speed. The speed sensor may be a rotational speed sensor. In one example, a separate rotational speed sensor may not be used. Instead, the Hall sensor signals may be used to determine motor speed. The sensed motor speed may be at least one of an average motor speed, a peak motor speed, or a peak-to-peak motor speed, determined during a sensed time period. The speed sensor may include the Hall sensors that magnetically sense magnetic flux of a magnet as a rotor is rotated, such as a rotor position sense magnet located on the motor shaft. The controller 40 may be configured to measure an angular position of the rotor based on information from the Hall sensors and to control a commutation of the motor 20 according to the measured angular position.

[0183] FIG. 16 conceptually shows how battery state can influence impact energy. The Y axis shows actual rotor speed, measured in RPM, of the motor 20. The X axis shows torque measured in, for example, N m at the output member rotated by the motor. FIG. 16 shows a trip torque 1602, where the rotary impact mechanism transitions from a continuous rotary mode to an impact mode. Motor curve 1604 is a motor speed versus torque curve for a power tool with a first battery having a first state, for example, a 5 Ah at 20Vwith a low battery impedance condition and when the battery' is fully charged, such as a DEWALT POWERSTACK DCBP52020V MAX 5 Ah Battery with a full charge. Motor curve 1606 is a motor speed versusP-US-TN-2023-0197-PCT - 0029-128W01 torque curve for a power tool with a second battery having a second state, for example, a 5.0Ah at 20V with nominal impedance battery condition and when the battery is fully charged, such as a DEWALT DCB205 20V MAX 5 Ah Battery with a full charge. Motor curve 1608 is a motor speed versus torque curve for a power tool with the second battery at a third state, for example, a 5.0Ah at 20V at nominal impedance battery condition and at a low state of charge (SOC) battery' condition, such as the DEWALT DCB205 20V MAX 5 Ah Batery with a low charge. Comparing curve 1606 and curve 1608, the lower SOC of the second battery results in the trip torque 1602 occurring at a lower motor speed, which according to Equation 3 will result in less impact energy per impact. For the same duration of an impact operation, a total impact energy (TIE) imparted by the power tool during the impact operation may, therefore, be less when the SOC of the battery is less and the battery state may influence the TIE delivered by the power tool to a fastener and the resulting torque the fastener is set to. Comparing curve 1606 associated with the second battery and curve 1604 associated with the first battery, the first battery has a greater amount of available energy or power than the second battery, which may result in a higher motor speed before the trip torque 1602 is reached, thereby resulting in a greater impact energy per impact.

[0184] Furthermore, the impact energy may be measured in the tool 10 while impacting under load without additional sensors as shown in FIG. 17. The speed can also be controlled via closed loop speed control. FIG. 17 shows dynamic rotor speed measurement while impacting. This measurement could be defined by an average speed, a maximum speed, or a minimum speed. With reference to FIG. 16 described above, curve W1 corresponds to the speed at which the trip torque is reached for motor curve 1604. W2 corresponds to the speed at which the trip torque is reached for motor curve 1606. W3 corresponds to the speed at which the trip torque is reached for motor curve 1608.

[0185] FIG. 18 shows an example output torque 1802 versus time. As the impact tool 10 impacts over time, the tool output torque increases and then plateaus at a maximum tool output or fastening torque. FIG. 18 shows output torque vs time. The output torque measured in, for example, N m of the tool 10 is shown on the Y-axis of the graph in FIG. 18 and the time (measured in seconds is shown on the X-axis of the graph in FIG. 18. That is, how quickly the torque climbs and how high the torque climbs are a function of both the impact rate and the impact energy per impact. Variations of this curve in FIG. 18 with specific impact rate and impact energy per impact vs. time may collected.P-US-TN-2023-0197-PCT - 0029-128W01

[0186] In an example, time impacting or impact duration refers to how long a fastener is subjected to intermittent rotary impacts or a duration of an impact operation. In other words, during a fastener tightening operation, time impacting or impact duration may be the duration of time that the impact mechanism operates in an impact mode of operation and applies rotational impacts to the output member. In an example, a controller may determine time impacting or impact duration according to a user-defined value either directly via a time input or indirectly via a torque setting.

[0187] Based on the Equation (1), the fastening torque can be determined or at least closely approximated according to the time impacting, impact rate and impact energy per impact. As shown in and described in detail above in Equation (3), the impact energy per impact is a function of motor speed. Both impact rate and the impact energy per impact may be measured from the existing sensors of the impact tool 10. Therefore, the torque is a function of the impact rate, the impact energy per impact, and the time spent impacting.

[0188] The impact tool 10 may be characterized to populate a data structure such as a look-up table based on, for example, the impact rate, the impact energy per impact, and the desired tool output torque. The impact rate and the impact energy per impact may vary based on or be a function of battery information such as the type of battery pack and battery state information such as the state of charge (SOC) of the battery, the battery temperature, etc. The data structure may include empirically derived values and / or theoretically calculated values that provide one or more control parameters for achieving a desired total impact energy or torque for a given set of input values. The empirical data may include variations corresponding to a large collection of empirical data. During an empirical data collection, the impact rate and the impact energy per impact can be varied by controlling the motor 20 at a plurality of constant value target speeds using closed loop pulse width modulation (PWM) control to achieve a more expansive look-up table capturing more combinations of input parameters. When the user selects a desired fastening torque, the controller 40 may be configured to look up the duration of impacting that will be needed to achieve the desired fastening torque for a given impact rate and impact energy per impact. FIG. 19 shows an example look-up table for determining a time duration for performing intermittent rotational impacts according to a torque setting. When the user selects a desired fastening torque, the controller 40 may be configured to run at a predetermined speed (either as selected by user or as selected by the controller 40) until detection of a first impact and then adjust the motor speed and duration needed to achieve the desired torque based on the look-up tables as shown in FIG. 19. Alternatively, the user mayP-US-TN-2023-0197-PCT - 0029-128W01 select a speed (e.g., speed 1, 2, or 3) and time (e.g., time 1, 2, 3, 4, or 5), and the controller may use a look-up table similar to the one in Fig. 6 to determine a desired fastening torque. Once the desired fastening torque is determined from the table in Fig. 6, the controller can use the look-up tables in Fig. 19 to determine an actual time duration for impacting. In the example shown in FIG. 19, the Speed 1, Speed 2, and Speed 3 refer to a motor control speed, for example, a no-load closed-loop motor control constant RPM value. During use, the motor controller may control the motor to rotate at a constant RPM according to speed 1, speed 2, or speed 3. When the power tool begins driving a fastener, the actual RPM may begin to vary from the target RPM as the torque on the fastener begins to increase.

[0189] Given the interrelationship between the above discussed function parameters, for a particular impact power tool it is possible to empirically generate a series of look-up tables, like the one as shown in FIG. 19 for example, that provide a time that impacting should be performed in order to achieve a given torque setting (e.g., as pre-set or selected by a user) based on the sensed impact rate (e.g., determined from the motor Hall sensor output or the current sensor output) or the sensed or controlled motor speed (e.g., also determined from the motor Hall sensor output or the current sensor output). Then, in use, if a user would like to secure a given fastener type to a predetermined torque, say Tx, or using a selected speed and time, the impact power tool’s controller may be configured to use look-up tables that correspond to the selected fastener, torque Tx, or total target impact energy (TTIE), speed, and / or time, sense the impact rate or sense the average motor speed, and allow the impact mechanism to impact for the time period set forth in a look-up table such as the example table shown in FIG. 19.

[0190] In an example, the controller 40 of the impact power tool 10 may be configured to receive a signal that corresponds to a fastening torque setting or torque setting. The controller 40 may be configured to determine when the impact mechanism 24 starts applying rotational impacts to the output member 26 and to determine a time duration during which impacting is to be performed based on a motor speed and the fastening torque setting, where the motor speed may be a target speed or speed setpoint, such as a no-load RPM corresponding to a speed setting. Or the motor speed may be an actual motor speed determined from a speed sensor or motor shaft position sensor.

[0191] The controller 40 may be configured to allow power to be delivered to the motor 20 for the determined time duration and then to reduce or shut off power to the motor 20 at theP-US-TN-2023-0197-PCT - 0029-128W01 end of the time duration. The signal may include both a user input of a target torque and a user input of a time and speed, as a proxy for a target torque (or some other proxy for torque). The selected speed setting may correspond to a maximum no-load speed of the motor 20.

[0192] As shown in FIG. 19, the present patent application may include look-up tables for desired torques of A, B, C, and D ft-lbs. The desired torque may interchangeably referred to as fastening torque setting. As described herein, the desired torque setting may also be, or correspond to, a target total impact energy (TTIE). In an example, the fastening torque setting of D may be 1000 ft-lbs; the fastening torque setting of C may be 750 ft-lbs; the fastening torque setting of B may be 500 ft-lbs; and the fastening torque setting of A may be 250 ft-lbs. In an example, the fastening torque setting of D may be 100 ft-lbs; the fastening torque setting of C may be 75 ft-lbs; the fastening torque setting of B may be 50 ft-lbs; and the fastening torque setting of A may be 25 ft-lbs. That is, the fastening torque setting A may be lower than the fastening torque setting B, which may be lower than the fastening torque setting C, which may be lower than fastening torque setting D. The fastening torque setting D may be higher than the fastening torque setting C, which may be higher than the fastening torque setting B, which may be higher than fastening torque setting A. In an example, the fastening torque setting of D may correspond to a TTIE of approximately 60 joules; the fastening torque setting of C may may correspond to a TTIE of approximately 45 joules; the fastening torque setting of B may may correspond to a TTIE of approximately 30 joules; and the fastening torque setting of A may may correspond to a TTIE of approximately 15 joules. In an example, the fastening torque setting of D may correspond to a TTIE of between approximately 200 joules and approximately 100 joules; the fastening torque setting of C may correspond to a TTIE of between approximately 150 joules and approximately 50 joules; the fastening torque setting of B may correspond to a TTIE of between approximately 100 joules and approximately 20 joules; and the fastening torque setting of A may correspond to a TTIE of between approximately 50 joules and approximately 5 joules.

[0193] The example look-up table may include a plurality of motor speeds, and time durations for each combination of motor speed or the impact rate and desired torque.

[0194] The plurality of impact rates may include an impact rate 1, an impact rate 2, and an impact rate 3. For example, the impact rate 1 may range between 1000 IPM and 1999 IPM; the impact rate 2 may range between 2000 IPM and 2999 IPM; and the impact rate 3 may be more than 3000 IPM. That is, the impact rate 1 is lower than the impact rate 2, which is lowerP-US-TN-2023-0197-PCT - 0029-128W01 than the impact rate 3. In other words, the impact rate 3 is higher than the impact rate 2, which is higher than the impact rate 1. Although only three impact rates are shown in the look-up table of FIG. 19, the number of impact rates may vary depending on the applications of the tool.

[0195] The plurality of motor speeds may include a motor speed 1, a motor speed 2, and a motor speed 3. For example, the motor speed 1 may range between 10000 RPM and 14999 RPM; the motor speed 2 may range between 15000 RPM and 19999 RPM; and the motor speed 3 may be more than 20000 RPM. That is, the motor speed 1 is lower than the motor speed 2, which is lower than the motor speed 3. In other words, the motor speed 3 is higher than the motor speed 2, which is higher than the motor speed 1. Although only three motor speeds are shown in the look-up table of FIG. 19, the number of motor speeds may vary depending on the applications of the tool.

[0196] In an example, the time duration for the impact rate 1 or motor speed 1 for the desired torque of D may be time duration 4 (e.g., 3.9 seconds); the time duration for the impact rate 2 or the motor speed 2 for the desired torque of D may be time duration 8 (e.g., 3.2 seconds); and the time duration for the impact rate 3 or the motor speed 3 for the desired torque of D may be time duration 12 (e.g., 2.5 seconds).

[0197] In an example, the time duration for the impact rate 1 or the motor speed 1 for the desired torque of C may be time duration 3 (e.g., 2.9 seconds); the time duration for the impact rate 2 or the motor speed 2 for the desired torque of C may be time duration 7 (e.g., 2.2 seconds); and the time duration for the impact rate 3 and the motor speed 3 for the desired torque of C may be time duration 11 (e.g., 1.5 seconds).

[0198] In an example, the time duration for the impact rate 1 or the motor speed 1 for the desired torque of B may be time duration 2 (e.g., 1.9 seconds); the time duration for the impact rate 2 or the motor speed 2 for the desired torque of B may be time duration 6 (e.g., 1.2 seconds); and the time duration for the impact rate 3 or the motor speed 3 for the desired torque of B may be time duration 10 (e.g., 0.5 seconds).

[0199] In an example, the time duration for the impact rate 1 or the motor speed 1 for the desired torque of A may be time duration 1 (e.g., 1.7 seconds); the time duration for the impact rate 2 and the motor speed 2 for the desired torque of A may be time duration 5 (e.g., 0.7 seconds); and the time duration for the impact rate 3 or the motor speed 3 for the desired torque of A may be time duration 9 (e.g., 0.05 seconds).P-US-TN-2023-0197-PCT - 0029-128W01

[0200] In an example, for a constant fastening torque setting, the time duration decreases as the motor speed increases. This pattern may be found in the example look-up table of FIG. 19. For example, for constant fastening torque setting (e.g., fastening torque setting D), the time duration decreases as the motor speed increases from the motor speed 1 (e.g., between 10000 RPM and 14999 RPM) to the motor speed 2 (e.g., between 15000 RPM and 19999 RPM) to the motor speed 3 (e.g., more than 20000 RPM). That is, the time duration 4 (e.g., 3.9 seconds) for the motor speed 1 is more than the time duration 8 (e.g., 3.2 seconds) for the motor speed 2, which is more than the time duration 12 (e.g., 2.5 seconds) for the motor speed 3.

[0201] As shown in FIG. 19, for a constant fastening torque setting, the time duration decreases as at least one of the impact rate or the motor speed increases. This pattern may be found in the example look-up table in FIG. 19. For example, for constant fastening torque setting (e.g., fastening torque setting D), the time duration decreases as at least one of the impact rate (e.g., impact rate 1 (e.g., between 1000 IPM and 1999 IPM), impact rate 2 (e.g., between 2000 IPM and 2999 IPM), or impact rate 3 (e.g., more than 3000 IPM)) or the motor speed (e.g., motor speed 1 (e.g., between 10000 IPM and 14999 RPM), motor speed 2 (e.g., between 15000 IPM and 19999 RPM), or motor speed 3 (e.g., more than 20000 RPM)) increases. In the look-up table in FIG. 19, for constant fastening torque setting (e.g., fastening torque setting D), the time duration 4 (e.g., 3.9 seconds) for the impact rate 1 or the motor speed 1 is more than the time duration 8 (e.g., 3.2 seconds) for the impact rate 2 or the motor speed 2, and the time duration 8 is more than the time duration 12 (e.g., 2.5 seconds) for the impact rate 3 or the motor speed 3. The same pattern may also be observed for each of the other constant fastening torque settings (e.g., fastening torque setting C, fastening torque setting B, and / or fastening torque setting A).

[0202] As shown in FIG. 19, for a constant fastening torque setting, the time duration increases as at least one of the impact rate or the motor speed decreases. This pattern may be found in the example look-up table in FIG. 19. For example, for constant fastening torque setting (e.g., fastening torque setting D), the time duration increases as at least one of the impact rate (e.g., impact rate 1 (e.g., between 1000 IPM and 1999 IPM), impact rate 2 (e.g., between 2000 IPM and 2999 IPM), or impact rate 3 (e.g., more than 3000 IPM)) or the motor speed (e.g., motor speed 1 (e.g., between 10000 IPM and 14999 RPM), motor speed 2 (e.g., between 15000 IPM and 19999 RPM), or motor speed 3 (e.g., more than 20000 RPM)) decreases. In the example look-up table in FIG. 19, for constant fastening torque setting (e.g., fastening torque setting D), the time duration 12 (e.g., 2.5 seconds) for the impact rate 3 and the motorP-US-TN-2023-0197-PCT - 0029-128W01 speed 3 is less than the time duration 8 (e.g., 3.2 seconds) for the impact rate 2 and the motor speed 2, and the time duration 8 is less than the time duration 4 (e.g., 3.9 seconds) for the impact rate 1 and the motor speed 1. The same pattern may also be observed for each of the other constant fastening torque settings (e.g., fastening torque setting C, fastening torque setting B, and / or fastening torque setting A).

[0203] As shown in FIG. 19, for a constant impact rate and a constant motor speed, the time duration decreases as the fastening torque setting decreases. The constant impact rate may include impact rate 1 (e.g., between 1000 IPM and 1999 IPM), impact rate 2 (e.g., between 2000 IPM and 2999 IPM), or impact rate 3 (e.g., more than 3000 IPM). The constant motor speed may include motor speed 1 (e.g., between 10000 IPM and 14999 RPM), motor speed 2 (e.g., between 15000 IPM and 19999 RPM), or motor speed 3 (e.g., more than 20000 RPM). For example, , for a constant impact rate (e.g., the impact rate 1) and a constant motor speed (e.g., the motor speed 1), the time duration 4 (e.g., 3.9 seconds) for the impact rate 1, for the motor speed 1, and the fastening torque setting D (e.g., 1000 ft-lbs) is more than the time duration 3(e.g., 2.9 seconds) for the impact rate 1, for the motor speed 1, and the fastening torque setting C (e.g., 750 ft-lbs). The time duration 3 is more than the time duration 2 (e.g., 1.9 seconds) for the impact rate 1, for the motor speed 1, and the fastening torque setting B (e.g., 500 ft-lbs). The time duration 2 is more than the time duration 1 (e.g., 1.7 seconds) for the impact rate 1, for the motor speed 1, and the fastening torque setting A (e.g., 250 ft-lbs). The same pattern may also be observed for each of combination of the impact rate and the motor speed across the fastening torque settings (e.g., fastening torque setting D, fastening torque setting C, fastening torque setting B, and / or fastening torque setting A).

[0204] As shown in FIG. 19, for a constant impact rate and a constant motor speed, the time duration increases as the fastening torque setting increases. The constant impact rate may include impact rate 1 (e.g., between 1000 IPM and 1999 IPM), impact rate 2 (e.g., between 2000 IPM and 2999 IPM), or impact rate 3 (e.g., more than 3000 IPM). The constant motor speed may include motor speed 1 (e.g., between 10000 IPM and 14999 RPM), motor speed 2 (e.g., between 15000 IPM and 19999 RPM), or motor speed 3 (e.g., more than 20000 RPM). For example, for a constant impact rate (e.g., impact rate 3) and a constant motor speed (e.g., motor speed 3), the time duration 9 (e.g., 0.05 seconds) for the impact rate 3, for the motor speed 3, and the fastening torque setting A (e.g., 250 ft-lbs) is less than the time duration 10 (e.g., 0.5 seconds) for the impact rate 3, for the motor speed 3, and the fastening torque setting B (e.g., 500 ft-lbs). The time duration 10 is less than the time duration 11 (e.g., 1.5 seconds)P-US-TN-2023-0197-PCT - 0029-128W01 for the impact rate 3, for the motor speed 3, and the fastening torque setting C (e.g., 750 ft-lbs). The time duration 11 is less than the time duration 12 (e.g., 2.5 seconds) for the impact rate 3, for the motor speed 3, and the fastening torque setting D (e.g., 1000 ft-lbs). The same pattern may also be observed for each of combination of the impact rate and the motor speed across the fastening torque settings (e.g., fastening torque setting D, fastening torque setting C, fastening torque setting B, and / or fastening torque setting A).

[0205] In an example, the controller 40 may be configured to receive one or more signals that correspond to a user selected speed setting and a user selected time setting. The controller 40 may be configured to determine when the impact mechanism 24 starts applying rotational impacts to the output member 26 and to determine a time duration during which impacting is to be performed based on a sensed impact rate, and / or a sensed motor speed, the speed setting, and the time setting. The speed setting may correspond to a no-load motor speed and the controller 40 may be configured to deliver power to the motor 20 to achieve the no- load motor speed. The time duration may be determined from a data structure accessible in memory such as a look-up table that is based on the sensed impact rate or the sensed motor speed or a speed setting, and the time setting.

[0206] The fastening torque setting may comprise a predetermined fastening torque setting. The fastening torque setting may comprise a user selected speed setting and a user selected time setting. The fastening torque setting may comprise a user selected fastening torque setting.

[0207] In the present patent application, the desired fastening torque setting may be selected by a user using the user interface 42. The user interface 42 may be configured for enabling the user to either directly or indirectly select a desired fastening torque setting. The user interface 42 is described in detail in the discussions above.

[0208] A direct interface where the user inputs a desired torque setting, whether by cycling a button to show a number of bars / indicators or via a numeric input from the user. In an example, the controller 40 does not control the motor speed; it simply measures the impact rate and / or the impact energy per impact and / or the motor speed and / or battery information that may include battery state and adjusts time impacting or the time duration of impacting. In another example, the controller 40 does control the motor speed; the controller may measure or determine the impact energy per impact to perform a closed loop control, for example, when using a fixed impact energy per impact value. For example, if the desired torque is on the lowerP-US-TN-2023-0197-PCT - 0029-128W01 range of the selectable settings, the motor no-load speed may be lowered via pulse width modulation (PWM) in order to better control the torque and provide more precision. For example, the time duration 9 on the desired Torque = 250 ft-lbs is relatively short which could make it more difficult to control. Rather, the motor speed may be lowered to effectively achieve somewhere in the range of time duration 5.

[0209] In an example, a user may input information that is directly indicative of a target fastening torque setting. There are many ways in which a user may input information indicative of a selected fastening torque setting. This may be a specific value e.g. 1, 2 or 3 but need not necessarily be a specific torque value, nor does the user interface need to display a number. For example, a user may press a button to scroll through a plurality of levels, such as “low” > “medium” > “high” settings, A > B > C settings, or a series of icons, each of which is associated with a specific torque value in the tool’s memory.

[0210] In one example, the durations 1 to 12 (as shown in FIG. 19) may have a linear pattern. In another example, the durations 1 to 12 may not have a linear pattern. For example, the durations 1 to 12 may follow an exponential (curve) pattern or may have a non-linear pattern. FIG. 20 shows an example graph of desired torque versus combinations of speed settings and time settings. The desired total output torque, measured in Foot-Pounds (Ft-Lbs) of the tool 10 is shown on the Y-axis of the graph in FIG. 20 and combinations of a time setting, measured in seconds and a speed setting , measured in RPM are shown on the X-axis of the graph in FIG. 20. As can be seen from FIG. 20, in an example, there may be overlap in the desired torque between two speed settings where a higher speed with a lower time corresponds to a lower desired torque setting than a lower speed with a higher time. In the example shown in FIG. 20, the power tool has a finer control of desired torque over the lower torque settings and more granular control of torque at the higher torque setting, with 9 combinations of speed and time (speed 1, time 1 to speed 2 time 3) across torques less than 100 ft-lbs, 5 combinations of speed and torque settings between 100 ft-lbs and 300 ft-lbs (speed 3, time 2 to speed 3, time 3) and two combinations of speed and torque settings between 300 ft-lbs and 500 ft-lbs (speed 3, time 4 and speed 5, time 5).

[0211] In another example, a direct interface may be used where the user selects a desired torque via a multi-button selectable matrix in which the user selects a motor speed setting and a time setting as shown and described in detail in FIGS. 5-13B above. Based upon the user's selection, a desired fastening torque setting is then determined and motor no-loadP-US-TN-2023-0197-PCT - 0029-128W01 speed is set. The impact rate and / or the impact energy per impact and / or the motor speed may be used to determine a time duration to achieve a desired fastening torque setting. The user may establish a time setting selection to achieve a desired fastening torque setting based on an advertised torque (or application centric matrix). The controller 40 may then adjust the time duration for impacting to achieve the desired fastening torque result.

[0212] In an example, a method for operating the impact power tool 10 having the impact mechanism 24 configured to be driven by the motor 20, the impact mechanism 24 configured to rotationally drive the output member 26 when a torque on the output member 26 is less than the trip torque and to apply rotational impacts to the output member 26 when the torque on the output member 26 reaches or exceeds the trip torque.

[0213] The method may comprise receiving a user input of a fastening torque setting; determining when the impact mechanism 24 starts applying rotational impacts to the output member 26; determining an impact rate of the impact mechanism 24; determining a speed of the motor 20; determining a time duration for impacting based on (a) the determined impact rate, (b) the determined motor speed; and (c) the fastening torque setting; and delivering power to the motor 20 for the time duration and then reducing or shutting off power to the motor 20 at the end of the time duration.

[0214] Although the terms first, second, third, etc. may be used herein to describe various control modes, speeds, time settings, etc., these modes / settings, speeds, time settings, should not be limited by these terms. These terms may be only used to distinguish one control mode, speed, time setting from another control mode, speed, time setting. Terms such as first, second, and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first control mode, a first speed, a first time setting discussed above could be termed a second control mode, a second speed, a second time setting, respectively without departing from the teachings of the example examples.

[0215] The impact power tool 10 may have greater or fewer number of modes / settings than those described above.

[0216] In an example, a power tool of the present disclosure may be configured to perform an impact operation until the power tool has delivered a torque, or total torque, or cumulative torque to a fastener that meets a target torque setting or target torque value or desired torque value. The impact operation may include intermittent impacts on an anvil by a hammer of an impact mechanism, such as intermittent impacts on the anvil 62 by the hammerP-US-TN-2023-0197-PCT - 0029-128W0156 of the impact mechanism 24 (FIG. 3). Each impact by the hammer imparts an impulse energy to the anvil, which is transmitted through the output member 26 to a fastener. During the course of an impact operation, the impact mechanism, therefore, applies a cumulative impact energy, or total impact energy (TIE) to the fastener. Aspects of the present disclosure include controllers, such as controller 40 (FIG. 4) that are designed and configured to control the motor 20 to apply a total impact energy that meets a target total impact energy (TTIE). A TTIE can be correlated to a torque setting as a function of fastener type. For example, a TTIE of A joules applied to fastener type 1 may result in the fastener 1 being fastened to a torque setting of X N-m, whereas the same TTIE of A joules applied to a different fastener 2 may result in the fastener 2 being fastened to a torque setting of Y N-m, that is different than the X N-m. The term torque setting or desired torque as used herein may, therefore, correspond to a TTIE for a specific fastener type. In some examples, two or more torque settings for two or more fastener types may correspond to substantially the same TTIE. By way of example, the desired torques A-D in example table 19 may have corresponding TTIE values, e.g., TTIE A, TTIE B, TTIE C, and TTIE D that result in the desired torque when the particular fastener type corresponding to the torque setting is used. If, for example, the desired torque A is selected for a different fastener type, the power tool 10 may still deliver the TTIE A to the fastener, but the corresponding fastening torque may be higher or lower than desired torque A due to the difference in the fastener type.

[0217] As described above in connection with Equation 3, the impact energy per impact is a function of actual motor speed, or sensed motor speed. The rotational speed of the impact mechanism 24, for example, the rotational speed or RPM of the hammer 56, as well as the impact rate or impacts per minute (IPM), are directly proportional to the actual motor speed, where the relationship is defined by the speed reduction ratio provided by the transmission 23. The impact energy per impact is greater at higher speeds and lower at lower speeds. Therefore, the total impact energy (TIE) is a function of the motor speed and the time impacting or a time duration of impacting. The total impact energy is directly related to the total torque or fastening torque.

[0218] As described above in connection with FIG. 16, the type of battery and state of the battery influences motor speed. For example, a lower energy battery may result in a lower motor speed, thereby requiring a longer impacting time duration to deliver the same total impact energy or torque. As shown in Equation 4 below, a target total impact energy, or TTIE can be defined as a function of a set motor speed or controlled motor speed (set speed) and aP-US-TN-2023-0197-PCT - 0029-128W01 set time duration (set time), where the set time duration is a duration of time to perform an impact operation at the set motor speed to achieve the target total impact energy. The set motor speed can be a motor speed associated with a speed setting, such as speed 1, speed 2, and speed 3 described above. The time duration can be a previously-determined or predetermined time duration that was determined, for example, during a calibration, for performing an impact operation at the set speed to achieve the TTIE.TTIE = f(A*set_speed, B*set_duration, actual speed, battery ID, battery state)Equation(4)

[0219] As shown in Equation 4, the TTIE can also be a function of an actual motor speed or sensed motor speed (actual speed). In some examples, the predefined actual speed may be the same as the predefined set speed. In some examples, the predefined actual speed may be different than the predefined set speed. For example, although the controller 40 may be controlling the motor 20 according to a set speed, such as 10,000 RPM, the actual speed of the motor when an impacting operation begins or during an impact operation may be different than the set speed. During use, the controller 40 may be configured to compare the sensed motor speed during impacting to the predefined actual speed.

[0220] In an example, the predefined actual speed, also referred to herein as a predetermined motor speed is an actual speed of the motor associated with the predefined set speed and predefined set duration. For example, the predefined set speed and predefined set duration may have been determined during a calibration procedure for a specified fastener to which the desired torque or torque setting will be applied and repeated. The predefined actual speed may be the actual speed of the motor during the calibration procedure. In an example, the predefined actual speed is the actual motor speed at the initiation or beginning of impacting. In an example, the predefined actual speed is a value that represents the actual motor speed during the impacting operation, such as an average value, a median value, or another statistical representation of the motor speed during impacting. In an example, the predefined actual speed is an array of motor speed values or a plurality of motor speed values, such as motor speed at initiation of impacting and one or more speeds at predefined times after initiation of impacting.

[0221] As shown in Equation 4, the TTIE can also be a function of battery information. The battery information, also referred to herein as predetermined battery information, canP-US-TN-2023-0197-PCT - 0029-128W01 include battery identification information (battery ID) which can indicate, for example, a type or size of battery pack, and battery state information (battery state), which may include any of a variety of battery state information that may be received at the controller, for example, from a battery management system or battery controller. Non-limiting examples of battery state information includes state of charge (SOC), impedance, resistance, temperature and age. During use, the controller 40 may be configured to compare the sensed battery information during impacting to the predefined battery ID and battery state values.

[0222] As shown in Equation 4, in an example, the determination of TTIE can include applying a scalar value, A, to the set speed value. The scalar value, A, can be equal to 1 when the sensed motor speed is approximately the same as the predefined actual speed value, the sensed battery ID is the same as the predefined battery ID value, and / or the sensed battery state is approximately the same as the predefined battery state value. The scalar value, A, can be greater than 1, thereby resulting in an increased motor speed during impacting, when the sensed motor speed is less than the predefined actual speed value, the sensed battery ID is different than the predefined battery ID value and indicates a lower power or energy is available from the battery, and / or the sensed battery state is different than the predefined battery state value indicating a lower power or energy is available from the battery, such as a lower SOC, a higher impedance, an older battery, or an off-nominal temperature, and the like.

[0223] The scalar value, A, can be less than 1, thereby resulting in a lower motor speed during impacting, when the sensed motor speed is greater than the predefined actual speed value, the sensed battery ID is different than the predefined battery ID value and indicates a higher power or energy or capacity is available from the battery, and / or the sensed battery state is different than the predefined battery state value indicating a higher power or energy or capacity is available from the battery.

[0224] As shown in Equation 4, in an example, the determination of TTIE can include applying a scalar value, B, to the set duration value. The scalar value, B, can be equal to 1 when the sensed motor speed is approximately the same as the predefined actual speed value, the sensed battery ID is the same as the predefined battery ID value, and / or the sensed battery state is approximately the same as the predefined battery state value. The scalar value, B, can be greater than 1, thereby resulting in a longer time duration of impacting, when the sensed motor speed is less than the predefined actual speed value, the sensed battery ID is different than the predefined battery ID value and indicates a lower power or energy or capacity isP-US-TN-2023-0197-PCT - 0029-128W01 available from the battery, and / or the sensed battery state is different than the predefined battery state value indicating a lower power or energy or capacity is available from the battery, such as a lower SOC, a higher impedance, an older battery, or an off-nominal temperature, and the like.

[0225] The scalar value, B, can be less than 1, thereby resulting in a shorter time duration of impacting, when the sensed motor speed is greater than the predefined actual speed value, the sensed battery ID is different than the predefined battery ID value and indicates a higher power or energy is available from the battery, and / or the sensed battery state is different than the predefined battery state value indicating a higher power or energy is available from the battery.

[0226] In an example, the controller 40 may be configured to compare the sensed motor speed to the predefined actual speed value, also referred to as a predefined motor speed, and dynamically adjust the time duration (set duration) during the intermittent rotational impacts according to the comparison. For example, in response to the actual motor speed dropping X% below the predefined motor speed during impacting, the controller 40 may dynamically increase the remaining amount of the time duration by Y% to account for the lower motor speed.

[0227] FIG. 21 provides a non-limiting example implementation of application of scalar values to the set speed and / or set time duration according to battery identification information. FIG. 21 includes a table 2102, a table 2104, and a table 2106. In the illustrated example, the scalar values are defined in data structures, for example, look-up tables, that define scalar values for ranges of TTIE, battery SOC, and battery type. In table 2102, the scalar values A1-A9 correspond to the scalar value A from Equation 4 and the scalar values B1-B9 correspond to the to the scalar value B from Equation 4. Table 2102 shows an example of applying a scalar value to both the set speed and the time duration according to a sensed battery ID (Pack ID 1, 2, 3), a sensed battery state information (SOC) and a target TTIE (between WWW joules and XXX joules). Tables 2104 and 2106 similarly illustrate scalar values for different TTIE energy ranges. In table 2104, values C1-C9 correspond to the scalar value A from Equation 4 and the scalar values D1-D9 correspond to the to the scalar value B from Equation 4. In table 2106, values E1-E9 correspond to the scalar value A from Equation 4 and the scalar values F1-F9 correspond to the to the scalar value B from Equation 4.P-US-TN-2023-0197-PCT - 0029-128W01

[0228] FIG. 21 is provided by way of example. In an example, a scalar value may be applied only to the set duration value and a value may not be applied to the set speed value. In an example, a scalar value may be applied only to the set speed value and a scalar value may not be applied to the set duration value. In an example, a scalar value may be applied to one or both of the set speed and the set time duration according to a sensed motor speed, where the sensed motor speed may be a sensed motor speed at the initiation of impacting and / or throughout an impact operation.

[0229] As shown in Equation 5 below, the TIE may be determined by finding the cumulative amount of impact energy.TIE = X Impact Energy Per ImpactEquation 5

[0230] As described above in connection with Equation 3, the impact energy per impact is a function of rotor speed and a constant value. The total impact energy (TIE) delivered by a power tool during an impact operation can, therefore, be determined by determining the impact energy at each impact according to the sensed motor speed at impact and integrating or adding the impact energies from each impact to find the total impact energy. In an example, a controller may be designed and configured to dynamically determine a cumulative impact energy during an impact operation according to a sensed motor speed during impacting and terminating the impact operation when the cumulative impact energy meets a target total impact energy (TTIE).

[0231] FIG. 22 is a flowchart of an example method 2200 of operating a power tool, such as the power tool 10. The example method 2200 may be performed by a controller, such as the controller 40. The example method 2200 may include, at block 2203, determining a time duration for performing intermittent rotational impacts according to a torque setting. The torque setting may be any of a variety of torque settings, including any of the torque settings disclosed herein, such as a desired torque or a target total impact energy (TTIE). In some examples, the torque setting may be determined according to a motor speed setting and a time setting, or torque level setting, or level setting, such as in the example table 600 (FIG. 6). The time duration may be a duration of time to perform an impact operation in order to transmit a total impact energy or a total torque that meets the torque setting. In an example, the time duration may be determined according to any of the methods disclosed herein, including by accessing a data structure, such as the example table shown in FIG. 19.P-US-TN-2023-0197-PCT - 0029-128W01

[0232] The example method 2200 may include, at block 2205, terminating the intermittent rotational impacts when a length of time after a start of the intermittent rotational impacts meets the determined time duration. In an example, a controller may determine the initiation of an impact operation according to any of the methods disclosed herein, such as according to a motor speed sensor signal, such as in the example shown in FIG. 14. The controller may reduce or terminate power to the motor when a duration of time after the determined beginning of the impact operation meets the determined time duration.

[0233] FIG. 23 is a flowchart of an example method 2300 of operating a power tool, such as the power tool 10. The example method 2300 may be performed by a controller, such as the controller 40. The example method 2300 may include, at block 2303, determining a modified motor speed by modifying a predetermined set motor speed according to a sensed motor speed and / or battery information. In an example, the predetermined set motor speed may correspond to the set speed values of FIG. 21 and the modified motor speed may correspond to the application of the scalar values A, C, or E from the example shown in FIG. 21. Block 2303 may include modifying the predetermined set motor speed when a sensed motor speed is above or below a predetermined actual motor speed as described above in connection with Equation 4. Block 2303 may include modifying the predetermined set motor speed when battery information, such as battery ID or battery state information are different than predetermined values as described above in connection with Equation 4.

[0234] At block 2305, the example method 2300 may include determining a modified time duration by modifying a predetermined time duration according to the sensed motor speed and / or the battery information. In an example, the predetermined time duration may correspond to the set duration values of FIG. 21 and the modified time duration may correspond to the application of the scalar values B, D, or F from the example shown in FIG. 21. Block 2305 may include modifying the predetermined time duration when a sensed motor speed is above or below a predetermined actual motor speed as described above in connection with Equation 4. Block 2305 may include modifying the predetermined time duration when battery information, such as battery ID or battery state information are different than predetermined values as described above in connection with Equation 4.

[0235] At block 2307, the example method 2300 may include applying intermittent rotational impacts at the modified motor speed, and at block 2309, terminating theP-US-TN-2023-0197-PCT - 0029-128W01 intermittent rotational impacts when a length of time after a start of the intermittent rotational impacts meets the modified time duration. In other examples, only block 2303 or block 2305 may be performed such that only the motor speed or only the time duration are modified rather than modifying both parameters.

[0236] FIG. 24 is a flowchart of an example method 2400 of operating a power tool, such as the power tool 10. The example method 2400 may be performed by a controller, such as the controller 40. The example method 2400 may include, at block 2403, determining a cumulative impact energy according to a number of rotational impacts and a sensed motor speed during the rotational impacts. In an example, block 2403 may be performed according to Equation 5. For example, block 2403 may be implemented by, during an impact operation, determining an impact energy of one or more impacts, for example, a plurality of impacts or substantially all of the impacts, or approximately all of the impacts, of an impact operation. The impact energy for a given impact may be determined according to a sensed motor speed, for example, according to Equation 3. In an example, block 2403 may include determining a number of impacts required to meet a target total impact energy according to a sensed motor speed.

[0237] At block 2405, the example method 2400 may include terminating the intermittent rotational impacts when the determined cumulative impact energy meets a target total impact energy, for example, by reducing or shutting off power to the motor or controlling the motor to a zero RPM speed. In an example, block 2405 may include terminating the intermittent rotational impacts when a number of impacts performed during an impact operation meets a determined number of impacts corresponding to a target total impact energy.

[0238] A target total impact energy (TTIE) as used herein may be directly related to a fastening torque setting or desired torque as described herein as set forth in Equation 6.Torque Setting = f(TIE, fastener type, material type)Equation (6)

[0239] As shown in FIG. 6, a torque setting for a power tool may be a function of the total impact energy as well as fastener type and the material type the fastener is driven in to, where the torque setting may be defined in units of N-m, the TIE may be defined in units of Joules, the fastener type may include a type and size of fastener, such as wood screw or concreteP-US-TN-2023-0197-PCT - 0029-128W01 screw and corresponding size information, such as shaft diameter and thread size, and material type may be any material type, such as wood or concrete.

[0240] FIG. 25 is a flowchart of an example method 2500 for determining one or more predetermined values for driving a fastener according to a torque setting. The example method 2500 may be performed as a calibration procedure for determining the predetermined values, also referred to herein as calibration parameters. The example method 2500 may include, at block 2503, setting an initial motor speed and time duration for driving a fastener type A into a material type B to a desired torque. At block 2505, the method may include driving the fastener type A into the material type B, where the driving includes controlling the motor at the motor speed set at block 2503 and performing an impact operation for a time duration equal to the time duration set at block 2503.

[0241] At block 2507, the example method may include recording one or more operating parameters of the tool during the impacting operation of block 2505. In an example, the operating parameters may include one or more of a sensed motor speed during the impacting and battery state information during the impacting.

[0242] At block 2509, the example method may include checking the fastening torque of the fastener with a second device. For example, block 2509 may be performed with a torque wrench to assess the torque level the fastener was driven to at block 2505.

[0243] At block 2511, the example method may include comparing the fastening torque measured at block 2509 to the desired torque. If the measured torque is not equal to or approximately equal to the desired torque, the method may return to block 2503, where the motor speed or time duration are adjusted and block 2505 to block 2511 are performed until the measured toque is equal to or approximately equal to the desired torque.

[0244] When the measured toque is equal to or approximately equal to the desired torque, at block 2513, the calibration parameters are saved. In an example, the motor speed and time duration saved as calibration parameters may correspond to the set speed and set duration, respectively in Equation 4. The operating parameters recorded at block 2507 may correspond to the actual speed, battery ID and battery state parameters of Equation 4.

[0245] Example method 2500 may be performed by the original equipment manufacturer during manufacturing to set the calibration parameters in the tool memory for use during operation which may be associated, for example, with a nominal, or default, or assumed or specified fastener type. Example method 2500 may also be performed by an endP-US-TN-2023-0197-PCT - 0029-128W01 user where the user can set a predefined speed and / or time duration for a particular fastener type and material type for repeatedly driving fasteners to a desired torque value. For example, aspects of the present disclosure may include a user interface with one or more control elements for performing the example method 2500, including control elements for selecting a calibration mode, setting the motor speed and time duration, and saving the calibration parameters to memory when the desired torque is achieved. The user interface 42 may be directly coupled to the power tool 10 or the user interface 42 may be on a remote computing device 50 that is in communication with the power tool 10 such as a mobile computing device.

[0246] The values / ranges noted above detailed description are merely provided by way of example. In an example, any stated value or range may be varied according to the application. In another example , the values / ranges are up to 5 percent greater than or up to 5 percent less than the value described above.

[0247] Examples have been provided so that this disclosure will be thorough, and to fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of examples of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example examples may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example examples, well-known processes, well-known device structures, and well- known technologies are not described in detail. For example, Further, any of the aforementioned modes may be used during forward and / or reverse operation of the motor and may be used for installing or removing fasteners as desired by the user.

[0248] The terminology used herein is for the purpose of describing particular examples only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specificallyP-US-TN-2023-0197-PCT - 0029-128W01 identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

[0249] When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0250] The term “approximately” includes values within ten percent greater or less than the stated value. Terms of degree such as “generally,” “substantially,” “approximately,” and “about” may be used herein when describing the relative positions, sizes, dimensions, or values of various elements, components, regions, layers and / or sections. These terms mean that such relative positions, sizes, dimensions, or values are within the defined range or comparison (e.g., equal or close to equal) with sufficient precision as would be understood by one of ordinary skill in the art in the context of the various elements, components, regions, layers and / or sections being described.

[0251] Numerous modifications may be made to the example implementations described above. These and other implementations are within the scope of this application.

Claims

P-US-TN-2023-0197-PCT - 0029-128W01WHAT IS CLAIMED IS:

1. An impact tool comprising: a housing; a motor disposed in the housing; a controller configured to control operation of the motor; an output member configured to be rotated when the motor is operated to rotatably drive a fastener; and an impact mechanism configured to be driven by the motor, the impact mechanism including a hammer and an anvil coupled to the output member, wherein the hammer applies intermittent rotational impacts to the anvil; wherein the controller is configured to: determine a time duration for performing the intermittent rotational impacts according to a torque setting; and reduce or terminate power to the motor when a length of time after a start of the intermittent rotational impacts meets the time duration.

2. The impact tool of claim 1, wherein the controller is configured to determine the torque setting according to a selection of at least one of a speed setting or a level setting.

3. The impact tool of claim 2, wherein the level setting corresponds to an amount of torque or energy transmitted from the impact tool to a fastener during the intermittent rotational impacts.

4. The impact tool of claim 2, wherein the impact tool further comprises an interface coupled to the housing that is configured to receive the selection of the speed setting and the level setting.

5. The impact tool of claim 2, wherein the speed setting corresponds to a maximum no-load speed of the motor.P-US-TN-2023-0197-PCT - 0029-128W016. The impact tool of claim 4, wherein the speed setting includes at least three speed settings and the level setting includes at least three level settings that correspond to at least nine torque settings.

7. The impact tool of claim 1, wherein the controller is further configured to determine the time duration according to a sensed motor speed.

8. The impact tool of claim 7, wherein the controller is configured to determine the time duration according to the torque setting and a comparison of the sensed motor speed to a predetermined motor speed.

9. The impact tool of claim 8, wherein the controller is configured to increase the time duration when the sensed motor speed is less than the predetermined motor speed.

10. The impact tool of claim 8, wherein the controller is configured to: compare the sensed motor speed to the predetermined motor speed during the intermittent rotational impacts; and dynamically adjust the time duration during the intermittent rotational impacts according to the comparison.

11. The impact tool of claim 10, wherein the predetermined motor speed is a motor speed that corresponds to the torque setting.

12. The impact tool of claim 11, wherein the predetermined motor speed includes a plurality of motor speeds that correspond to the torque setting, including a motor speed at a beginning of the intermittent rotational impacts and a motor speed during the intermittent rotational impacts.

13. The impact tool of claim 1, wherein the controller is further configured to determine the time duration according to at least one of a sensed motor speed and battery information.

14. The impact tool of claim 13, wherein the battery information is at least one of battery identification information or battery state information.P-US-TN-2023-0197-PCT - 0029-128W0115. The impact tool of claim 14, wherein the battery state information includes at least one of state of charge, impedance, temperature, or age.

16. The impact tool of claim 13, wherein the controller is configured to determine a time duration that is different from a predetermined time duration when the battery information is different from predetermined battery information corresponding to the torque setting.

17. The impact tool of claim 13, wherein the controller is configured to determine a time duration that is shorter than a predetermined time duration when the battery information includes a battery identification indicating a higher capacity battery than a predetermined battery identification corresponding to the torque setting.

18. The impact tool of claim 13, wherein the controller is configured to determine a time duration that is longer than a predetermined time duration when the battery information includes battery state information indicating a lower battery capacity than a predetermined battery capacity corresponding to the torque setting.

19. The impact tool of claim 1, wherein the hammer applies the intermittent rotational impacts to the anvil when a torque on the output member reaches or exceeds a trip torque.

20. An impact tool comprising: a housing; a motor disposed in the housing; a controller configured to control operation of the motor; an output member configured to be rotated when the motor is operated to rotatably drive a fastener; and an impact mechanism configured to be driven by the motor, the impact mechanism including a hammer and an anvil coupled to the output member, wherein the hammer applies intermittent rotational impacts to the anvil; wherein the controller is configured to:P-US-TN-2023-0197-PCT - 0029-128W01 determine a cumulative impact energy transmitted to a workpiece by the impact mechanism according to a sensed motor speed during the intermittent rotational impacts; and reduce or terminate power to the motor when the determined cumulative impact energy meets a target total impact energy.

21. The impact tool of claim 20, wherein the controller is configured to determine the target total impact energy according to a selection of at least one of a speed setting or a level setting.

22. The impact tool of claim 20, wherein the hammer applies the intermittent rotational impacts to the anvil when a torque on the output member reaches or exceeds a trip torque.

23. A method for operating an impact power tool having an impact mechanism configured to be driven by a motor, the impact mechanism including a hammer and an anvil coupled to an output member, wherein the hammer applies intermittent rotational impacts to the anvil, the method comprising: determining a time duration for performing the intermittent rotational impacts according to a torque setting; and reducing or terminating power to the motor when a length of time after a start of the intermittent rotational impacts meets the time duration.

24. The method of claim 23, the method further comprising determining the torque setting according to a user selection of at least one of a speed setting or a time setting.

25. The method of claim 23, wherein the hammer applies the intermittent rotational impacts to the anvil when a torque on the output member reaches or exceeds a trip torque.

26. An impact tool comprising: a housing; a motor disposed in the housing; a controller configured to control operation of the motor;P-US-TN-2023-0197-PCT - 0029-128W01 an output member configured to be rotated when the motor is operated to rotatably drive a fastener; an impact mechanism configured to be driven by the motor, the impact mechanism including a hammer and an anvil coupled to the output member, wherein the hammer applies intermittent rotational impacts to the anvil; and an interface coupled to the housing that is configured to receive a selection of a speed setting and a time setting; wherein the controller is configured to determine a torque setting according to the selection of the speed setting and the time setting.

27. The impact tool of claim 26, wherein the controller is further configured to: determine a time duration for performing the intermittent rotational impacts according to the torque setting; and reduce or terminate power to the motor when a length of time after a start of the intermittent rotational impacts meets the time duration.

28. The impact tool of claim 26, wherein the hammer applies the intermittent rotational impacts to the anvil when a torque on the output member reaches or exceeds a trip torque.

29. The impact tool of claim 26, wherein the speed setting corresponds to a maximum no-load speed of the motor.

30. The impact tool of claim 26, wherein interface is configured to enable selection among at least a first speed setting, a second speed setting and a third speed setting, which corresponds to a maximum no-load speed of the motor that is a low speed, a medium speed, and a high speed, respectively.

31. The impact tool of claim 30, wherein the interface enables selection among a plurality of time settings.

32. The impact tool of claim 31, wherein the plurality of time settings are indicated by a plurality of light sources.P-US-TN-2023-0197-PCT - 0029-128W0133. The impact tool of claim 32, wherein the time setting is presented as a progression of the plurality of light sources for longer time durations.

34. The impact tool of claim 32, wherein, when none of the plurality of light sources are on, there is no time limit for impacting.

35. The impact tool of claim 31, wherein the time settings are set in variable combination with the selected speed setting to deliver a wide range of fastening torque settings.

36. The impact tool of claim 26, wherein the controller is configured to determine when the impact mechanism starts applying rotational impacts to the output member, and to determine a time duration during which impacting is to be performed based on a sensed impact rate, a sensed motor speed, and the fastening torque setting.

37. The impact tool of claim 36, wherein the controller is configured to allow power to be delivered to the motor for the time duration and then to reduce or shut off power to the motor at an end of the time duration.

38. The impact tool of claim 36, wherein the time duration is not equal to the time setting.

39. The impact tool of claim 36, wherein the selected speed setting corresponds to a maximum no-load speed of the motor.

40. An impact tool comprising: a housing; a motor disposed in the housing; a controller configured to control operation of the motor; an output member configured to be rotated when the motor is operated to rotatably drive a fastener; and an impact mechanism configured to be driven by the motor, the impact mechanism including a hammer and an anvil coupled to the output member, wherein the hammer applies intermittent rotational impacts to the anvil; wherein the controller is configured to:P-US-TN-2023-0197-PCT - 0029-128W01 determine a time duration for performing the intermittent rotational impacts according to a selection of a speed setting and a time setting; and reduce or terminate power to the motor when a length of time after a start of the intermittent rotational impacts meets the time duration.

41. The impact tool of claim 40, wherein the hammer applies the intermittent rotational impacts to the anvil when a torque on the output member reaches or exceeds a trip torque.

42. The impact tool of claim 40, wherein the time duration is different from the time setting.

43. The impact tool of claim 40, wherein the speed setting corresponds to a no-load motor speed and the controller is configured to deliver power to the motor to achieve the no-load motor speed.

44. The impact tool of claim 40, wherein the time duration is determined from a look-up table that is based on the speed setting and the time setting.

45. The impact tool of claim 40, further comprises a speed sensor configured to detect a speed of the motor and output a sensed motor speed.

46. The impact tool of claim 45, wherein the speed sensor is a rotational speed sensor.

47. The impact tool of claim 40, wherein the controller is further configured to determine the time duration according to a sensed motor speed, wherein the sensed motor speed is at least one of an average motor speed, a peak motor speed, or a peak-to-peak motor speed, determined during a sensed time period.

48. The impact tool of claim 45, wherein the speed sensor includes Hall sensors that magnetically sense magnetic flux of a rotor magnet as a rotor is rotated, and wherein the controller is configured to measure an angular position of the rotor based on information from the Hall sensors and to control a commutation of the motor according to the measured angular position.P-US-TN-2023-0197-PCT - 0029-128W0149. The impact tool of claim 48, wherein an impact rate is determined from an output of the Hall sensors.

50. The impact tool of claim 49, wherein the output of the Hall sensors includes periodic accelerations and decelerations of the motor that are caused by the rotational impacts impacted by the impact power tool.

51. The impact tool of claim 40, further comprises a current sensor configured to detect an amount of electric current drawn by the motor to drive the motor.

52. The impact tool of claim 51, wherein an impact rate is determined from an output of the current sensor.

53. The impact tool of claim 52, wherein the output of the current sensor includes periodic changes in the current drawn by the motor that are caused by the rotational impacts impacted by the impact power tool.

54. The impact tool of claim 40, wherein the speed setting and the time setting correspond to a fastening torque setting.

55. The impact tool of claim 54, wherein the fastening torque setting comprises a user selected fastening torque setting.

56. The impact tool of claim 55, further comprises an interface coupled to the housing, wherein the interface is actuatable by a user to select the speed setting and the time setting, and wherein the controller is configured to determine the fastening torque setting based on the speed setting and the time setting.

57. The impact tool of claim 54, wherein, for a constant fastening torque setting, the time duration decreases as the motor speed increases.P-US-TN-2023-0197-PCT - 0029-128W0158. The impact tool of claim 54, wherein, for a constant fastening torque setting, the time duration increases as the motor speed decreases.

59. The impact tool of claim 54, wherein, for a constant impact rate and a constant motor speed, the time duration decreases as the fastening torque setting decreases.

60. The impact tool of claim 54, wherein, for a constant impact rate and a constant motor speed, the time duration increases as the fastening torque setting increases.

61. An impact power tool comprising: a housing; a motor disposed in the housing; a controller configured to control operation of the motor; an output member configured to be rotated when the motor is operated to rotatably drive a fastener; an impact mechanism configured to be driven by the motor, the impact mechanism including a hammer and an anvil coupled to the output member, wherein the hammer applies intermittent rotational impacts to the anvil; and an interface coupled to the housing that is configured to receive a selection of a speed setting and a time setting; wherein the controller is configured to determine a time duration for performing the intermittent rotational impacts according to the selection of the speed setting and the time setting.

62. The impact tool of claim 61, wherein the hammer applies the intermittent rotational impacts to the anvil when a torque on the output member reaches or exceeds a trip torque.

63. An impact power tool comprising: a housing; a motor disposed in the housing; a controller configured to control operation of the motor; an output member configured to be rotated when the motor is operated to rotatably drive a fastener; andP-US-TN-2023-0197-PCT - 0029-128W01 an impact mechanism configured to be driven by the motor, the impact mechanism configured to rotationally drive the output member when a torque on the output member is less than a trip torque and to apply rotational impacts to the output member when the torque on the output member reaches or exceeds the trip torque; wherein the controller is configured to receive a signal that corresponds to a fastening torque setting, determine when the impact mechanism starts applying rotational impacts to the output member, and determine a time duration during which impacting is to be performed based on a sensed motor speed and the fastening torque setting, and wherein the controller is configured to allow power to be delivered to the motor for the time duration and then to reduce or shut off power to the motor at an end of the time duration.

64. The impact tool of claim 63, wherein the sensed motor speed is at least one of an average motor speed, a peak motor speed, or a peak-to-peak motor speed, determined during a sensed time period.

65. The impact tool of claim 63, further comprises a speed sensor configured to detect a speed of the motor and output the sensed motor speed.

66. The impact tool of claim 65, wherein the speed sensor is a rotational speed sensor.

67. The impact tool of claim 65, wherein the speed sensor includes Hall sensors that magnetically sense magnetic flux of a rotor magnet as a rotor is rotated, and wherein the controller is configured to measure an angular position of the rotor based on information from the Hall sensors and to control a commutation of the motor according to the measured angular position.

68. The impact tool of claim 67, wherein the sensed motor speed is determined from an output of the Hall sensors.

69. The impact tool of claim 68, wherein the output of the Hall sensors includes periodic accelerations and decelerations of the motor that are caused by the rotational impacts impacted by the impact power tool.P-US-TN-2023-0197-PCT - 0029-128W0170. The impact tool of claim 63, further comprises a current sensor configured to detect an amount of electric current drawn by the motor to drive the motor.

71. The impact tool of claim 70, wherein the sensed motor speed is determined from an output of the current sensor.

72. The impact tool of claim 71, wherein the output of the current sensor includes periodic changes in the current drawn by the motor that are caused by the rotational impacts impacted by the impact power tool.

73. The impact tool of claim 63, wherein the fastening torque setting comprises a predetermined fastening torque setting.

74. The impact tool of claim 63, wherein the fastening torque setting comprises a user selected speed setting and a user selected time setting.

75. The impact tool of claim 63, wherein the fastening torque setting comprises a user selected fastening torque setting.

76. The impact tool of claim 75, further comprises a mode change interface coupled to the housing, wherein the mode change interface is actuatable by the user to select a speed setting and a time setting, and wherein the controller is configured to determine the user selected fastening torque setting based on the selected speed setting and the selected time setting.

77. The impact tool of claim 63, wherein, for a constant impact rate and a constant fastening torque setting, the time duration decreases as the motor speed increases.

78. The impact tool of claim 63, wherein, for a constant impact rate and a constant fastening torque setting, the time duration increases as the motor speed decreases.P-US-TN-2023-0197-PCT - 0029-128W0179. The impact tool of claim 63, wherein, for a constant fastening torque setting, the time duration decreases as the motor speed increases.

80. The impact tool of claim 63, wherein, for a constant fastening torque setting, the time duration increases as the motor speed decreases.

81. The impact tool of claim 63, wherein, for a constant motor speed, the time duration decreases as the fastening torque setting decreases.

82. The impact tool of claim 63, wherein, for a constant motor speed, the time duration increases as the fastening torque setting increases.

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