Angled Rotary Tool Chuck with Sensor-Based Speed Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing rotary drivers for fasteners often require a separate activation switch and have inline chucks, limiting access to fasteners in angled locations and requiring additional effort to manage torque, especially in high-torque applications.
Innovation Solution
A rotary tool with a motor of variable output speed and a chuck assembly oriented at a non-parallel angle, where the chuck's movement is detectable by a sensor, allowing control of motor activation and speed based on applied force, using a magnetic field and a resilient element to enhance torque delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a separate activation switch is used, then the tool can be controlled, but the device complexity increases and ease of operation decreases
Solution Approach 1:
The activation switch function is merged with the chuck assembly. The chuck assembly itself serves as the activation mechanism through its movable portion that detects fastener contact, eliminating the need for a separate activation switch and simplifying the overall device structure.
Solution Approach 2:
The chuck assembly activates the motor automatically when it contacts the fastener. The movable portion detects the contact and triggers motor activation without requiring separate user action, making the system self-activating and easier to operate.
2Adaptability or versatility
If an inline chuck is used, then the structure is simple, but access to angled fasteners becomes difficult
Solution Approach 1:
The chuck assembly is oriented at an angle (non-parallel) relative to the motor drive axis, allowing access to fasteners in angled locations. This angular orientation provides versatility for different fastener positions while the integrated sensor system manages the added complexity.
Solution Approach 2:
The chuck assembly is made movable along the chuck axis, allowing it to dynamically adjust its position and orientation relative to the motor. This dynamic capability enables the chuck to reach angled fasteners while the movement is detected by the sensor system.
3Ease of operation
If torque management is simplified, then ease of operation improves, but control precision over motor speed decreases
Solution Approach 1:
A sensor detects the position or movement of the movable portion of the chuck assembly and provides feedback to control the motor speed. This feedback mechanism maintains control precision by automatically adjusting motor speed based on the chuck's actual position and the force applied to the fastener.
Solution Approach 2:
The mechanical torque management system is replaced with a sensor-based detection system. Instead of complex mechanical torque control mechanisms, the patent uses sensors to detect chuck movement and electronically control motor speed, simplifying operation while maintaining precision through electronic feedback control.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables precise control over motor activation and speed, facilitating easier access to angled fasteners and reducing user effort in high-torque applications by integrating the activation mechanism within the tool's design, while providing enhanced torque capabilities.
Implementation Method 1
the movable end portion may include a magnetic element or magnet that produces a magnetic field, with the strength of the magnetic field being detectable by a variable voltage device or magnetoresponsive sensor in the tool
Implementation Method 2
the sensor or variable voltage device may comprise a Hall effect sensor or transformer for detecting the field strength of a magnetic field emitted by a field device
Data Source
AI summary
A rotary angle tool is provided for driving a fastener while controlling the rotational speed of the chuck by varying the pressure or force of the tool against the fastener. The tool includes an angled chuck assembly that is drivable by a motor, an output shaft of the chuck assembly having a rotational axis that is non-parallel to the rotational axis of the motor drive shaft. A sensor is responsive to the proximity of or movement of a detectable element at the chuck output shaft. The sensor generates a signal for controlling the output of the motor in response to detection of the proximity or movement of the detectable element. Moving the chuck output shaft by urging the rotary tool against a fastener varies the proximity of the detectable element relative to the sensor and the sensor output or control proportionally varies the power supplied to the motor.