High Resolution Anvil Angle Sensor Magnetic Encoder
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Solution Overview
Problem
Existing rotary power tools, such as impact wrenches, face challenges in accurately measuring the angular velocity or position of rotating anvils due to limited sensor resolution, particularly for small incremental motions, which can lead to inaccurate torque configurations.
Innovation Solution
The implementation of a high-resolution anvil angle sensor using a magnetic encoder sensor chip in conjunction with a disc magnet attached to the anvil's flange, allowing for precise measurement of the anvil's angle with a resolution of under one degree, thereby overcoming the limitations of traditional toothed gear encoder sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional toothed gear encoder sensors are used to measure anvil angle, then the device complexity is reduced, but the measurement precision deteriorates for small incremental motions
Solution Approach 1:
The patent replaces the mechanical toothed gear encoder sensor with a magnetic encoder sensor chip that detects changes in magnetic field position. This substitution eliminates the need for mechanical teeth and gears, reducing device complexity while achieving superior measurement precision of less than one degree for small incremental anvil angle changes.
Solution Approach 2:
The patent changes the measurement parameter from mechanical tooth position detection to magnetic field position detection. By using a disc magnet with alternating magnetic poles and a magnetic encoder sensor chip, the system achieves higher resolution angle measurements through magnetic field variations rather than mechanical tooth engagement.
2Measurement precision
If high-resolution magnetic encoder sensor chip is used, then the measurement precision of small incremental motions is improved, but the device complexity increases
Solution Approach 1:
The patent extracts the sensing function from a complex mechanical encoder assembly and isolates it into a compact magnetic encoder sensor chip. This chip is positioned close to the disc magnet on the anvil, eliminating the need for complex mechanical transmission components while maintaining high measurement precision for small incremental motions.
Solution Approach 2:
The patent introduces a disc magnet as an intermediary between the anvil and the magnetic encoder sensor chip. This magnet serves as the mediator that translates anvil angular position into detectable magnetic field variations, enabling high-resolution measurement without direct mechanical contact between the sensor and anvil.
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
This solution enables accurate measurement of small incremental motions, reducing errors in torque configurations and enhancing the precision of rotary power tools, particularly during the final stages of bolt tightening.
Implementation Method 1
The implementation of a high-resolution anvil angle sensor using a magnetic encoder sensor chip in conjunction with a disc magnet attached to the anvil's flange
Data Source
AI summary
A rotary power tool assembly including a hammercase an axis extending between a forward end and a rearward end, a drive mechanism housed within the hammercase, and a hammer driven by the drive mechanism to apply a rotational impact force on an anvil. The anvil includes an output shaft rotatable about the axis, a plurality of anvil jaws extending from the axis, and a flange fixedly connected to an end of the output shaft and extending radially from the axis, wherein the flange supports the plurality of anvil jaws, the flange extending over the plurality of anvil jaws. The anvil includes a magnet attached to the flange opposite to the plurality of anvil jaws. An anvil angle sensor is configured to read and interpret magnetic flux changes of the magnet and determine the position of the anvil rotating about the axis.