Bolt Setting Device Motor Fault Detection via Hall Sensor Feedback
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Solution Overview
Problem
Conventional electrically operable bolt-firing tools lack effective real-time fault monitoring, leading to potential damage during operation due to undiagnosed mechanical issues like jamming in the tensioning mechanism.
Innovation Solution
Integration of a diagnostic device within the tool to monitor the speed of the electric drive motor and position of the actuator, allowing for immediate detection of faults and automatic shutdown of the motor to prevent damage, using a BLDC motor and commutation frequency analysis to determine the actuator position and detect mechanical faults.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If real-time monitoring of the electric drive motor and actuator position is implemented, then operational safety and fault detection capability are improved, but device complexity increases
Solution Approach 1:
The patent implements feedback by using Hall sensors to monitor the position of the actuator and the rotational position of the electric drive motor in real-time. This feedback is continuously sent to the control unit, which processes the information and can trigger protective actions when faults are detected, thereby improving operational safety through real-time monitoring without requiring complex external monitoring systems.
Solution Approach 2:
The control unit performs self-diagnosis by evaluating feedback signals from the Hall sensors and autonomously determining fault conditions such as actuator position deviations or motor abnormalities. The system can automatically switch off the motor when faults are detected, enabling self-protection without external intervention and reducing the need for additional monitoring complexity.
2Object-affected harmful factors
If immediate shutdown of the electric drive motor upon fault detection is implemented, then damage prevention is improved, but response time and operational continuity are affected
Solution Approach 1:
The patent applies preliminary anti-action by pre-programming the control unit with fault detection criteria and protective response protocols. When specific fault conditions are detected (such as actuator position deviations or motor anomalies), the system automatically executes pre-planned protective actions including immediate motor shutdown, preventing damage before it occurs. This preemptive approach minimizes damage while maintaining operational continuity by quickly restoring normal operation after fault resolution.
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 immediate diagnosis and prevention of mechanical faults, reducing the risk of damage and allowing for specific error handling and user notification, thereby enhancing operational safety.
Implementation Method 1
an electric drive motor (20) for tensioning the spring element (11)
Implementation Method 2
two Hall sensors (28, 29) for detecting the position of the actuator (16) and the rotational position of the electric drive motor (20)
Data Source
Figure 1~2
Figure 3~6
Figure 7~8
AI summary
The driver (1) has a monitoring and/or diagnostic device i.e. electronic controller (24), for monitoring a state of the driver. A set of switching and/or sensor devices monitors the state of the driver. An electrical drive motor (20) i.e. brushless direct current motor, delivers driving power for setting a bolt (9). The monitoring and/or diagnostic device is connected with the drive motor. The rotational speed of the drive motor is detected for operating the driver. The drive motor is switched off or reverses its direction during occurrence of an error. An independent claim is also included for a method for operating an electrically actuated bolt driver.