Brushless DC Motor Powered Threader with Electronic Control
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Solution Overview
Problem
Existing powered threader devices are inefficient in terms of power consumption and limited in control features, resulting in low productivity and durability due to the use of components susceptible to wear, such as brushes.
Innovation Solution
A powered threader device equipped with a brushless DC electric motor, a selectively releasable chuck assembly, and a positionable die assembly, along with advanced control provisions and sensors for monitoring operations, enabling efficient threading, cutting, and reaming with improved operator control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional brushed DC motors are used in powered threader devices, then the device can be manufactured with simpler components and lower cost, but the device exhibits reduced durability and reliability due to wear of brush components
Solution Approach 1:
The patent replaces the mechanical brush-commutator system with an electronic commutation system using Hall effect sensors and electronic control circuitry. This substitution eliminates the wear-prone mechanical contacts while providing equivalent motor control functionality, thereby improving durability without significantly increasing overall system complexity.
2Productivity
If traditional powered threader devices are used, then the device structure can be simpler, but the device exhibits low productivity and efficiency due to limited control features and high power consumption
Solution Approach 1:
The patent implements variable speed control of the motor through electronic regulation, allowing the threading speed to be dynamically adjusted based on workpiece material, thread size, and operational requirements. This dynamic control enables optimized productivity while reducing energy consumption by operating at lower speeds when high speed is not required, rather than running at constant high speed.
Solution Approach 2:
The patent incorporates sensors (including Hall effect sensors for motor commutation and position sensing) that provide feedback to the control system. This feedback enables the controller to monitor and adjust motor speed and torque in real-time, optimizing both productivity and energy efficiency by matching power delivery to actual operational needs rather than providing constant maximum power.
3Ease of operation
If traditional powered threader devices are used, then the device can operate with basic functionality, but the device exhibits limited control features resulting in low productivity
Solution Approach 1:
The patent replaces manual mechanical control mechanisms with an electronic control system that uses sensors and microprocessor-based regulation. This substitution provides precise digital control of motor speed and die positioning while maintaining ease of operation through electronic interfaces that are simpler to adjust and more accurate than mechanical dials and levers.
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
The device achieves increased efficiency, productivity, and durability by utilizing a brushless DC motor, reducing wear and tear, and providing advanced control features for precise operation.
Implementation Method 1
a brushless DC electric motor supported by the frame assembly. The brushless motor provides a powered rotary output
Data Source
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AI summary
A device and associated system for threading, cutting, and reaming pipe ends are described. The device and system utilizes a brushless DC electric motor. The devices also include on-board electronics and operator interface(s) to provide sophisticated control and information as to the various operations. Also described are methods of operating the devices and several different modes for performing various operations.