Chipping Hammer Handle Sensing for Controlled Drive Activation

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Solution Overview

Problem

Chipping hammers often start operating at full power unexpectedly, making it difficult for users to maintain control and ensuring safe operation, as the activation and strike output can surprise users who are not yet prepared.

Innovation Solution

A method for open-loop and closed-loop control of a chipping hammer that includes a pivotable lever element with a signal transmitter, allowing the control device to sense positions and set the drive from a deactivation mode to an activation mode based on predetermined threshold values, ensuring controlled activation and variable sensitivity settings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the chipping hammer is activated with a simple switch, then the activation process is simple and quick, but the drive operates at full power immediately which can surprise the user and make control difficult

Engineering Contradiction:

Improveactivation simplicityVSAvoidsafe operation

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The system performs preliminary detection of user grip and readiness before activating the drive. The sensor device detects when the user has firmly held the chipping hammer and positioned both hands on the handles, then activates the drive only after this preparatory condition is met, preventing unexpected full-power operation

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system continuously monitors the operational state through sensor feedback. The sensor device detects handle position, user grip force, and operational mode, providing real-time feedback to the control device which adjusts drive activation accordingly, ensuring safe operation while maintaining ease of use

Inventive Principle:

Principle #23Feedback

2Productivity

If the drive operates at maximum rotational speed upon activation, then productivity is high, but the user cannot maintain adequate control if they are not yet firmly holding the chipping hammer

Engineering Contradiction:

Improvestrike outputVSAvoidhandling control

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The system dynamically adjusts drive activation based on real-time sensor feedback. Instead of a fixed immediate activation, the drive activation timing and power level are dynamically controlled based on detected handle position, user grip stability, and operational context, allowing high productivity when conditions are favorable while maintaining safety when conditions are not yet optimal

Inventive Principle:

Principle #15Dynamics

3Ease of operation

If the activation switch is easily accessible, then ease of operation is improved, but unexpected activation can occur when the user is not prepared

Engineering Contradiction:

Improveswitch accessibilityVSAvoidunexpected start-up

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The system uses sensor feedback to detect user readiness before allowing activation. The sensor device monitors handle position, grip force, and operational context, and the control device only permits drive activation when the feedback indicates the user is prepared, preventing unexpected start-ups while keeping the activation switch accessible

Inventive Principle:

Principle #23Feedback

4Reliability

If a sensor device and control mechanism are added to detect handle position and control activation, then safe operation is improved, but device complexity increases

Engineering Contradiction:

Improvesafe operationVSAvoidcontrol system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The system replaces complex mechanical safety interlocks and switches with electronic sensor-based detection. Optical or magnetic sensors detect handle position and user grip, and electronic control logic manages activation timing, reducing mechanical complexity while improving safety and reliability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 safe and easy operation of the chipping hammer by allowing users to control the activation and power output, ensuring adequate handling and preventing unexpected start-ups.

Implementation Method 1

a lever element with a signal transmitter, said lever element being pivotable relative to the sensor device

Methodology Applied

Scientific EffectSignal transmission and detection:

Data Source

PatentUS20240109172A1Method for the open-loop and closed-loop control of a power tool

Publication Date: 2024.04.04 HILTI AG

AI summary

Method for the open-loop and closed-loop control of a power tool, having a drive, a control device, a sensor device, a transmission device and a handle apparatus, wherein the handle apparatus contains a lever element with a signal transmitter, the lever element being pivotable relative to the sensor device. The method involves the method steps of: sensing a first and second position of the signal transmitter; determining a distance covered from the first position to the second position; and setting the drive from a deactivation mode into an activation mode when the distance reaches a first threshold value. A handle apparatus on a power tool is also provided.