Depth-Sensing Power Tool Control for Precise Fastening
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Solution Overview
Problem
Existing power tools lack effective distance sensing and control mechanisms to accurately determine and adjust their operation based on the distance to a workpiece, leading to inconsistent fastening depth and efficiency.
Innovation Solution
Incorporating a depth sensor adjacent to the output drive device and an electronic controller that monitors distance signals to control the motor's operation, adjusting speed or stopping it when a predetermined threshold distance is reached, and implementing a pulsed operation mode to achieve precise fastening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a depth sensor and electronic controller are added to enable distance-based motor control, then fastening depth precision is improved, but device complexity increases
Solution Approach 1:
The depth sensor continuously monitors the distance between the power tool and workpiece, providing real-time feedback to the electronic controller. The controller adjusts motor operation based on this feedback, creating a closed-loop control system that maintains precise fastening depth without requiring complex mechanical depth adjustment mechanisms.
Solution Approach 2:
The patent replaces traditional mechanical depth control mechanisms (such as adjustable stops or manual depth gauges) with an electronic sensing and control system. The depth sensor optically or electromagnetically measures distance, and the electronic controller programmatically adjusts motor parameters, substituting mechanical complexity with electronic control.
2Manufacturing precision
If the motor speed is dynamically adjusted based on distance measurements, then fastening depth accuracy is improved, but control complexity increases
Solution Approach 1:
The electronic controller dynamically adjusts motor operating parameters (speed, torque, PWM duty cycle) in real-time based on the distance measurements from the depth sensor. This dynamic control allows the motor to adapt its performance throughout the fastening process, maintaining optimal speed-torque characteristics for precise depth control without requiring manual intervention.
Solution Approach 2:
The system performs self-adjustment of motor parameters based on automatic distance measurement and control algorithm execution. The electronic controller autonomously monitors depth sensor data and modifies motor operation without user input, making the complex control transparent to the operator while maintaining high precision.
3Productivity
If continuous monitoring of distance signals is implemented during motor operation, then feed rate consistency is improved, but energy consumption increases
Solution Approach 1:
The depth sensor and electronic controller implement periodic sampling of distance signals during motor operation rather than truly continuous monitoring. The controller measures distance at predetermined time intervals or at specific operational milestones, maintaining adequate feed rate control while reducing the energy burden of constant sensing and processing.
Data Source
AI summary
A power tool includes a housing, a motor, and an actuator configured to be actuated by a user to cause the motor to operate. The power tool includes a depth sensor located adjacent to the output drive device and configured to generate a distance signal. The power tool includes an electronic controller coupled to the actuator and to the depth sensor. The electronic controller determines a first distance between the depth sensor and the workpiece by monitoring the distance signal from the depth sensor during operation of the motor. The electronic controller determines that the first distance has decreased to be less than or equal to the predetermined threshold distance. The electronic controller changes how the motor is controlled to operate in response to determining that the first distance has decreased to be less than or equal to the predetermined threshold distance.