Dual Hall Position Detection for Reciprocating Tool Malfunction Sensing
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Solution Overview
Problem
Existing reciprocating tools fail to detect malfunctions in position detection systems, leading to unintended ejection of components like nails due to the failure of Hall elements, which can cause user safety issues.
Innovation Solution
Implementing a dual position detection system with a first and second position detector, along with a control circuit to monitor the receipt of position detection signals, allowing for the detection of malfunctions by identifying missed signals, and preventing further motor operation when malfunctions are detected.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single position detector (Hall element) is used to detect the position of the reciprocating member, then the device complexity is low, but the reliability of position detection is insufficient and malfunctions cannot be detected
Solution Approach 1:
The position detection function is segmented into multiple independent detectors (first position detector at first position, second position detector at second position). Each detector independently monitors a specific position, and the control circuit compares signals from both detectors to identify malfunctions, thereby improving overall detection reliability without requiring a single complex detector
Solution Approach 2:
The control circuit continuously receives position detection signals from both detectors and provides feedback by comparing expected signal patterns with actual received signals. When a discrepancy is detected (indicating a malfunction), the system triggers an error state and stops motor operation, creating a closed-loop feedback system that enhances reliability
2Object-affected harmful factors
If position detection malfunctions are not detected, then the device complexity remains simple, but harmful factors increase due to unintended ejection of components
Solution Approach 1:
The system takes preliminary anti-action by detecting position detection malfunctions before they can cause harmful effects. The control circuit continuously monitors for missed position detection signals and stops motor operation in advance, preventing the reciprocating member from operating in an unsafe state that could lead to unintended ejection of nails or other components
Solution Approach 2:
The position detection system performs self-service by using its own components (first and second position detectors with control circuit) to monitor its own operational status. The system automatically detects when a detector malfunctions by comparing signal patterns, eliminating the need for external monitoring systems and reducing overall device complexity while enhancing safety
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 dual position detection system effectively identifies and prevents malfunctions, ensuring the reciprocating tool operates safely and accurately by stopping the motor when malfunctions occur, thereby preventing unintended ejections.
Implementation Method 1
a first Hall element detects a magnetic field of the first permanent magnet when a piston of the driver reaches a standby position
Data Source
AI summary
One aspect of the present disclosure provides a reciprocating tool including a reciprocating member, a first position detector, a second position detector, and a control circuit. The control circuit detects occurrence of malfunction associated with the first position detector or the second position detector based on (i) the control circuit having failed to receive a second position detection signal from the second position detector between an mth reception and an (m-1)th reception of a first position detection signal from the first position detector or (ii) the control circuit having failed to receive the first position detection signal between an nth reception and an (n-1)th reception of the second position detection signal, where m and n are any integers greater than or equal to two.