Power Tool Angle Guidance With Dual Sensors for Angled Cuts
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Solution Overview
Problem
Existing power tools lack an efficient system for assisting users in making angled cuts or boreholes in workpieces, relying on manual alignment and setup which can be time-consuming and prone to errors.
Innovation Solution
A power tool system equipped with an electronic controller, multiple distance sensors, and an angle output indicator, which measures distances to a workpiece and calculates the angle between the tool and the workpiece, providing real-time feedback to the user for precise angled operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual alignment methods are used for angled cuts, then device complexity is reduced, but manufacturing precision and measurement precision deteriorate
Solution Approach 1:
The patent replaces manual mechanical alignment methods with an electronic measurement and control system. Distance sensors optically measure the distance between the workpiece and power tool, and an electronic controller processes these measurements to provide alignment guidance, substituting the mechanical manual alignment process with an optical-electronic system.
Solution Approach 2:
The system enables the power tool to automatically measure its own alignment status relative to the workpiece using integrated distance sensors and controller, without requiring external alignment tools or complex mechanical fixtures. The tool self-diagnoses its angular position and provides feedback for correction.
2Productivity
If manual alignment procedures are used, then setup time is reduced, but productivity deteriorates due to repeated adjustments
Solution Approach 1:
The system continuously measures the distance between the workpiece and power tool using distance sensors and provides real-time feedback through the controller. This feedback mechanism allows operators to immediately see alignment status and make corrective adjustments, eliminating the need for repeated trial-and-error adjustments and reducing total alignment time.
Solution Approach 2:
The distance sensors and controller are pre-configured to measure and evaluate alignment before the cutting operation begins. The system performs preliminary alignment assessment and guidance, allowing the operator to establish correct angular positioning before engaging the cutting blade, thereby preventing time-wasting mid-operation adjustments.
3Measurement precision
If multiple distance sensors are used for angle measurement, then measurement precision improves, but device complexity increases
Solution Approach 1:
The alignment measurement function is segmented into multiple independent distance sensors positioned at different locations on the power tool. Each sensor independently measures the distance to the workpiece at its specific position, and the controller integrates these segmented measurements to calculate the overall alignment angle, dividing the complex measurement task into simpler independent sensing elements.
Data Source
AI summary
Power tool methods and systems are provided for aligning a power tool to implement an angled cut in a workpiece. The power tool includes a first distance sensor and a second distance sensor. The power tool measures a first distance to the workpiece with the first distance sensor and a second distance to the workpiece with the second distance sensor. The power tool calculates an angle between the power tool and the workpiece based on the first and second distances, and indicates the angle via an angle output indicator of the power tool. The power tool may measure an angle between the power tool and the workpiece using a proximate edge and a distal edge of the workpiece, and indicate whether the power tool maintains a correct angle as it traverses a cut through the workpiece from the proximate edge to the distal edge.