Electromechanical Gear Selection for Core Drill Speed-Torque Control
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Solution Overview
Problem
Core drills face challenges in precisely coordinating the rotational speed and torque of the drill bit with varying drill bit diameters and material characteristics, leading to inefficient operations or potential damage due to lack of fine-tuning mechanisms in existing power tools.
Innovation Solution
A method for setting gears in a power tool transmission using an electric motor, controller, operating device, shift fork, and actuator, where sensors and signal transmitters facilitate mechanical gear changes and rotational speed adjustments, enabling precise gear selection and torque control through electronic and mechanical interactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional mechanical gear selection devices are used in core drills, then the structure is simple and easy to manufacture, but the gear selection cannot be precisely coordinated with drill bit diameter and material characteristics
Solution Approach 1:
The patent replaces traditional mechanical gear selection mechanisms with an electromechanical system. An actuator with a motor converts rotational movement into linear movement to position the shift fork, enabling precise gear selection controlled by electronic signals rather than purely mechanical linkages. This substitution allows for more precise coordination with drill bit diameter and material characteristics.
Solution Approach 2:
The patent introduces a shift fork as an intermediary component between the actuator and the gear selection mechanism. The shift fork translates the linear movement from the actuator into the appropriate gear engagement, serving as a mediator that connects the electromechanical control system with the mechanical transmission system, thereby achieving precise gear selection.
2Productivity
If rotational speed is increased for larger drill bits, then work progress improves, but damage to the power tool or drill bit may occur
Solution Approach 1:
The patent implements a feedback control system where sensors detect the position of the operating device and the selected gear, and this information is fed back to the controller. The controller uses this feedback to automatically adjust the rotational speed of the motor to match the selected gear and drill bit size, preventing excessive speed that could cause damage while maximizing productivity.
Solution Approach 2:
The patent changes the operational parameters of the motor based on the selected gear and drill bit characteristics. The controller adjusts the rotational speed parameter dynamically according to the gear selection, ensuring optimal speed for each drilling condition - higher speeds for smaller bits and appropriate lower speeds for larger bits, thereby preventing damage while maintaining efficiency.
3Adaptability or versatility
If fine-tuning mechanisms are added for precise gear and speed coordination, then adaptability to different drill bit sizes improves, but device complexity increases
Solution Approach 1:
The patent designs the electromechanical gear selection system to serve multiple functions: it selects gears, provides feedback for speed control, and adapts to different drill bit sizes through a unified control mechanism. The actuator and controller work together as a multi-functional system that handles gear selection and speed coordination simultaneously, reducing the need for separate adjustment mechanisms.
Solution Approach 2:
The patent implements a self-service control system where the controller automatically adjusts the motor speed based on the gear selection and detected operating conditions. The feedback from sensors enables the system to self-regulate without requiring manual fine-tuning mechanisms, achieving adaptability to different drill bit sizes while keeping the device structure relatively simple.
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
This solution allows for efficient and material-friendly core drilling operations by enabling precise adjustment of rotational speed and torque, preventing damage and improving work progress by allowing users to fine-tune settings according to drill bit size and material characteristics.
Implementation Method 1
an actuator (12) for converting a signal into a mechanical movement of the shift fork (13)
Data Source
AI summary
A method for setting a gear in a transmission of a power tool, the power tool including an electric motor as well as a controller for setting the rotational speed of the electric motor. A transmission includes an operating device for selecting a gear in the transmission, a shift fork as well as an actuator, the operating device including a signal transmitter as well as a sensor for receiving a signal of the signal transmitter. The method includes: setting the operating device from a first position to a second position for selecting a gear in the transmission; detecting a signal by the at least one sensor according to the second position of the operating device; transmitting a signal to the controller; setting the rotational speed of the electric motor from a first value to a second value by the controller; positioning the operating device from the second position into a third position; detecting a signal by the sensor according to the third position of the operating device; transmitting a signal to the actuator; and setting the shift fork from a first position to a second position with the aid of the actuator for the purpose of changing from a first gear into a second gear.