Electronic Clutch Power Tool for One-Handed Multi-Mode Fastening
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Solution Overview
Problem
Conventional power tools require users to hold the tool with one hand and manipulate controls with the other, which can be awkward and space-consuming, and often limit operational control of the clutch to manual or automatic modes.
Innovation Solution
A power tool with a rotary potentiometer/switch assembly allows one-handed operation, enabling selection between drill and drive modes, and includes a controller that monitors torque and interrupts it automatically when a fastener reaches a desired position, using linear regression to determine the optimal stopping point.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional controls (switches, knobs) are provided on the power tool, then operational control is enabled, but the controls take up substantial space and are awkward to manipulate while holding the tool
Solution Approach 1:
The patent combines multiple control functions (clutch setting selection, forward/reverse direction control, and mode selection) into a single rotary member that can be operated with the thumb while holding the tool. This merging of controls eliminates the need for separate switches and knobs, reducing space occupation and enabling one-handed operation.
Solution Approach 2:
The rotary member serves multiple functions: selecting clutch torque settings, controlling rotation direction (forward/reverse), and switching between drill mode and drive mode. This multi-functionality reduces the number of separate control components needed, thereby reducing overall control space while maintaining comprehensive operational control.
2Adaptability or versatility
If manual clutch control is provided, then operational control is enabled, but the clutch operation is limited and requires two-handed operation
Solution Approach 1:
The patent replaces the traditional mechanical clutch system with an electronic clutch controlled by a controller that receives signals from the rotary member. This substitution enables automated torque interruption based on detected fastener seating, providing both manual and automated operation modes while maintaining one-handed control through the rotary interface.
Solution Approach 2:
The automated drive mode enables the clutch to self-regulate torque interruption based on real-time monitoring of fastener seating conditions. The controller automatically detects when the fastener is properly seated and interrupts torque accordingly, eliminating the need for continuous manual adjustment while maintaining precise control.
3Manufacturing precision
If automated torque interruption is implemented, then fastener driving precision is improved, but control system complexity increases
Solution Approach 1:
The controller implements feedback by continuously monitoring the torque signal from the clutch mechanism and adjusting torque interruption timing based on detected fastener seating conditions. This feedback loop enables precise automated control of fastener installation while using relatively simple sensing and control logic.
Data Source
AI summary
A hand-held power tool is configured to receive an input indicative of a clutch setting for an electronic clutch from the tool operator, where the clutch setting is selectable from a drill mode, an automated drive mode and one or more user-defined drive modes. Each of the user-defined drive modes specifies a different value of torque at which to interrupt transmission of torque to the output spindle. In an automated drive mode, the controller interrupt torque to the output spindle in an automated manner when a fastener being driven reaches a desired stopping position. In a selected one of the user-defined drive modes, the controller sets a value of a maximum current threshold in accordance with the selected one of the user-defined drive modes and interrupts torque to the output spindle when current measures exceeding the maximum current threshold.