Electronic Clutch Braking for Fastener Driver Speed Control
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Solution Overview
Problem
Existing fastener drivers lack efficient mechanisms to manage motor speed drops and provide electronic braking, leading to suboptimal performance and control.
Innovation Solution
The implementation of an electronic clutch system in a powered fastener driver, which includes a motor, trigger, lifting assembly, position sensor, speed sensor, and a controller that activates the electronic clutch to electronically brake the motor when a speed drop threshold is met.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If an electronic clutch system is implemented to enable electronic braking, then motor speed control precision is improved, but device complexity increases
Solution Approach 1:
The electronic clutch system integrates multiple functions including speed sensing, position sensing, electronic braking, and motor control within a unified controller architecture. The controller simultaneously manages the clutch actuator, monitors motor parameters via sensors, and executes braking commands, thereby achieving precise speed control while consolidating control functions to mitigate complexity increases.
Solution Approach 2:
The electronic clutch acts as an intermediary component between the motor and the load, providing controlled braking action. The clutch is positioned in the power transmission path and can be selectively engaged to create drag on the motor shaft, enabling speed control and braking without directly modifying the motor itself, thus maintaining relative system simplicity.
2Loss of time
If electronic braking is activated to respond to speed drops, then motor speed control response time is improved, but energy consumption increases
Solution Approach 1:
The electronic braking is activated periodically or event-driven based on detected speed drops rather than continuously. The controller monitors motor speed and only engages the electronic clutch when a speed threshold is violated, allowing the motor to operate freely during normal conditions and applying braking only when corrective action is needed, thus reducing overall energy consumption while maintaining rapid response capability.
3Measurement precision
If the electronic clutch is used to brake the motor, then torque control precision is improved, but the lifting assembly position stability deteriorates
Solution Approach 1:
The system employs position sensors to continuously monitor the lifting assembly position and feeds this information back to the controller. When electronic braking is applied to correct motor speed deviations, the controller simultaneously monitors position feedback to detect any unwanted movement of the lifting assembly and can adjust braking intensity or duration to maintain position stability while still achieving precise torque control.
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 enables precise control over the motor's speed and torque, allowing for efficient electronic braking and improved overall performance of the fastener driver.
Implementation Method 1
The speed sensor is configured to sense a speed of the motor
Implementation Method 2
The position sensor is configured to sense a position of the lifting assembly
Implementation Method 3
activate the electronic clutch, in response to determining that the speed of the motor has dropped by the speed drop threshold within the first period of time, to electronically brake the motor
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
Systems and methods for implementing an electronic clutch in a powered fastener driver. One fastener driver includes a motor, a trigger, a position sensor, a speed sensor, and a controller. The position sensor is configured to sense a position of the lifting assembly. The speed sensor is configured to sense a speed of the motor. The controller is configured to provide power to the motor. The controller is configured to receive speed signals from the speed sensor indicative of the speed of the motor, and determine whether the speed of the motor has dropped by a speed drop threshold within a first period of time. The controller is configured to activate an electronic clutch to electronically brake the motor for a second period of time. In response to the second period of time having passed, the controller is configured to provide power to the motor.