Electronic Clutch Mapping for Precise Multi-Speed Power Tool Torque
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Solution Overview
Problem
Power tools with traditional mechanical clutches lack flexibility and precision in torque control, limiting user customization and efficiency in various operating modes.
Innovation Solution
A power tool with an electronic clutch system that includes a clutch collar with multiple settings, a wireless transceiver, and a processor that receives torque mappings from a remote device, allowing for real-time torque level detection and adjustment, and generates feedback to the user when the desired torque is reached, enabling continuous rotation and finer torque granularity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a traditional mechanical clutch is used, then the device complexity is reduced, but the torque control precision and flexibility deteriorate
Solution Approach 1:
The patent replaces the traditional mechanical clutch system with an electronic clutch system that uses a motor, wireless transceiver, and processor to control torque levels. This substitution enables precise torque control through electronic means while eliminating the need for mechanical clutch components, directly resolving the contradiction between torque control precision and device complexity.
Solution Approach 2:
The patent implements variable torque control by receiving torque level mappings from remote devices and adjusting motor operation based on these parameters. The system can dynamically change torque levels through electronic control, providing continuous adjustment capability rather than fixed mechanical settings, thereby achieving high torque control precision.
2Adaptability or versatility
If an electronic clutch system with multiple settings is implemented, then the adaptability and torque control flexibility are improved, but the device complexity increases
Solution Approach 1:
The electronic clutch system serves multiple functions: it receives torque mappings from remote devices, detects clutch collar settings, determines torque levels, monitors torque during operation, and generates feedback indications. This multi-functional integration provides high adaptability and torque control flexibility while consolidating control logic in a single processor.
Solution Approach 2:
The system implements feedback by detecting the clutch collar setting, determining the corresponding torque level, monitoring actual torque during operation, and generating an indication when the desired torque is reached. This closed-loop feedback mechanism enables precise torque control and enhances adaptability to different operating conditions.
3Ease of operation
If continuous rotation capability is added, then the ease of operation is improved, but the device complexity increases
Solution Approach 1:
The patent implements continuous rotation capability by replacing the traditional mechanical clutch with an electronically controlled motor system. The motor can rotate continuously without the mechanical constraints of a clutch collar, and the electronic control system dynamically adjusts torque levels during rotation, improving ease of operation while managing complexity through electronic control.
Data Source
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AI summary
A power tool and a method of operating a power tool including a motor, a clutch collar including a plurality of settings, a wireless transceiver operable to form a wireless connection with a remote device, and a processor coupled to the clutch collar and the wireless transceiver. The processor receives, via the wireless transceiver, a mapping including a plurality of torque levels corresponding to the plurality of settings. The processor detects that the clutch collar is set to a setting of the plurality of settings. The processor is further determines the torque level for the setting from the mapping and detects, during the operation of the power tool, that a torque of the power tool exceeds the torque level. The processor is also configured to generate an indication that the torque exceeds the torque level. The indication may include flashing a light, ratcheting the motor, and stopping the motor.