Fastener Driver Electronic Clutch for Predictive Torque Control
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Solution Overview
Problem
Existing fastener drivers lack efficient torque control mechanisms, leading to potential over-torque conditions that can damage components and affect performance.
Innovation Solution
Implementing an electronic clutch system in fastener drivers that utilizes sensors to monitor motor speed, voltage, and current, determining torque thresholds, and activates the clutch to brake the motor when torque exceeds a predetermined limit, thereby preventing over-torque.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an electronic clutch system is implemented to control torque, then component protection and performance consistency are improved, but device complexity increases
Solution Approach 1:
The patent replaces traditional mechanical torque control mechanisms with an electronic clutch system that uses electronic sensors and control circuits to monitor and regulate motor torque. This substitution of mechanical systems with electronic ones enables more precise torque control and component protection while managing the complexity through integration of multiple sensors and a unified control algorithm.
Solution Approach 2:
The electronic clutch system incorporates feedback mechanisms where sensors continuously monitor motor parameters (speed, voltage, current) and provide real-time data to the control system. This feedback loop enables dynamic torque adjustment and prevents over-torque conditions, improving reliability through continuous monitoring and adaptive control.
2Measurement precision
If multiple sensors are added to monitor motor parameters, then torque measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent employs a multi-functional sensor system where the same sensors (speed sensor, voltage sensor, current sensor) serve multiple purposes: monitoring motor operation, measuring torque, and providing feedback for control adjustments. This universal use of sensors reduces the need for separate dedicated torque sensors, thereby improving measurement precision without proportionally increasing device complexity.
Solution Approach 2:
The control system merges the data from multiple sensors (speed, voltage, current) into a unified torque calculation and control strategy. By combining these sensor inputs in the control algorithm, the system achieves precise torque measurement and control while managing complexity through integrated processing rather than separate independent systems.
3Reliability
If the electronic clutch activates to brake the motor, then over-torque conditions are prevented, but motor operation duration is reduced
Solution Approach 1:
The electronic clutch operates in a periodic manner, activating only when over-torque conditions are detected and deactivating when normal operation resumes. This periodic activation pattern allows the motor to maintain full operation duration during normal conditions while providing protective braking intervention only when necessary, thus balancing reliability with operational continuity.
Solution Approach 2:
The feedback-based control system continuously monitors motor parameters and adjusts clutch activation accordingly. This enables precise timing of clutch engagement and disengagement, ensuring that the motor operates at full duration during normal conditions while providing targeted protection only when over-torque thresholds are exceeded, thereby minimizing impact on overall operation duration.
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
The electronic clutch system effectively prevents over-torque, protecting components and ensuring consistent performance by dynamically adjusting motor operation based on real-time torque measurements.
Implementation Method 1
activate, in response to determining that the torque of the motor is less than or equal to the torque threshold, the electronic clutch to electronically brake the motor
Data Source
AI summary
A fastener driver includes a motor, a trigger, and a lifting assembly operable to be moved by the motor. The fastener driver includes a speed sensor, a voltage sensor, and a current sensor. A controller is configured to provide, in response to actuation of the trigger, power to the motor, receive speed signals from the speed sensor indicative of the speed of the motor, receive voltage signals from the voltage sensor indicative of the voltage of a battery pack, and receive current signals from the current sensor indicative of the current of the motor. The controller determines a torque of the motor based on the signals, determines whether the torque of the motor is less than or equal to a torque threshold, and activate an electronic clutch, in response to the torque of the motor being less than or equal to the torque threshold, to electronically brake the motor.