Power Tool Object Sensing for Flesh Detection and Motor Control
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Solution Overview
Problem
Power tools lack the ability to automatically detect and respond to objects in their operating path, particularly to prevent accidents by identifying and reacting to the presence of flesh or specific materials that could be damaged during operation.
Innovation Solution
Incorporating an object detection sensor system within power tools that generates signals indicative of materials in the operating path, allowing a controller to determine the presence and type of objects and adjust the motor's operation accordingly, such as interrupting power when flesh is detected.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If power tools operate without object detection, then productivity and ease of operation are maintained, but safety and reliability deteriorate due to inability to detect flesh or damaged materials
Solution Approach 1:
The patent replaces mechanical/object-based detection methods with sensor-based detection systems. Sensors detect objects, flesh, or material conditions and send signals to a controller that automatically adjusts motor operation, eliminating the need for manual monitoring and improving safety without requiring complex mechanical intervention systems.
Solution Approach 2:
The patent implements feedback control by using sensors to continuously monitor the operating path for objects, flesh, or material conditions. The controller receives sensor signals and automatically adjusts motor operation in real-time, creating a closed-loop safety system that responds dynamically to detected conditions.
2Reliability
If object detection sensors are added to power tools, then safety and reliability improve, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent designs the sensor system and controller to perform multiple functions: detecting objects, detecting flesh, detecting material conditions (such as damaged vs. undamaged material), and automatically adjusting motor operation. This multi-functionality reduces the need for separate specialized components and simplifies manufacturing.
Solution Approach 2:
The power tool system performs self-monitoring and self-adjustment through integrated sensors and controllers that automatically detect unsafe conditions and modify operation without external intervention. This self-service capability reduces the need for additional manual safety systems or complex external monitoring equipment.
3Reliability
If the controller continuously monitors sensor output to detect material changes, then safety improves, but energy consumption and device complexity increase
Solution Approach 1:
The controller monitors sensor output at periodic intervals during power tool operation rather than continuously at maximum capacity. This periodic monitoring maintains safety by detecting material changes and flesh presence while reducing energy consumption compared to continuous high-frequency monitoring.
Data Source
AI summary
A power tool and methods are provided for detecting objects (e.g., flesh or other materials) in the operating path of a power tool's output component (e.g., saw blade or drill bit). An object detection sensor in the power tool generates an output signal indicative of a type of material detected in the operating path of the power tool. A power tool controller receives the object detection sensor output and determines when a material in the operating path of the power tool changes. The controller changes operation of a motor of the power tool (e.g., increasing or decreasing speed or stopping the motor) in response to the detected material change. The object detection sensor may include, for example, an RF sensor, a capacitive sensor, a camera, a conductivity probe, or an ultrasound probe.