Flywheel-Sensed Fastener Tool Speed Control for Lower Wear
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Solution Overview
Problem
Existing fastener tools often operate at excessively high drive velocities, leading to unnecessary wear on components and user neglect of speed adjustment settings, despite the availability of speed select switches.
Innovation Solution
A fastener tool equipped with sensors and a controller that adjusts driver speed based on measured angular velocities and characteristics of the flywheel and motor, allowing for dynamic speed adjustments based on workpiece and fastener properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the fastener tool operates at high drive velocity to maintain power for every shot, then the power requirement is satisfied, but component wear increases prematurely
Solution Approach 1:
The system dynamically adjusts drive velocity based on real-time sensor feedback about workpiece characteristics. The controller modifies motor power delivery and flywheel engagement timing to optimize drive speed for each specific shooting condition, rather than operating at fixed high velocity, thereby reducing component wear while maintaining sufficient power
Solution Approach 2:
The system changes operational parameters (drive velocity, motor power, flywheel speed) based on detected workpiece properties. Sensors measure characteristics like material density and fastener type, and the controller adjusts corresponding drive parameters to match the actual power requirements, preventing excessive wear from consistently high-speed operation
2Adaptability or versatility
If a speed select switch is provided for user adjustment, then adaptability is improved, but users do not perceive immediate benefit and leave the tool in high power mode
Solution Approach 1:
The system performs automatic speed optimization without requiring user intervention. Sensors continuously monitor workpiece and fastener characteristics, and the controller autonomously adjusts drive parameters in real-time, eliminating the need for users to manually select speed settings and ensuring optimal performance is always maintained
Solution Approach 2:
The system implements closed-loop feedback control where sensors detect workpiece characteristics and fastener properties, feed this information to the controller, which then adjusts drive velocity accordingly. This automatic feedback mechanism ensures the tool adapts to each shooting condition without requiring user perception or manual adjustment
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
Reduces component wear by optimizing drive speed according to workpiece and fastener characteristics, enhancing tool longevity and user convenience.
Implementation Method 1
The flywheel is configured to be driven by the motor and is configured to transmit energy to the driver to cause the driver to move along the drive axis
Implementation Method 2
The one or more sensors is configured to measure and output at least (a) a signal indicative of an angular velocity of the flywheel
Data Source
AI summary
A fastener tool that drives a fastener into a workpiece includes a housing, a nose assembly, a driver, a motor, a flywheel, one or more sensors, and a controller. The controller is configured to adjust a speed of the driver based on 1) a difference between a first angular velocity of the flywheel measured by the one or more sensors at or before the start of the drive commencement and a second angular velocity measured by one or more sensors after the start of the drive commencement; or 2) a time difference between a first time after the start of the drive commencement when the driver and the flywheel are in engagement with each other and when the driver and the flywheel are moving at the same speed and a second time when the characteristic of the motor meets a predetermined threshold.