Force-Responsive Power Tool Speed Control for Precision Work
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Solution Overview
Problem
Conventional power tools lack the necessary control and finesse for precise operations, often resulting in safety concerns and reduced work quality, as they operate at fixed speeds, leading to issues like gouging or misalignment during material processing.
Innovation Solution
A power tool system that allows operators to control the rate of work by adjusting the force applied between the workpiece and the working surface, using a force detector and a controller with a sensitivity profile to manageably adjust the speed and power of the motion actuator, enabling more precise control over rotary, linear, or reciprocating motion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional power tools operate at fixed speeds, then productivity is maintained at high levels, but manufacturing precision deteriorates due to lack of control during fine operations
Solution Approach 1:
The patent implements dynamic speed adjustment by linking the power tool's operating speed to the operator's applied force through a force detector and controller. The speed varies dynamically based on the force profile, allowing high speed during light operations for productivity and low speed during heavy operations for precision, thereby resolving the contradiction between fixed speed productivity and variable speed precision
Solution Approach 2:
The system changes the speed parameter dynamically based on the force applied by the operator. The controller adjusts the motor speed according to the force detector readings, enabling the tool to operate at optimal speeds for different operational phases - high speed for material removal and low speed for fine finishing - thus achieving both productivity and precision
2Productivity
If power tools provide high speed operation, then productivity increases, but manufacturing precision worsens due to gouging and misalignment during fine operations
Solution Approach 1:
The patent employs feedback control where the force detector continuously monitors the operator's applied force and feeds this information to the controller, which then adjusts the motor speed accordingly. This closed-loop feedback system ensures the tool operates at appropriate speeds - high when force is light for productivity, and low when force is heavy for precision - eliminating gouging and misalignment while maintaining overall productivity
3Manufacturing precision
If power tools operate at variable speeds, then manufacturing precision improves through better control, but device complexity increases due to additional control systems
Solution Approach 1:
The system uses the operator's own applied force as the control signal, eliminating the need for separate control mechanisms. The force detector measures the operator's natural force application, and the controller automatically translates this into appropriate speed adjustments. This self-service approach achieves precision control without adding complex external control systems, as the operator's input directly drives the control function
Data Source
AI summary
A tool for operating on a workpiece includes a motion actuator and a controller that responsively varies a speed of the motion actuator and an operating speed of a working surface. The controller is configured to respond to a derived force that is a function an applied force exerted by an operator to manageably adjust pressure on the working surface to achieve a rate of work. The controller changes simultaneously both a rate of work on the workpiece and the operating speed of the working surface according to a sensitivity profile. The simultaneous change of rate of work and operating speed is manageable under both acceleration and deceleration by the operator with the applied force. The sensitivity profile expresses a relationship of a monotonically increasing positive slope between the derived force and the operating speed of the working surface within the range.