Gyro Sensor Power Tool Control for Router Kickback Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing power tools, such as routers, face challenges with kickback events and improper handling, which can lead to user injury and workpiece damage. Current safety features may not adequately detect these issues, especially in routers where tools can flip around in all three axes.
Innovation Solution
A power tool design incorporating a gyro sensor module with multiple gyro sensors to detect angular rotation and inclination in multiple axes, along with an accelerometer sensor module to detect linear acceleration. This setup allows the controller to determine error conditions such as kickback, tilting, and excessive acceleration, triggering notifications and automatic shut-off if necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a single-axis angular speed sensor is used to detect kickback events, then the device complexity is reduced, but the measurement precision is insufficient for detecting kickback in routers where tools can flip around in all three axes
Solution Approach 1:
The patent transitions from single-axis angular speed detection to three-axis angular velocity detection using a gyro sensor module. This dimensional expansion enables comprehensive detection of kickback events in all spatial directions (X, Y, Z axes), accurately capturing the complex rotational movements when a router flips around during operation.
Solution Approach 2:
The gyro sensor module serves multiple functions: detecting kickback events, monitoring tool orientation, and identifying improper handling. By integrating three-axis detection capability into a single module, the system achieves multi-functional detection without proportionally increasing complexity.
2Ease of operation
If actuators and sensors are employed to automatically correct tool tilt, then the ease of operation is improved, but the device complexity and cost increase
Solution Approach 1:
The system continuously monitors tool orientation using the gyro sensor module and provides real-time feedback to the user through visual or haptic notifications when improper tilting is detected. This feedback mechanism guides users to maintain correct tool orientation without requiring complex automatic correction systems.
Solution Approach 2:
Instead of implementing complex actuators to automatically correct tilt, the system empowers users to self-correct by providing them with orientation information through notifications. Users adjust the tool based on feedback, maintaining simplicity while improving operational control.
3Measurement precision
If multiple gyro sensors are used to detect movement in all three axes, then the measurement precision is improved, but the device complexity increases
Solution Approach 1:
The patent integrates three gyro sensors into a single gyro sensor module, combining the functionality of multiple sensors into one compact unit. This merging approach maintains three-axis detection capability while reducing the overall component count and simplifying integration into the power tool housing.
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 solution enhances safety and control during power tool operation by accurately detecting potential hazards and promoting proper handling techniques, thereby reducing the risk of injury and damage.
Implementation Method 1
The gyro sensor module includes at least one gyro sensor configured to detect angular rotation of the housing about a first axis and angular inclination of the first axis from a reference first axis
Implementation Method 2
an accelerometer sensor module mounted on the housing. The accelerometer sensor module is configured to detect linear acceleration of the housing with respect to a workpiece
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A power tool comprises a housing, a motor mounted in the housing, and a too holderl operatively coupled to the motor. The power tool also includes a gyro sensor module mounted on the housing, which comprises at least one gyro sensor configured to detect angular rotation of the housing about a first axis and angular inclination of the first axis from a reference first axis. A controller is configured to receive sensor signals from the gyro sensor module, determine a first error condition of the power tool based on a threshold angular velocity being exceeded, and determine a second error condition of the power tool based on a threshold angular inclination being exceeded.