Rotation Speed Control for Impact Fastening Tools
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Solution Overview
Problem
Current impact type fastening tools lack an efficient rotation speed control method that allows for optimal torque application during the screwing phase while preventing damage to fasteners, as they often require users to choose between low torque to avoid damage and high torque for effective fastening, leading to inefficiency.
Innovation Solution
A method utilizing a motor, electronic switch, and feedback system for pulse-width modulation (PWM) control, which dynamically adjusts rotation speed based on user-set working positions and real-time feedback signals to ensure efficient driving and suitable torque application, automatically shifting to optimal settings upon detecting the impact phase.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a low rotation speed and low torsion are used to prevent fastener damage during the impact phase, then the fastener safety is improved, but the screwing phase efficiency deteriorates
Solution Approach 1:
The patent applies dynamics by transitioning from static rotation speed control (fixed positions) to dynamic rotation speed control. The system automatically adjusts rotation speed in real-time based on operational phase detection: high speed during screwing phase for efficiency, and low speed during impact phase for safety. This dynamic adaptation resolves the contradiction by allowing both high productivity and high reliability at different stages of the fastening operation.
Solution Approach 2:
The patent uses preliminary action by detecting the transition from screwing phase to impact phase in advance. The feedback system monitors operational parameters and predicts when the impact phase will begin, allowing the control system to proactively adjust rotation speed before the impact occurs. This prevents fastener damage while maintaining efficient screwing, as the system is already prepared with the appropriate speed setting.
2Productivity
If a high rotation speed and high torsion are used to improve screwing phase efficiency, then the productivity is improved, but the risk of fastener damage increases
Solution Approach 1:
The patent implements feedback control by continuously monitoring operational parameters (current, vibration, sound, or acceleration) and using this information to automatically adjust rotation speed. The feedback system detects when the fastening operation transitions from screwing to impact phase, and the control system responds by reducing rotation speed to prevent fastener damage. This closed-loop control eliminates the need for users to manually select between high-speed and low-speed modes, resolving the contradiction between productivity and safety.
3Adaptability or versatility
If multiple fixed rotation speed control positions are provided, then the adaptability to different fastening requirements is improved, but the device complexity increases
Solution Approach 1:
The patent applies self-service by enabling the system to automatically determine and select the appropriate rotation speed based on the detected operational phase. Instead of requiring users to manually select from multiple fixed control positions, the system autonomously adjusts rotation speed according to real-time feedback. This eliminates the need for complex multi-position control mechanisms while maintaining adaptability to different fastening requirements, as the system automatically adapts to screwing and impact phases without user intervention.
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
This approach enhances work efficiency by allowing higher rotation speeds during the screwing phase while ensuring suitable torque is applied during the impact phase, improving user experience and operational efficiency.
Implementation Method 1
A motor is configured to convert electrical energy to a desired torque
Implementation Method 2
A feedback means is configured to collect actual physical quantities constituting a trigger and convert them into a feedback signal that can be received and processed by the main controller
Data Source
AI summary
A rotation speed control method for impact type fastening tools has a presetting step and a dynamic control step. The presetting step includes setting a plurality of working positions, and setting a PWM signal with a larger duty cycle as a driving signal in a period after energization so that a motor can rotate at a higher speed and improve work efficiency. When a main controller judges, according to feedback, that the operation enters an impact phase and torsion control is needed to reduce rotation speed, the main controller makes adjustment by driving the motor with a PWM signal with a lower duty cycle corresponding to a working position currently set by the user. The control method improves work efficiency, and meet the user's need of driving a fastener with a higher rotation speed at an early stage of operation. In the torsion control phase, the method according to the present invention can automatically use a suitable torsion to drive the fastener to better meet the user's needs in operation and enable the user to obtain an excellent experience of use.