Impact Tool Dynamic Speed Control for Vibration Reduction
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Solution Overview
Problem
Impact tools designed for soft or hard joints often perform inadequately on the opposite type due to motor speed limitations, resulting in excessive vibration when operating on joints with different rebound characteristics.
Innovation Solution
An impact tool with a motor, drive train, inertial sensor, and electronic controller that adjusts rotational speed based on sensed acceleration and rebound distance to optimize operation on both soft and hard joints by reducing speed when excessive vibration occurs and increasing speed when stable operation is maintained.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If impact tools are designed to operate on soft joints with high motor speed, then they achieve good performance on soft joints, but they produce significant vibration when operating on hard joints
Solution Approach 1:
The patent implements dynamic speed control by adjusting the motor speed based on the detected joint hardness. The system transitions from a fixed-speed design to a variable-speed design where the motor speed is continuously adjusted according to real-time feedback from sensors detecting rebound characteristics, thereby optimizing performance across different joint types.
Solution Approach 2:
The patent employs feedback control mechanisms using sensors (such as accelerometers or position sensors) to detect the rebound distance or acceleration after hammer impact. This detected information is fed back to the control system, which then adjusts the motor speed accordingly - reducing speed when hard joint rebound is detected and maintaining high speed when soft joint conditions are detected.
2Object-affected harmful factors
If impact tools are designed to operate on hard joints with lower motor speed, then they reduce vibration, but they perform inadequately on soft joints
Solution Approach 1:
The system dynamically adjusts motor speed based on operating conditions, transitioning from a static low-speed design optimized for hard joints to a variable-speed design that can operate at high speeds for soft joints and low speeds for hard joints, thereby eliminating the performance compromise.
Solution Approach 2:
The patent changes the operational parameters (motor speed) based on the detected joint characteristics. By varying the speed parameter in response to feedback about joint hardness, the system optimizes both vibration control and productivity across different operating conditions.
3Device complexity
If fixed component design (spring, balls, camshaft grooves) is used for broad range operation, then device complexity is reduced, but adaptability to different joint types deteriorates
Solution Approach 1:
The patent introduces feedback control systems with sensors that detect operational conditions (rebound distance, acceleration) and provide this information to a control mechanism that adjusts motor speed accordingly, enabling the system to adapt to different joint types without requiring complex mechanical component designs.
Solution Approach 2:
The patent replaces complex mechanical adaptation mechanisms (such as adjustable springs, interchangeable balls, or variable camshaft grooves) with an electronic control system that uses sensors and variable speed control to achieve adaptability, thereby simplifying the mechanical design while improving versatility.
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 impact tool effectively operates on both soft and hard joints without compromising, reducing vibrations and maintaining driving force by dynamically adjusting motor speed in response to operational conditions.
Implementation Method 1
an inertial sensor configured to sense an acceleration of the drive train along the axis
Data Source
AI summary
In at least one illustrative embodiment, an impact tool may comprise an impact mechanism including a hammer and an anvil. The hammer may be configured to rotate about an axis and to translate along the axis to impact the anvil to cause rotation of the anvil about the axis. The impact tool may further comprise a motor, a drive train, an inertial sensor, and an electronic controller. The drive train may be configured to transfer rotation from the motor to the hammer of the impact mechanism. The inertial sensor may be configured to sense an acceleration of the drive train along the axis. Further, the electronic controller may be operably coupled to the motor and to the inertial sensor and configured to decrease a rotational speed of the motor in response to determining that the acceleration of the drive train has exceeded a threshold acceleration.