Rotary Impact Tool Striker Sensing for Impact Energy Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing power tools lack effective methods for accurately measuring impact energy and controlling operations based on impact parameters, leading to inefficiencies and potential wear without real-time monitoring.
Innovation Solution
Incorporating sensors, such as inductive sensors or linear variable differential transformers, to detect the position and velocity of the striker within the spindle, allowing for precise calculation of impact energy and coefficient of restitution, and adjusting motor operation to maintain optimal performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If no sensor is used to detect striker position, then the device complexity is reduced, but the measurement precision of impact energy is insufficient
Solution Approach 1:
The patent replaces mechanical measurement systems with electromagnetic sensing. Inductive sensors or LVDTs detect striker position through magnetic field changes rather than direct mechanical contact, enabling precise impact energy measurement while reducing mechanical complexity. The sensor system converts mechanical position data into electrical signals for processing.
Solution Approach 2:
The patent introduces magnetic fields as an intermediary between the striker and sensor. The striker's magnetic properties interact with the sensor's magnetic field, allowing indirect detection of position and velocity without direct mechanical contact. This intermediary approach enables precise measurement while isolating the sensor from harsh mechanical environments.
2Productivity
If real-time monitoring of striker position is implemented, then the productivity is improved through optimized operation, but the device complexity increases due to additional sensors and control systems
Solution Approach 1:
The patent implements feedback control by continuously monitoring striker position and velocity through sensors, calculating impact energy in real-time, and using this data to optimize motor operation. The system adjusts operational parameters based on measured impact energy to maintain optimal productivity while preventing excessive wear.
Solution Approach 2:
The patent integrates multiple functions into a unified control system. The same sensor system that measures striker position also enables impact energy calculation, wear detection, and operational optimization. This multi-functionality improves productivity without proportionally increasing device complexity.
3Measurement precision
If inductive sensors are used to detect striker position, then the measurement precision is improved, but the manufacturing precision requirements for sensor alignment increase
Solution Approach 1:
The patent employs LVDT sensors that measure position through changes in magnetic coupling rather than direct geometric alignment. This parameter change from spatial alignment to magnetic field interaction reduces manufacturing precision requirements while maintaining high measurement precision for striker position detection.
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
Enables real-time control of impact energy and wear detection, improving tool efficiency, extending tool life, and optimizing performance for various workpiece types.
Implementation Method 1
determining the first position or the second position can include generating a magnetic field that the striker passes through and detecting a change in the magnetic field
Implementation Method 2
the sensor can include a bobbin and a plurality of coils wrapped on the bobbin
Implementation Method 3
In some examples, the sensor can be a linear variable differential transformer (LVDT).
Data Source
AI summary
A method of detecting positions of a striker for a rotary impact tool is provided. A first position of the striker can be determined before impacting an anvil of the rotary impact tool along an axial direction of the rotary impact tool. A second position of the striker can be determined after impacting the anvil along the axial direction. Operation of the rotary impact tool can be controlled based on the first position and the second position.