Impact Wrench Commutation Feedback for Stable Low-Speed Torque
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing power tools face difficulties in maintaining a constant low rotational speed during impact actions on soft materials, leading to issues like locked rotor and incomplete tasks due to low speed and low torque.
Innovation Solution
A power tool system comprising an electric motor, an output shaft, a commutation detection device, and a controller that adjusts control signals based on real-time commutation information to maintain a target rotational speed between 100 RPM and 300 RPM, ensuring stable operation even at low speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the power tool operates at low rotational speed for impact actions on soft materials, then the tool can perform specialized tasks requiring low speed, but the tool experiences locked rotor conditions and insufficient torque
Solution Approach 1:
The controller continuously monitors commutation information from the commutation detection device and uses this feedback to detect abnormal commutation states. When commutation information indicates an abnormal state (such as prolonged commutation time or missed commutations), the controller adjusts the control signal to prevent locked rotor conditions, enabling reliable low-speed operation on soft materials
Solution Approach 2:
The system dynamically adjusts the control signal based on real-time commutation information. The controller modifies operating parameters adaptively according to the detected commutation state, allowing the tool to maintain optimal performance across different operating conditions including low-speed impact actions on soft materials
2Adaptability or versatility
If the power tool operates at low rotational speed, then the tool can align small drill bits and work on soft materials, but the tool cannot maintain constant speed and completes tasks inefficiently
Solution Approach 1:
The commutation detection device provides continuous feedback on the motor's commutation state, allowing the controller to monitor actual rotational speed. This feedback enables the controller to maintain constant low speed operation by adjusting the control signal in response to speed variations, ensuring efficient task completion while working on soft materials and aligning small drill bits
Solution Approach 2:
The controller changes operating parameters (control signal) based on detected commutation information to maintain the desired low rotational speed. By dynamically adjusting parameters in response to commutation state changes, the system maintains constant speed operation that improves productivity for specialized low-speed tasks
Data Source
AI summary
A power tool includes a motor, an output shaft, a commutation detection device, and a controller. The commutation detection device is connected to the motor and used for obtaining commutation information of the motor. The controller is capable of outputting a control signal to control the motor to rotate. When the commutation information does not match a preset commutation condition, the control signal is adjusted based on the commutation information such that a rotational speed of the motor is maintained to be a target rotational speed.