Handheld Knife Power Pack Relay Control for Unsafe Drive Detection

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Solution Overview

Problem

Existing powered rotary knives in the meat processing industry are hazardous to operate and prone to premature failure due to rudimentary drive controls and design flaws, leading to unsafe conditions and unnecessary wear.

Innovation Solution

A power pack system with a motor controller and relay circuit that includes a processor and non-transitory computer-readable storage media to monitor operation, disconnecting the electric motor from the power supply when deviations are detected, and implementing a watchdog algorithm for failsafe operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If rudimentary drive controls are used in powered rotary knives, then device complexity is reduced, but safety and reliability deteriorate

Engineering Contradiction:
Improvedrive control complexityVSAvoidoperational safety
Core Design Contradiction:
Device complexityVSReliability

Solution Approach 1:

The motor controller continuously monitors operational parameters (current, speed, temperature) and compares them against safe operating thresholds. When deviations are detected, the system automatically adjusts motor operation or shuts down to prevent unsafe conditions, creating a closed-loop feedback control system that enhances safety without requiring complex manual intervention

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The watchdog algorithm and monitoring system operate autonomously to detect faults and trigger protective actions. The system self-diagnoses operational anomalies and automatically implements corrective measures, eliminating the need for constant human supervision while maintaining high safety standards

Inventive Principle:
Principle #25Self-service

2Reliability

If intelligent monitoring and failsafe mechanisms are implemented, then safety and reliability are improved, but device complexity increases

Engineering Contradiction:
Improveoperational safetyVSAvoidcontrol system complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The motor controller serves as an intermediary layer between the power supply and the electric motor, incorporating monitoring and protection functions. This centralized control architecture consolidates multiple functions (power regulation, parameter monitoring, fault detection, protective shutdown) into a single control unit, managing complexity through functional integration rather than proliferation of separate components

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The system replaces mechanical safety mechanisms and manual monitoring with electronic and software-based solutions. The watchdog algorithm and electronic sensors detect faults and trigger electronic shutdowns, substituting physical safety devices with intelligent control logic that achieves superior reliability with reduced mechanical complexity

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

3Duration of action of stationary object

If continuous monitoring and automatic disconnection are implemented, then component lifespan is extended, but energy use and system complexity increase

Engineering Contradiction:
Improvemotor lifespanVSAvoidmonitoring energy consumption
Core Design Contradiction:
Duration of action of stationary objectVSUse of energy by moving object

Solution Approach 1:

The monitoring system operates by periodically sampling operational parameters at predetermined intervals rather than continuous high-frequency monitoring. This periodic measurement approach reduces computational load and energy consumption while still detecting trends and anomalies that indicate developing faults, thereby extending component life with minimal energy overhead

Inventive Principle:
Principle #19Periodic action

Data Source

PatentUS12397456B2Systems and methods for monitoring a wireless motor drive control system for handheld knives
Publication Date: 2025.08.26 HANTOVER INC
  • US12397456B2 patent drawing
  • US12397456B2 patent drawing
  • US12397456B2 patent drawing

AI summary

A power pack for a power tool. The power pack includes an electric motor configured for driving engagement with the power tool. The power pack also includes a motor controller having a relay circuit connected a electric motor. The relay circuit includes has a switch selectively connected to a power supply. The power supply powers the electric motor. The motor controller also includes non-transitory computer-readable storage media having computer-executable instructions for monitoring operation of the stored power pack. When executed by at least one processor, the computer-executable instructions cause the at least one processor to: monitor input data relating to operation of the power pack; determine, based on the input data, that operation of the power pack deviated from an ideal state; and, based on the determination of deviation, cause the switch to electrically disconnect the electric motor from the power supply.