Battery-Powered Machine Tool Control for Locked Tool Release
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Solution Overview
Problem
Existing machine tools with battery-powered electric motors face issues of increased motor current and potential damage due to locked rotors and sudden braking, especially when drilling deep holes or hard surfaces, which mechanical couplings cannot effectively address without adding weight, cost, and wear.
Innovation Solution
Implementing an electronically controlled coupling that switches to a second operating mode with varying current pulses based on battery charge status to provide haptic feedback and release locked tools, reducing energy consumption and preventing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mechanical coupling is used to decouple the output shaft from the electric motor when high torque is applied, then the machine tool is protected from damage, but the weight, space requirements, and manufacturing costs increase
Solution Approach 1:
The patent replaces the mechanical coupling system with an electronic control system that monitors motor current and torque parameters. When abnormal conditions are detected (such as locked rotor or excessive braking torque), the control system automatically interrupts power supply or adjusts motor operation to protect the machine tool, eliminating the need for mechanical couplings and their associated weight and complexity.
2Reliability
If a mechanical coupling is used to provide protection, then damage prevention is achieved, but the device complexity and manufacturing costs increase
Solution Approach 1:
The patent replaces complex mechanical protection mechanisms with a simplified electronic control system that uses sensors and control algorithms to monitor motor operation parameters. The system detects abnormal conditions such as locked rotors or excessive braking torque through electrical parameter monitoring and responds through electronic control, significantly reducing mechanical complexity.
Solution Approach 2:
The control system continuously monitors motor current, torque, and operational parameters in real-time and automatically takes protective actions when abnormal conditions are detected. The system self-regulates power supply, adjusts motor operation, and protects critical components without requiring external mechanical protection devices or manual intervention.
3Ease of operation
If high current pulses are applied to release a locked tool in the second operating mode, then the locked tool can be released, but the battery charge level decreases rapidly
Solution Approach 1:
The patent implements a two-mode operation system where the motor operates in normal continuous mode during standard operation and switches to periodic pulsed mode when locked conditions are detected. The pulsed mode applies high current in intermittent bursts rather than continuously, providing sufficient force to break free from locked conditions while minimizing overall energy consumption and preserving battery charge.
Solution Approach 2:
The control system dynamically adjusts motor operation parameters based on real-time feedback from torque and current sensors. When locked conditions are detected, the system transitions from steady-state operation to dynamic pulsed operation, optimizing the balance between releasing the locked tool and conserving battery energy through adaptive current control.
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
Provides haptic feedback similar to mechanical couplings while optimizing energy use, allowing prolonged operation and preventing motor damage by adapting current pulse levels to battery charge, ensuring safe voltage and efficient torque application.
Implementation Method 1
an electric motor (3) which is designed to rotationally drive an output shaft (4)
Implementation Method 2
a battery (2), and an electric motor (3)
Data Source
AI summary
A method for operating a machine tool having a battery and an electric motor which is designed to rotationally drive an output shaft that can be coupled to a tool is described, a control device for actuating the electric motor and a device for determining a parameter being provided, it being possible for the machine tool to be operated in a first operating mode and a second operating mode, and the control device transferring the machine tool from the first operating mode into the second operating mode if the parameter determined by the device exceeds or falls below a defined threshold value. The electric motor (3) is controlled in the second operating mode by an amperage profile comprising current pulses (10, 10′, 11), a level a maximum amperage (A1, A1′, A2) of the current pulses (10, 10′, 11) being varied depending on an actual charge status of the battery (2). A machine tool that can be operated using a method of this kind is also described.